Heatweb Wiki - User contributions [en]

Heatbank Xcel Installation and User Instructions

2018-05-11T15:26:34Z

Jameshorscroft:

This page is currently a Work In Progress. May 2018.

This page is intended to form a repository of information intended to form a kernel of content that will ultimately lead to an up to date set of Installation and User Instructions for the Xcel.

=='''Introduction'''==

Congratulations on your purchase of the Xcel Heat Bank® Thermal Store. The Xcel is manufactured in the UK from high quality Duplex stainless steel offering exceptional strength and corrosion resistance, back up by a lifetime <ref>The internal stainless steel structure of the thermal store is guaranteed for a period of 25 Years against perforation due to corrosion, from the date of delivery to the client. This guarantee is subject to the store having been installed and commissioned in accordance with these instructions, and clear records being kept of all checks and top ups/replacements of the corrosion inhibitor to demonstrate that it is maintained at the correct strength and efficacy as stated by the inhibitor manufacturer’s instructions. This warranty excludes failure of welds to the cylinder bosses and the cylinder structure. The warranty excludes any works or costs for the decommissioning, removal and transport, of a faulty cylinder and reinstallation and recommissioning of a replacement unit – this is to be provided by others. This warranty shall be considered null and void if the thermal store is decommissioned and removed from its original install location. </ref> guarantee. The insulation levels of the cylinder meet the requirements of Building Regulations Part L.

The Xcel store is intended to permit a variety of different heat sources to contribute towards the provision of domestic hot water (DHW) and central heating in your property. The store is not a heating appliance in its own right and is reliant on the appliances that are connected to it to deliver the energy required to support your hot water and heating requirements. <u>It is therefore important that those heating appliances are correctly rated for the size and configuration of the Xcel store they will connect to, and for the heating and hot water demands of the property it is installed in.</u>

The Xcel store is manufactured in a number of different variants and your unit will be supplied in a specification matching those requirements given to Thermal Integration by the purchaser at the time the unit was ordered. The following set of installation and user instructions are tailored towards that specification. If your system has a different specification, or you require information on other variants available, please contact [[Thermal Integration Contacts|Thermal Integration Ltd]]. (Tel: 0845 2411441).

<references />

=='''Overview / Principle of Operation'''==

The Xcel thermal store permits the connection of two or more heat sources together into one system, to collect primary heated water that can be delivered to central heating circuits – radiators and/or underfloor heating (UFH) - or can be utilised to create domestic hot water (DHW). These heat sources can either be conventional, fossil fuelled boilers (oil, gas, LPG) or renewable sources (wood burning boiler stoves, biomass boilers, solar thermal panels). Furthermore, electric immersion heaters can be installed that allow back up or secondary heat input from either the mains electricity supply or solar PV (if installed).

By combining the heat from these different sources into one store, it not only permits sources such as solar to contribute to central heating as well as hot water, but the cylinder itself acts a buffer, (where solar is connected) collecting and storing energy captured during the daytime when there is little or no demand, and allowing it to be utilised in the evening when this source has diminished or disappeared. The physical structure of the cylinder also acts as a ‘neutral point’ in the overall system – in other words it permits different appliances to be interconnected and operate simultaneously without each one impacting on the other due to circulation forces from pumps, thermos-syphoning, etc. Another feature, if a wood burning stove is linked with an oil/gas boiler, is that the store controls permit the wood burner to deliver the maximum input it can to the store (dependent on rating of stove and frequency of refuelling) and thus respond to hot water/heating load, but with the oil/gas boiler providing a supporting or back up role. This enables the most to be obtained from the renewable heat source whilst minimising the reliance on fossil fuel.

It is important to understand that whilst the cylinder contains heated water, it is actually ‘Primary hot water’, that is, it is the water that passes through the heat exchanger of the oil/gas boiler, or the back boiler of a wood burning or biomass boiler. This same water is also what passes through radiators and/or underfloor heating loops. The cylinder does not, therefore contain Domestic Hot Water (DHW). Whenever a hot tap is opened, DHW is created ‘on demand’, at the moment it is required. This is done by passing the heated water from the store through one side of a plate heat exchanger, which heats up cold water from the mains passing through the other side of the plate. A very similar process takes place in a ‘Combi’ boiler. The reason for using a plate is the far superior performance this gives over a coil – both in duration and total DHW quantity delivered before the store becomes depleted. A more detailed analysis of the advantages are discussed [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Xcel_uses_a_Plate_Heat_Exchanger_for_Hot_Water_rather_than_a_Coil Here:]

The thermal store acts like a large vertical column of water, where the hottest water will naturally rise to the top of the store, and the coolest will fall to the base. This temperature gradient, or stratification, is an important feature of its operation. The higher temperature heat sources (gas/oil/wood/solid fuel) are delivered to the top of the store, with higher temperature demands (DHW, radiators) also drawn out of this upper region. Inputs from intermittent and variable sources like solar thermal are delivered to the coolest section at the store base to maximise low temperature gains; UFH which operates cooler than radiators also draws off lower down the store. The store is intended to operate ideally in the region of 70° to 75°C – that is, whilst on demand, the upper to mid region of the store should be heated to these temperatures for the best performance from DHW and for central heating by radiator. Higher temperatures are possible, for example from solid fuel or wood burning stoves, or possibly from solar thermal (depending on the set up of the solar controller, and weather conditions. The maximum operating temperature is 90°C: Temperatures in excess of this will cause the safety controls to start operating to reduce the stores temperature.

Heat sources are delivered to the top or upper part of the store and cooler water drawn from lower down. This enables a ‘top-down’ heating process that assists in maintaining stratification. Apart from solar thermal input, which is via a coil in the base of the store, heat sources are by default and preference connected directly to the store. Not only does this permit top down heating, it also allows the full output of the heat source to be delivered directly into the top of the store. Excepting solar, heat exchanger coils are not used in Xcel cylinders except where no other alternative is suitable. This is because their heat transfer capacity is often less than the output of the heat source, but also because they deliver diffuse heat to a region in the lower and mid sections of the cylinder which then convects to the top. The result is that heat up/recovery times are slower and depletion occurs more quickly than with direct systems. For example: Consider an Xcel store with direct boiler input versus a conventional hot water cylinder with boiler coil. From cold, the hot water cylinder may take at least 20 – 30 minutes before the tank is warm enough to deliver useable DHW. With the Xcel it may require less than 5 minutes before there is hot water available for basins and sinks.

The default mode of system installation and operation for the store is conventional, open vented. This permits the direct connection of most wood burning and solid fuel stoves and avoids the necessity to install discharge pipework for temperature/expansion relief safety valve, but still enables mains pressure DHW to be supplied. Furthermore this removes the need for installation and commissioning by a registered Unvented <ref>Note that the installation and commissioning of any connected heating appliance fuelled by gas, oil, LPG or solid fuel/biomass, or of an Unvented Domestic Hot Water cylinder is a Controlled Work and must be undertaken by an appropriately qualified and registered Competent Person for the relevant type of appliance or fuel (for unvented cylinders the installer must hold a Part G3 Vented & Unvented Hot Water Storage Systems qualification). Furthermore, the undertaking of such works may also be notifiable to your local Building Control Officer. See also Installation and Commissioning notes. </ref> installer or for subsequent annual inspection and maintenance visits. If installation on a Sealed System configuration is however required, the appropriate controls and safety devices can be supplied pre-installed on the cylinder.

<references />

=='''Unit Variants / Options'''==

The Xcel thermal store is available in a number of options, covering a range of different heat source combinations and configurations. The standard options, referred to as Data Sheets are listed below – the options specify only the intended heat inputs. Unless specified, all stores are supplied fitted with a plate heat exchanger for the generation of DHW. Note that each option can be further altered or added to, to produce a bespoke product to better match the specifics of your system requirements:

*DS-1 Biomass boiler/stove Buffer Store (no DHW assembly)
*DS-2 Biomass boiler/stove Thermal Store – DHW via coil in tank
*DS-3 Biomass boiler/stove Thermal Store
*DS-4 Biomass boiler/stove + Gravity Wood Burner + Solar Thermal
*DS-5 Biomass boiler/stove + Solar Thermal
*DS-6 Gas/Oil fired boiler + Gravity Wood Burner + Solar Thermal
*DS-7 Gravity Wood Burner
*DS-8 Gravity Wood Burner + Solar Thermal
*DS-9 Biomass boiler/stove + Gravity Wood Burner
*DS-10 Gas/Oil fired boiler + Solar Thermal
*DS-11 Gas/Oil fired boiler + Gravity Wood Burner
*DS-12 Biomass boiler/stove + Solar Thermal – DHW via coil in tank
*DS-13 Biomass boiler/stove + Pumped Wood Burner + Solar Thermal
*DS-14 Gas/Oil fired boiler + Pumped Wood Burner + Solar Thermal
*DS-15 Pumped Wood Burner
*DS-16 Pumped Wood Burner + Solar Thermal
*DS-17 Biomass boiler/stove + Pumped Wood Burner
*DS-18 Gas/Oil fired boiler + Pumped Wood Burner
*DS-23 Gas/Oil fired boiler (Sealed System) + Pumped Wood Burner + Solar Thermal

==Principles of Operation==

As discussed earlier, the Xcel store is designed to establish and maintain a temperature gradient, or stratification, from the top to the bottom of the store so that heat from various sources is delivered to the upper part of the store where it can be then drawn out of and delivered to its destination, whilst cooler water for reheating, or returning from the target, is drawn from / delivered to the lower part. Thus in the heating phase, the store is heated from the top down, whist on demand, heat is draw from the top and cooler return water is delivered from the bottom up. A boundary region between these hotter & cooler layers is established and in normal operation this layer moves up and down within the store as heating capacity versus demand varies.

===Heat Inputs===

For those heat sources that are directly connected to the store, and are on pumped circulation, connection of the heat input – or Flow – is made at or very close to, the top of the cylinder. These sources include: Biomass boilers & stoves; Oil/Gas/LPG fired boilers; Wood burning or Solid Fuel boiler stoves on fully pumped or pump assisted connection.
In all these cases it is intended that the temperature of primary water flowing into the store is controlled by a mixing valve (either pre-installed or required as part of the installation work), which ensures that the water entering the top of the store is at a minimum of 55° to 60°C. Cooler water going back to the appliance for reheating - or Return - is draw off the bottom of the store. Thus, in a heating only phase (i.e. no demand placed on store), primary heat is pumped into the top of the store and the body of heated water travels down the store, pushing the hooter/cooler boundary region down, until the store is fully heated from top to bottom.

*Note: Where a solar thermal coil is fitted at the base of the store, the Return connection is made just above the top of the coil. This allows for a ‘Solar Reserve’ at the base of the store, in the region that this coil sits in, that remains relatively cool in relation to the rest of the store as it is not directly boiler/stove heated, enabling the maximisation of solar thermal gains. An exception to this is made where the store is configured for partial or fully pumped wood /solid fuel input, and store heating is of the full volume including the coil region. This is because the store is sized to safely accommodate a full burn from the stove at maximum output, and because the stove’s operation will generally coincide with periods of minimal solar gains.

Other heat sources or input modes will generally rely on convection of heat to the top of the store:

*Gravity wood burner: The Flow connection will generally be 200 – 300mm below the top of the cylinder. This is because the flow temperature is unregulated, so when in operation, if the flow temperature is below that of the water presently sitting in the top of the store, this will convect down below it to a region that matches it. If however it matches or exceeds the upper temperature, this flow will rise to the top of this store. This process prevents the hottest water at the store top from being displaced or diluted by lower temperature water entering the store, in turn disrupting DHW delivery.

*Solar Thermal: A solar thermal coil sits at the base of the store in a region that is not influenced by other heat inputs or demands – i.e. no heat input or heat load tappings are connected in this region (excepting partial/fully pumped wood & solid fuel stoves). This permits the coil to sit in a relatively cool region of the store. Heat from the solar panel array will only be transported down & through the coil if the panel temperature exceeds that of the water immediately surrounding the coil, and a defined minimum value. In a heating phase, the water surrounding the coil starts to heat and once it exceeds the temperature of the water around it, it convects upwards, displacing cooler water downwards. The hotter the coil / array can heat the store water, the higher this heat rises/convects upwards & hotter the store ultimately gets.

*Electric immersion heater: Standard immersion bosses are located at approximately mid-way down the store. When energised, the immersion element heats the water immediately surrounding it, and store heating, by convection, is then the same as described for solar thermal.

Heatbank Xcel Installation and User Instructions

2018-05-11T14:11:45Z

Jameshorscroft:

Heatbank Xcel Installation and User Instructions

2018-05-11T13:52:45Z

Jameshorscroft: Created page with " This page is currently a Work In Progress. May 2018. This page is intended to form a repository of information intended to form a kernel of content that will ultimately lead..."

Amazon HXIN Unvented DHW Cylinder

2018-02-07T15:57:11Z

Jameshorscroft:

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|center|620px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most conventional indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants.

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - this can be an issue with conventional single thermostat systems - and thus the dual thermostat aids boiler efficiency.

When the cylinder temperature at the 'Buffer Off' position drops below its set point, it energises the 'Buffer On' thermostat; If this is simultaneously calling for heat it turns the plate heat exchanger pump on. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel. The cool water is heated and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate heat exchanger, in order to maintain the stored DHW at the required set point. As the DHW flowing away from the plate heat exchanger approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied with the plate heat exchanger and bronze pump pre-plumbed, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder manufacturer’s Instructions. Expansion and Temperature / Pressure relief valves should be connected to discharge pipework (via the tundish) which must be installed in accordance with Building Regulations Document G, as described in the cylinder Manufacturer’s Instructions.

Consideration must be given by the installer to the primary flow and return temperature delta and flow rates of the boiler plant or primary heat source that is to be connected. The set up and operation of the unit assumes a delta on the Cold Water Mains in / Domestic Hot Water out sides of the plate heat exchanger of 50°C in a single pass. The resultant delta on the primary side can be in the region of 40 - 45°C and flow rates of 15 - 35 Litres/min., dependent on the power of the heat source and its flow temperature. If the connected plant or heat source cannot operate with these deltas or flow rates, suitable bypass and flow regulation equipment must be sourced and fitted by the installer upstream of the plate heat exchanger, to accommodate this.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base; and a further connection made between the DHW output of the pre-assembled plate heat exchanger, and the secondary return connection of the second cylinder using the pipework & second flow setter assembly (supplied loose). The image below is indicative of the resulting assembly. Refer to Section '''Commissioning''' for adjustment of the flow setters. Note that in this instance, the total required flow rate for the system must be split equally across the two components.

[[File:Amazon HXIN Twin picture for manual.png|center|250px]]

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual V3.png|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. It is suggested that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) are all taken from the wiring centre in order to balance with the switched live outputs to both the boiler when called, and zone control for space heating, and provide a single point of isolation for the DHW and CH plan; however the installer may choose to derive their own solution, in which case it is imperative that suitable labelling is provided to indicate which circuits/components may remain live if the cylinder supply is isolated.

==Set up and commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

The following datasheets are sent with the Amazon HXIN Unvented DHW Cylinder, and can also be found on our Wiki site, http://www.heatweb.co.uk/w

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}

Amazon HXIN Unvented DHW Cylinder

2018-02-07T15:50:59Z

Jameshorscroft: Ammended HXIN Twin section

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|center|620px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most conventional indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants.

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - this can be an issue with conventional single thermostat systems - and thus the dual thermostat aids boiler efficiency.

When the cylinder temperature at the 'Buffer Off' position drops below its set point, it energises the 'Buffer On' thermostat; If this is simultaneously calling for heat it turns the plate heat exchanger pump on. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel. The cool water is heated and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate heat exchanger, in order to maintain the stored DHW at the required set point. As the DHW flowing away from the plate heat exchanger approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied with the plate heat exchanger and bronze pump pre-plumbed, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder manufacturer’s Instructions. Expansion and Temperature / Pressure relief valves should be connected to discharge pipework (via the tundish) which must be installed in accordance with Building Regulations Document G, as described in the cylinder Manufacturer’s Instructions.

Consideration must be given by the installer to the primary flow and return temperature delta and flow rates of the boiler plant or primary heat source that is to be connected. The set up and operation of the unit assumes a delta on the Cold Water Mains in / Domestic Hot Water out sides of the plate heat exchanger of 50°C in a single pass. The resultant delta on the primary side can be in the region of 40 - 45°C and flow rates of 15 - 35 Litres/min., dependent on the power of the heat source and its flow temperature. If the connected plant or heat source cannot operate with these deltas or flow rates, suitable bypass and flow regulation equipment must be sourced and fitted by the installer upstream of the plate heat exchanger, to accommodate this.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base; and a further connection made between the DHW output of the pre-assembled plate heat exchanger, and the secondary return connection of the second cylinder using the pipework & second flow setter assembly (supplied loose). The image below is indicative of the resulting assembly. Refer to '''Section Set up and commissioning of DHW controls.''' for adjustment of the flow setters. Note that in this instance, the total required flow rate for the system must be split equally across the two components. E.g. for a 70KW boiler input, each flow setter to be adjusted to 10 litres/min.

[[File:Amazon HXIN Twin picture for manual.png|center|250px]]

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual V3.png|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. It is suggested that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) are all taken from the wiring centre in order to balance with the switched live outputs to both the boiler when called, and zone control for space heating, and provide a single point of isolation for the DHW and CH plan; however the installer may choose to derive their own solution, in which case it is imperative that suitable labelling is provided to indicate which circuits/components may remain live if the cylinder supply is isolated.

==Set up and commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

The following datasheets are sent with the Amazon HXIN Unvented DHW Cylinder, and can also be found on our Wiki site, http://www.heatweb.co.uk/w

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}

File:Amazon HXIN Twin picture for manual.png

2018-02-07T15:30:30Z

Jameshorscroft:

Amazon HXIN Unvented DHW Cylinder

2018-01-09T10:30:42Z

Jameshorscroft:

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|center|620px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most conventional indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants.

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - this can be an issue with conventional single thermostat systems - and thus the dual thermostat aids boiler efficiency.

When the cylinder temperature at the 'Buffer Off' position drops below its set point, it energises the 'Buffer On' thermostat; If this is simultaneously calling for heat it turns the plate heat exchanger pump on. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel. The cool water is heated and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate heat exchanger, in order to maintain the stored DHW at the required set point. As the DHW flowing away from the plate heat exchanger approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied with the plate heat exchanger and bronze pump pre-plumbed, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder manufacturer’s Instructions. Expansion and Temperature / Pressure relief valves should be connected to discharge pipework (via the tundish) which must be installed in accordance with Building Regulations Document G, as described in the cylinder Manufacturer’s Instructions.

Consideration must be given by the installer to the primary flow and return temperature delta and flow rates of the boiler plant or primary heat source that is to be connected. The set up and operation of the unit assumes a delta on the Cold Water Mains in / Domestic Hot Water out sides of the plate heat exchanger of 50°C in a single pass. The resultant delta on the primary side can be in the region of 40 - 45°C and flow rates of 15 - 35 Litres/min., dependent on the power of the heat source and its flow temperature. If the connected plant or heat source cannot operate with these deltas or flow rates, suitable bypass and flow regulation equipment must be sourced and fitted by the installer upstream of the plate heat exchanger, to accommodate this.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base, and a further connection made between the two push fit fittings seen at mid level on each cylinder using the pipework & flow setter assembly (supplied loose).

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual V3.png|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. It is suggested that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) are all taken from the wiring centre in order to balance with the switched live outputs to both the boiler when called, and zone control for space heating, and provide a single point of isolation for the DHW and CH plan; however the installer may choose to derive their own solution, in which case it is imperative that suitable labelling is provided to indicate which circuits/components may remain live if the cylinder supply is isolated.

==Set up and commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

The following datasheets are sent with the Amazon HXIN Unvented DHW Cylinder, and can also be found on our Wiki site, http://www.heatweb.co.uk/w

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}

Heatbank Xcel Standard Assemblies

2017-06-16T11:28:23Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will ultimately lead to an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

<b>Pump for radiator circuit</b>

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11B==

<b>Pump for boiler circuit</b>

===Operation===

This assembly consists of a standard ‘A’ rated pump to act as a circulator between the store and a conventional boiler. A pump will usually be required when connecting to a conventional, open vented boiler which has no internal circulator: As such, this assembly is intended to be paired with <b>X2009-5 /-5B Direct boiler heat input assembly</b> (although can be paired with indirect assembly <b>X2009-6</b> if the install requires).

Control of the pump will by default be from the cylinder thermostat when a call for heat is generated, however if the connected boiler has pump control functionality (e.g. pump overrun), the factory wiring needs to be modified slightly to enable this.

===Installation===

<u>Note: The following guidance is provided assuming the store is supplied with any of options <b>X2009-5 /-6 /-8P</b></u>

Hydraulic:
*Connect the boiler flow and returns to the store assembly at the labelled positions: The flow connection is on a tee near the top of the store, above the mixer valve. The return connection will be off the bottom of the pump

Electrical:
*If the connected boiler <u>does not</u> require or have the option for pump control, then the pre-wired boiler & pump controls require no further work asides from connecting the switched live to the boiler to Terminal 12 (plus Permanent Live, Neutral & Earth).
*If the boiler <u>does</u> require pump control the following alterations should be made to the factory wiring:
**Remove the link wire between Terminals 6 and 12
**Connect the ‘Pump Live’ terminal on the boiler to Terminal 6 in the wiring centre
**Connect the ‘Switched Live/Call’ from the boiler to Terminal 12

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-14 / 14-30L==

<b>Plate Heat Exchanger assembly for indirect central heating circuit</B>

===Operation===

This assembly can be used to deliver primary heat to a space heating circuit (radiators or UFH) indirectly using the energy in the thermal store, as opposed to tapping directly off it. It can be used in situations where there is a requirement to separate the two circuits, often where the store is installed as an open vented system, e.g.: Needing to feed radiators installed above the header tank; or supplying a UFH system that has minimum head requirement, or small bore pipework & fitting and where the store is linked to a wood/multi fuel burner. Note that two pumps comprise this circulation system: The pre-installed one on the assembly, and the one that circulates across the other side of the plate and around the radiators/UFH (supplied by installer).

The pre-installed assembly comprises: A plate heat exchanger (PHE); a flow setter; A circulation pump; Pre-installed pipework and fittings linking the standard ‘Radiator’ flow & return connections on the store via one channel of the plate; and provides connections for the space heating circuit flow & return on the other channel. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves <u>and circulation pump</u>) are not included in this assembly and are to be provided by the installer.

NOTE: The independent circuit this assembly supplies requires its own feed / expansion and filling provision. The installer may choose to supply their own equipment, alternatively a 'Robokit' can be purchased from Thermal Integration in 8 or 12 Litre versions <b>(ROBOKIT-8L / ROBOKIT-12L)</b>.

When a ‘Call for Heat’ is received from the central heating system, this energises the pump on that circuit; Simultaneously, the pump on the PHE assembly is also energised. This draws heat out of the upper part of the store and down through one channel of the plate. At the same time the return from the space heating is pumped upwards through the second channel in counter current, collect heat then flows out to the emitters. Both pumps then stop at the same time when the demand is satisfied.

===Installation===

Electrically, installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pre-installed pump live wire. The pump live will be pre-wired to Terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.</b>

Hydraulic Installation:

*Connect the space heat ‘Flow’ pipe to the upper of the two free PHE connections. The ‘Return’ pipe to be connected to the lower fitting.
**It is suggested that the heating circuit pump is installed on the Flow pipework, pumping away from the upper PHE connection.
*Adjust the flow setter on the assembly to correspond with the calculated heatload of the connected circuit. The table below gives a range of settings based on an average Flow/Return delta of 15°C. Note that the pump speed can also be altered as required to achieve this value. If the installation is working off different delta’s please refer to the [http://heatweb.co.uk/technical/design-tools/ Power and Flow calculator] on our website to calculate your own specific requirements.

===Component list===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>
</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-15==

<b>UFH Temperature Control Valve<br />
To be combined with Pump for UFH Circuit (X2009-11C)</b>

===Operation===

This assembly is used to provide temperature limitation or control to a space heating circuit being supplied by the store. Typically this is used in underfloor heating (UFH) systems, although it can also be deployed on radiators circuits as well where flow limitation to 65°C maximum or less is required. It should be considered that in nearly all UFH systems, temperature control as well as circulation requirements are catered for in the manifolds that are supplied with the rest of the UFH equipment and the need for additional temperature control on the store is not normally required. Furthermore: This assembly is regarded as an optional extra item to be coupled with a UFH circulation pump <b>X2009-11C</b>, principally as the pump needs to pump away from the store and through the valve. Therefore, pre-installation of the valve alone is not envisaged.

In operation, when heat is called for and the pump circulates, the valve delivers primary heat from the upper/mid part of the store to the heating circuit, and the circuit return is delivered to the lower/base part of the store. If the primary heat into the valve exceeds the valve set point, the cold inlet port opens and allows the circuit return to be fed back into the flow, thus blending the flow temperature down to the set point.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance ‘Heatguard’ UFH Tempering Valve</td>
<td> 7018283</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring diagram===

==X2009-16A / -16J==

<b>3KW Immersion Heater</b>

===Operation===

Immersion heaters, where installed, are generally for the provision of temporary back up DHW where other heat sources have failed, or as a secondary / supplementary heat source (e.g. Solar PV) depending on the particular configuration of the store, number of heaters, and the client’s system requirements. Standard immersion heaters are rated at 3KW, 230 VAC, 50Hz, Single Phase.

Each immersion heater comprises an element and two thermostats: A control thermostat and a high limit / overheat thermostat. The control thermostat is factory set to 72°C and should not require adjustment at Commissioning. The overheat thermostat is factory set to 90°C <u>and should not be altered</u>. In normal operation, when energised the element will heat the store down to its level, to the set temperature of the control thermostat. In the event of store overheating, the overheat thermostat features a non self-resetting Energy Cut Out button that pops out and disconnects the power supply to the element if the water reaches the temperature it is set to.

Immersion <b>X2009-16J</b> is usually specified for temporary back up use. Immersion <b>X2009-16A</b> is usually specified where it is intended for supplementary heat input. It features a longer (lower Watt-Density, quieter operation) element than <b>-16J</b> and also features dry fire protection of the element. The immersions are not supplied pre-wired therefore all wiring and controls/timers (if applicable) are for the installing engineer.

===Installation===

<b>All wiring must comply with the relevant IEE Wiring Regulations, Building Regulations and BS:EN Standards, and be carried out by a Competent Person.</b>

Each 3KW 230VAC immersion heater must be supplied from a dedicated supply from the Consumer Unit, protected with a suitably rated MCB (e.g. 16 Amp), via a fused Double Pole Isolator. The heater must be wired using cable that is heat resistant to 90°C or better.<br />
<b>Warning: The heater must be Earthed.</b><br />
The Live connection must be made onto the overheat thermostat, and the Neutral connection onto the element terminal, as per the diagram below. The Earth must be connected onto the post on the immersion body. The cable must be secured via the cable clamp onto its outer insulation.

<b>Warning: The immersion heater must be isolated from the mains supply before and whilst the outer cover is removed.</b>

If it is intended that the heaters are operated on a regular, periodic basis then a suitable programmer/timer should be installed (e.g. Grasslin ‘Ecosave’ timeswitch).

===Wiring Diagram===

==X2009-16B==

<b>6KW Immersion Heater</b>

This heater has the same operational and installation details as <b>X2009-16A/-J</b> except that:
#The Consumer Unit supply to be suitably rated & protected (e.g. 32 Amp MCB).
#A suitable Contactor relay <b>must</b> be installed to switch the load to the element: If required the internal link wire from thermostat to element must be removed and the thermostat output connected to the Contactor switch (refer to the below diagram).

==X2009-19 / -A / -B / -C==

<b>Primary Sealed System kit for thermal store</b>

The Xcel thermal store can, subject to the heating appliances being connected to it, be installed on either open vented or sealed system configurations. To permit sealed system operation, this pre-fitted option <b>(X2009-19)</b> is available, comprising:

*Temporary filling loop; expansion relief valve; connection point for expansion vessel; Combined Temperature & Pressure Relief valve; Temperature/Pressure gauge; Auto Air Vent (supplied loose).

Alternative options also include a floor standing expansion vessel (supplied loose), as follows:
*<b>X2009-19A</b> – includes 50 Litre vessel
*<b>X2009-19B</b> – includes 80 Litre vessel
*<b>X2009-19C</b> – includes 100 Litre vessel

These vessels should be sized to accommodate both the volume of the thermal store and total connected systems (heat sources, heating circuits).

===Installation===

Refer to the ‘Installation and Commissioning Instructions’ for full details. In brief:
*Complete all hydraulic connections: Fit Auto Air Vent to top vent connection on store
*Perform system flushing, pressure testing/leak detection
*Adjust Pressure Reducing Valve to 1 Bar
*Dose system with corrosion inhibitor; Connect temporary filling loop; Fill system cold until 1 Bar observed on temp/pressure gauge; Disconnect filling loop.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Temp. Filling Connection + DCV / Isolation Valve</td>
<td> Altecnic Ecofil</td>
<td> 7069559</td>
<td>  </td>
</tr>
<tr>
<td> Expansion Relief Valve</td>
<td> Altecnic 2.5 Bar PRV</td>
<td> 70674</td>
<td>  </td>
</tr>
<tr>
<td> PRV with gauge</td>
<td> Caleffi PRV 15mm</td>
<td> 7026131</td>
<td>  </td>
</tr>
<tr>
<td> Auto Air Vent</td>
<td> Advantay AAV 1/2"</td>
<td> 7026187</td>
<td>  </td>
</tr>
<tr>
<td> TPRV</td>
<td> Altecnic 3/4" 3 Bar 90°C</td>
<td> 7069034</td>
<td>  </td>
</tr>
</tbody>

</table>
</html>

Amazon HXIN Unvented DHW Cylinder

2017-04-13T14:23:22Z

Jameshorscroft:

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|none|500px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most conventional indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants.

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - this can be an issue with conventional single thermostat systems - and thus the dual thermostat aids boiler efficiency.

When the cylinder temperature at the 'Buffer Off' position drops below its set point, it energises the 'Buffer On' thermostat; If this is simultaneously calling for heat it turns the plate heat exchanger pump on. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel. The cool water is heated and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate heat exchanger, in order to maintain the stored DHW at the required set point. As the DHW flowing away from the plate heat exchanger approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied with the plate heat exchanger and bronze pump pre-plumbed, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder manufacturer’s Instructions. Expansion and Temperature / Pressure relief valves should be connected to discharge pipework (via the tundish) which must be installed in accordance with Building Regulations Document G, as described in the cylinder Manufacturer’s Instructions.

Consideration must be given by the installer to the primary flow and return temperature delta and flow rates of the boiler plant or primary heat source that is to be connected. The set up and operation of the unit assumes a delta on the Cold Water Mains in / Domestic Hot Water out sides of the plate heat exchanger of 50°C in a single pass. The resultant delta on the primary side can be in the region of 40 - 45°C and flow rates of 15 - 35 Litres/min., dependent on the power of the heat source and its flow temperature. If the connected plant or heat source cannot operate with these deltas or flow rates, suitable bypass and flow regulation equipment must be sourced and fitted by the installer upstream of the plate heat exchanger, to accommodate this.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base, and a further connection made between the two push fit fittings seen at mid level on each cylinder using the pipework & flow setter assembly (supplied loose).

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual V2.jpg|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. Note that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) should all be taken from the wiring centre in order to achieve electrical balance with the switched live outputs to both the boiler when called, and zone control for space heating.

==Set up and commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}

File:Amazon HXIN Wiring for Install Manual V2.jpg

2017-04-13T14:21:17Z

Jameshorscroft:

File:X2009-6 wiring for new manual.jpg

2017-04-11T10:27:17Z

Jameshorscroft:

File:X2009-5 wiring for new manual.jpg

2017-04-11T10:18:28Z

Jameshorscroft:

File:X2009-2 wiring for new manual.jpg

2017-04-11T10:06:25Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-04-10T16:06:18Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

<b>Pump for radiator circuit</b>

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11B==

<b>Pump for boiler circuit</b>

===Operation===

This assembly consists of a standard ‘A’ rated pump to act as a circulator between the store and a conventional boiler. A pump will usually be required when connecting to a conventional, open vented boiler which has no internal circulator: As such, this assembly is intended to be paired with <b>X2009-5 /-5B Direct boiler heat input assembly</b> (although can be paired with indirect assembly <b>X2009-6</b> if the install requires).

Control of the pump will by default be from the cylinder thermostat when a call for heat is generated, however if the connected boiler has pump control functionality (e.g. pump overrun), the factory wiring needs to be modified slightly to enable this.

===Installation===

<u>Note: The following guidance is provided assuming the store is supplied with any of options <b>X2009-5 /-6 /-8P</b></u>

Hydraulic:
*Connect the boiler flow and returns to the store assembly at the labelled positions: The flow connection is on a tee near the top of the store, above the mixer valve. The return connection will be off the bottom of the pump

Electrical:
*If the connected boiler <u>does not</u> require or have the option for pump control, then the pre-wired boiler & pump controls require no further work asides from connecting the switched live to the boiler to Terminal 12 (plus Permanent Live, Neutral & Earth).
*If the boiler <u>does</u> require pump control the following alterations should be made to the factory wiring:
**Remove the link wire between Terminals 6 and 12
**Connect the ‘Pump Live’ terminal on the boiler to Terminal 6 in the wiring centre
**Connect the ‘Switched Live/Call’ from the boiler to Terminal 12

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-14 / 14-30L==

<b>Plate Heat Exchanger assembly for indirect central heating circuit</B>

===Operation===

This assembly can be used to deliver primary heat to a space heating circuit (radiators or UFH) indirectly using the energy in the thermal store, as opposed to tapping directly off it. It can be used in situations where there is a requirement to separate the two circuits, often where the store is installed as an open vented system, e.g.: Needing to feed radiators installed above the header tank; or supplying a UFH system that has minimum head requirement, or small bore pipework & fitting and where the store is linked to a wood/multi fuel burner. Note that two pumps comprise this circulation system: The pre-installed one on the assembly, and the one that circulates across the other side of the plate and around the radiators/UFH (supplied by installer).

The pre-installed assembly comprises: A plate heat exchanger (PHE); a flow setter; A circulation pump; Pre-installed pipework and fittings linking the standard ‘Radiator’ flow & return connections on the store via one channel of the plate; and provides connections for the space heating circuit flow & return on the other channel. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves <u>and circulation pump</u>) are not included in this assembly and are to be provided by the installer.

NOTE: The independent circuit this assembly supplies requires its own feed / expansion and filling provision. The installer may choose to supply their own equipment, alternatively a 'Robokit' can be purchased from Thermal Integration in 8 or 12 Litre versions <b>(ROBOKIT-8L / ROBOKIT-12L)</b>.

When a ‘Call for Heat’ is received from the central heating system, this energises the pump on that circuit; Simultaneously, the pump on the PHE assembly is also energised. This draws heat out of the upper part of the store and down through one channel of the plate. At the same time the return from the space heating is pumped upwards through the second channel in counter current, collect heat then flows out to the emitters. Both pumps then stop at the same time when the demand is satisfied.

===Installation===

Electrically, installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pre-installed pump live wire. The pump live will be pre-wired to Terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.</b>

Hydraulic Installation:

*Connect the space heat ‘Flow’ pipe to the upper of the two free PHE connections. The ‘Return’ pipe to be connected to the lower fitting.
**It is suggested that the heating circuit pump is installed on the Flow pipework, pumping away from the upper PHE connection.
*Adjust the flow setter on the assembly to correspond with the calculated heatload of the connected circuit. The table below gives a range of settings based on an average Flow/Return delta of 15°C. Note that the pump speed can also be altered as required to achieve this value. If the installation is working off different delta’s please refer to the [http://heatweb.co.uk/technical/design-tools/ Power and Flow calculator] on our website to calculate your own specific requirements.

===Component list===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>
</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-15==

<b>UFH Temperature Control Valve<br />
To be combined with Pump for UFH Circuit (X2009-11C)</b>

===Operation===

This assembly is used to provide temperature limitation or control to a space heating circuit being supplied by the store. Typically this is used in underfloor heating (UFH) systems, although it can also be deployed on radiators circuits as well where flow limitation to 65°C maximum or less is required. It should be considered that in nearly all UFH systems, temperature control as well as circulation requirements are catered for in the manifolds that are supplied with the rest of the UFH equipment and the need for additional temperature control on the store is not normally required. Furthermore: This assembly is regarded as an optional extra item to be coupled with a UFH circulation pump <b>X2009-11C</b>, principally as the pump needs to pump away from the store and through the valve. Therefore, pre-installation of the valve alone is not envisaged.

In operation, when heat is called for and the pump circulates, the valve delivers primary heat from the upper/mid part of the store to the heating circuit, and the circuit return is delivered to the lower/base part of the store. If the primary heat into the valve exceeds the valve set point, the cold inlet port opens and allows the circuit return to be fed back into the flow, thus blending the flow temperature down to the set point.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance ‘Heatguard’ UFH Tempering Valve</td>
<td> 7018283</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring diagram===

==X2009-16A / -16J==

<b>3KW Immersion Heater</b>

===Operation===

Immersion heaters, where installed, are generally for the provision of temporary back up DHW where other heat sources have failed, or as a secondary / supplementary heat source (e.g. Solar PV) depending on the particular configuration of the store, number of heaters, and the client’s system requirements. Standard immersion heaters are rated at 3KW, 230 VAC, 50Hz, Single Phase.

Each immersion heater comprises an element and two thermostats: A control thermostat and a high limit / overheat thermostat. The control thermostat is factory set to 72°C and should not require adjustment at Commissioning. The overheat thermostat is factory set to 90°C <u>and should not be altered</u>. In normal operation, when energised the element will heat the store down to its level, to the set temperature of the control thermostat. In the event of store overheating, the overheat thermostat features a non self-resetting Energy Cut Out button that pops out and disconnects the power supply to the element if the water reaches the temperature it is set to.

Immersion <b>X2009-16J</b> is usually specified for temporary back up use. Immersion <b>X2009-16A</b> is usually specified where it is intended for supplementary heat input. It features a longer (lower Watt-Density, quieter operation) element than <b>-16J</b> and also features dry fire protection of the element. The immersions are not supplied pre-wired therefore all wiring and controls/timers (if applicable) are for the installing engineer.

===Installation===

<b>All wiring must comply with the relevant IEE Wiring Regulations, Building Regulations and BS:EN Standards, and be carried out by a Competent Person.</b>

Each 3KW 230VAC immersion heater must be supplied from a dedicated supply from the Consumer Unit, protected with a suitably rated MCB (e.g. 16 Amp), via a fused Double Pole Isolator. The heater must be wired using cable that is heat resistant to 90°C or better.<br />
<b>Warning: The heater must be Earthed.</b><br />
The Live connection must be made onto the overheat thermostat, and the Neutral connection onto the element terminal, as per the diagram below. The Earth must be connected onto the post on the immersion body. The cable must be secured via the cable clamp onto its outer insulation.

<b>Warning: The immersion heater must be isolated from the mains supply before and whilst the outer cover is removed.</b>

If it is intended that the heaters are operated on a regular, periodic basis then a suitable programmer/timer should be installed (e.g. Grasslin ‘Ecosave’ timeswitch).

===Wiring Diagram===

==X2009-16B==

<b>6KW Immersion Heater</b>

This heater has the same operational and installation details as <b>X2009-16A/-J</b> except that:
#The Consumer Unit supply to be suitably rated & protected (e.g. 32 Amp MCB).
#A suitable Contactor relay <b>must</b> be installed to switch the load to the element: If required the internal link wire from thermostat to element must be removed and the thermostat output connected to the Contactor switch (refer to the below diagram).

==X2009-19 / -A / -B / -C==

<b>Primary Sealed System kit for thermal store</b>

The Xcel thermal store can, subject to the heating appliances being connected to it, be installed on either open vented or sealed system configurations. To permit sealed system operation, this pre-fitted option <b>(X2009-19)</b> is available, comprising:

*Temporary filling loop; expansion relief valve; connection point for expansion vessel; Combined Temperature & Pressure Relief valve; Temperature/Pressure gauge; Auto Air Vent (supplied loose).

Alternative options also include a floor standing expansion vessel (supplied loose), as follows:
*<b>X2009-19A</b> – includes 50 Litre vessel
*<b>X2009-19B</b> – includes 80 Litre vessel
*<b>X2009-19C</b> – includes 100 Litre vessel

These vessels should be sized to accommodate both the volume of the thermal store and total connected systems (heat sources, heating circuits).

===Installation===

Refer to the ‘Installation and Commissioning Instructions’ for full details. In brief:
*Complete all hydraulic connections: Fit Auto Air Vent to top vent connection on store
*Perform system flushing, pressure testing/leak detection
*Adjust Pressure Reducing Valve to 1 Bar
*Dose system with corrosion inhibitor; Connect temporary filling loop; Fill system cold until 1 Bar observed on temp/pressure gauge; Disconnect filling loop.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Temp. Filling Connection + DCV / Isolation Valve</td>
<td> Altecnic Ecofil</td>
<td> 7069559</td>
<td>  </td>
</tr>
<tr>
<td> Expansion Relief Valve</td>
<td> Altecnic 2.5 Bar PRV</td>
<td> 70674</td>
<td>  </td>
</tr>
<tr>
<td> PRV with gauge</td>
<td> Caleffi PRV 15mm</td>
<td> 7026131</td>
<td>  </td>
</tr>
<tr>
<td> Auto Air Vent</td>
<td> Advantay AAV 1/2"</td>
<td> 7026187</td>
<td>  </td>
</tr>
<tr>
<td> TPRV</td>
<td> Altecnic 3/4" 3 Bar 90°C</td>
<td> 7069034</td>
<td>  </td>
</tr>
</tbody>

</table>
</html>

Heatbank Xcel Standard Assemblies

2017-04-10T15:05:44Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

<b>Pump for radiator circuit</b>

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11B==

<b>Pump for boiler circuit</b>

===Operation===

This assembly consists of a standard ‘A’ rated pump to act as a circulator between the store and a conventional boiler. A pump will usually be required when connecting to a conventional, open vented boiler which has no internal circulator: As such, this assembly is intended to be paired with <b>X2009-5 /-5B Direct boiler heat input assembly</b> (although can be paired with indirect assembly <b>X2009-6</b> if the install requires).

Control of the pump will by default be from the cylinder thermostat when a call for heat is generated, however if the connected boiler has pump control functionality (e.g. pump overrun), the factory wiring needs to be modified slightly to enable this.

===Installation===

<u>Note: The following guidance is provided assuming the store is supplied with any of options <b>X2009-5 /-6 /-8P</b></u>

Hydraulic:
*Connect the boiler flow and returns to the store assembly at the labelled positions: The flow connection is on a tee near the top of the store, above the mixer valve. The return connection will be off the bottom of the pump

Electrical:
*If the connected boiler <u>does not</u> require or have the option for pump control, then the pre-wired boiler & pump controls require no further work asides from connecting the switched live to the boiler to Terminal 12 (plus Permanent Live, Neutral & Earth).
*If the boiler <u>does</u> require pump control the following alterations should be made to the factory wiring:
**Remove the link wire between Terminals 6 and 12
**Connect the ‘Pump Live’ terminal on the boiler to Terminal 6 in the wiring centre
**Connect the ‘Switched Live/Call’ from the boiler to Terminal 12

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-14 / 14-30L==

<b>Plate Heat Exchanger assembly for indirect central heating circuit</B>

===Operation===

This assembly can be used to deliver primary heat to a space heating circuit (radiators or UFH) indirectly using the energy in the thermal store, as opposed to tapping directly off it. It can be used in situations where there is a requirement to separate the two circuits, often where the store is installed as an open vented system, e.g.: Needing to feed radiators installed above the header tank; or supplying a UFH system that has minimum head requirement, or small bore pipework & fitting and where the store is linked to a wood/multi fuel burner. Note that two pumps comprise this circulation system: The pre-installed one on the assembly, and the one that circulates across the other side of the plate and around the radiators/UFH (supplied by installer).

The pre-installed assembly comprises: A plate heat exchanger (PHE); a flow setter; A circulation pump; Pre-installed pipework and fittings linking the standard ‘Radiator’ flow & return connections on the store via one channel of the plate; and provides connections for the space heating circuit flow & return on the other channel. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves and circulation pump) are not included in this assembly and are to be provided by the installer.

NOTE: The independent circuit this assembly supplies requires its own feed / expansion and filling provision. The installer may choose to supply their own equipment, alternatively a 'Robokit' can be purchased from Thermal Integration in 8 or 12 Litre versions <b>(ROBOKIT-8L / ROBOKIT-12L)</b>.

When a ‘Call for Heat’ is received from the central heating system, this energises the pump on that circuit; Simultaneously, the pump on the PHE assembly is also energised. This draws heat out of the upper part of the store and down through one channel of the plate. At the same time the return from the space heating is pumped upwards through the second channel in counter current, collect heat then flows out to the emitters. Both pumps then stop at the same time when the demand is satisfied.

===Installation===

Electrically, installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pre-installed pump live wire. The pump live will be pre-wired to Terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.</b>

Hydraulic Installation:

*Connect the space heat ‘Flow’ pipe to the upper of the two free PHE connections. The ‘Return’ pipe to be connected to the lower fitting.
**It is suggested that the heating circuit pump is installed on the Flow pipework, pumping away from the upper PHE connection.
*Adjust the flow setter on the assembly to correspond with the calculated heatload of the connected circuit. The table below gives a range of settings based on an average Flow/Return delta of 15°C. Note that the pump speed can also be altered as required to achieve this value. If the installation is working off different delta’s please refer to the [http://heatweb.co.uk/technical/design-tools/ Power and Flow calculator] on our website to calculate your own specific requirements.

===Component list===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>
</tr>

</tbody>
</table>

</html>

Heatbank Xcel Standard Assemblies

2017-04-10T14:36:53Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

<b>Pump for radiator circuit</b>

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11B==

<b>Pump for boiler circuit</b>

===Operation===

This assembly consists of a standard ‘A’ rated pump to act as a circulator between the store and a conventional boiler. A pump will usually be required when connecting to a conventional, open vented boiler which has no internal circulator: As such, this assembly is intended to be paired with <b>X2009-5 /-5B Direct boiler heat input assembly</b> (although can be paired with indirect assembly <b>X2009-6</b> if the install requires).

Control of the pump will by default be from the cylinder thermostat when a call for heat is generated, however if the connected boiler has pump control functionality (e.g. pump overrun), the factory wiring needs to be modified slightly to enable this.

===Installation===

<u>Note: The following guidance is provided assuming the store is supplied with any of options <b>X2009-5 /-6 /-8P</b></u>

Hydraulic:
*Connect the boiler flow and returns to the store assembly at the labelled positions: The flow connection is on a tee near the top of the store, above the mixer valve. The return connection will be off the bottom of the pump

Electrical:
*If the connected boiler <u>does not</u> require or have the option for pump control, then the pre-wired boiler & pump controls require no further work asides from connecting the switched live to the boiler to Terminal 12 (plus Permanent Live, Neutral & Earth).
*If the boiler <u>does</u> require pump control the following alterations should be made to the factory wiring:
**Remove the link wire between Terminals 6 and 12
**Connect the ‘Pump Live’ terminal on the boiler to Terminal 6 in the wiring centre
**Connect the ‘Switched Live/Call’ from the boiler to Terminal 12

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-14 / 14-30L==

<b>Plate Heat Exchanger assembly for indirect central heating circuit</B>

===Operation===

This assembly can be used to deliver primary heat to a space heating circuit (radiators or UFH) indirectly using the energy in the thermal store, as opposed to tapping directly off it. It can be used in situations where there is a requirement to separate the two circuits, often where the store is installed as an open vented system, e.g.: Needing to feed radiators installed above the header tank; or supplying a UFH system that has minimum head requirement, or small bore pipework & fitting and where the store is linked to a wood/multi fuel burner. Note that two pumps comprise this circulation system: The pre-installed one on the assembly, and the one that circulates across the other side of the plate and around the radiators/UFH (supplied by installer).

The pre-installed assembly comprises: A plate heat exchanger (PHE); a flow setter; A circulation pump; Pre-installed pipework and fittings linking the standard ‘Radiator’ flow & return connections on the store via one channel of the plate; and provides connections for the space heating circuit flow & return on the other channel. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves and circulation pump) are not included in this assembly and are to be provided by the installer.

NOTE: The independent circuit this assembly supplies requires its own feed / expansion and filling provision. The installer may choose to supply their own equipment, alternatively a 'Robokit' can be purchased from Thermal Integration in 8 or 12 Litre versions <b>(ROBOKIT-8L / ROBOKIT-12L)</b>.

When a ‘Call for Heat’ is received from the central heating system, this energises the pump on that circuit; Simultaneously, the pump on the PHE assembly is also energised. This draws heat out of the upper part of the store and down through one channel of the plate. At the same time the return from the space heating is pumped upwards through the second channel in counter current, collect heat then flows out to the emitters. Both pumps then stop at the same time when the demand is satisfied.

===Installation===

Electrically, installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pre-installed pump live wire. The pump live will be pre-wired to Terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.</b>

Hydraulic Installation:

*Connect the space heat ‘Flow’ pipe to the upper of the two free PHE connections. The ‘Return’ pipe to be connected to the lower fitting.
**It is suggested that the heating circuit pump is installed on the Flow pipework, pumping away from the upper PHE connection.
*Adjust the flow setter on the assembly to correspond with the calculated heatload of the connected circuit. The table below gives a range of settings based on an average Flow/Return delta of 15°C. Note that the pump speed can also be altered as required to achieve this value. If the installation is working off different delta’s please refer to the Power and Flow calculator on our website xxxx to calculate your own specific requirements.

===Component list===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>
</tr>

</tbody>
</table>

</html>

Heatbank Xcel Standard Assemblies

2017-04-10T14:20:51Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11B==

===Operation===

This assembly consists of a standard ‘A’ rated pump to act as a circulator between the store and a conventional boiler. A pump will usually be required when connecting to a conventional, open vented boiler which has no internal circulator: As such, this assembly is intended to be paired with <b>X2009-5 /-5B Direct boiler heat input assembly</b> (although can be paired with indirect assembly <b>X2009-6</b> if the install requires).

Control of the pump will by default be from the cylinder thermostat when a call for heat is generated, however if the connected boiler has pump control functionality (e.g. pump overrun), the factory wiring needs to be modified slightly to enable this.

===Installation===

<u>Note: The following guidance is provided assuming the store is supplied with any of options <b>X2009-5 /-6 /-8P</b></u>

Hydraulic:
*Connect the boiler flow and returns to the store assembly at the labelled positions: The flow connection is on a tee near the top of the store, above the mixer valve. The return connection will be off the bottom of the pump

Electrical:
*If the connected boiler <u>does not</u> require or have the option for pump control, then the pre-wired boiler & pump controls require no further work asides from connecting the switched live to the boiler to Terminal 12 (plus Permanent Live, Neutral & Earth).
*If the boiler <u>does</u> require pump control the following alterations should be made to the factory wiring:
**Remove the link wire between Terminals 6 and 12
**Connect the ‘Pump Live’ terminal on the boiler to Terminal 6 in the wiring centre
**Connect the ‘Switched Live/Call’ from the boiler to Terminal 12

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

Heatbank Xcel Standard Assemblies

2017-04-10T13:46:47Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

===Wiring Diagram===

==X2009-11B==

===Operation===

This assembly consists of a standard ‘A’ rated pump to act as a circulator between the store and a conventional boiler. A pump will usually be required when connecting to a conventional, open vented boiler which has no internal circulator: As such, this assembly is intended to be paired with <b>X2009-5 /-5B Direct boiler heat input assembly</b> (although can be paired with indirect assembly <b>X2009-6</b> if the install requires).

Control of the pump will by default be from the cylinder thermostat when a call for heat is generated, however if the connected boiler has pump control functionality (e.g. pump overrun), the factory wiring needs to be modified slightly to enable this.

===Installation===

Note: The following guidance is provided assuming the store is supplied with any of options <b>X2009-5 /-6 /-8P</b>

Hydraulic:
*Connect the boiler flow and returns to the store assembly at the labelled positions: The flow connection is on a tee near the top of the store, above the mixer valve. The return connection will be off the bottom of the pump

Electrical:
*If the connected boiler <u>does not</u> require or have the option for pump control, then the pre-wired boiler & pump controls require no further work asides from connecting the switched live to the boiler to Terminal 12 (plus Permanent Live, Neutral & Earth).
*If the boiler <u>does</u> require pump control the following alterations should be made to the factory wiring:
**Remove the link wire between Terminals 6 and 12
**Connect the ‘Pump Live’ terminal on the boiler to Terminal 6 in the wiring centre
**Connect the ‘Switched Live/Call’ from the boiler to Terminal 12

===Component List===

===Wiring Diagram===

Heatbank Xcel Standard Assemblies

2017-03-20T17:04:08Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref>

This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
*<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
*<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

===Wiring Diagram===

Heatbank Xcel Standard Assemblies

2017-03-20T16:28:52Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-11A==

===Operation===

The assembly consists of a standard ‘A’ rated pump to act as a circulator to a central heating radiator circuit. The pump is connected to the ‘Flow’ connection of the cylinder, i.e. pumping away from the store.The installer is provided with a pushfit Tectite fitting on the pump outlet, plus compression fitting on the return port on the cylinder to connect the circuit to. All other controls required for the operation of the central heating system (e.g. programmer, room thermostat or programmable thermostat, motorised zone valves) are not included in this assembly and are to be provided by the installer <ref>In the greater majority of installations it is found that the client and/or installer will wish to choose one from a considerable range of space heating controls solutions in the market, for functionality and aesthetics reasons. For this reason Thermal Integration usually expects that these works and their sourcing fall outside the scope of the service we provide. However, if a simple control system is requested to be supplied with the store, we can offer these options:</ref><br />
This option could also be specified if connecting to an Underfloor Heating circuit (UFH) where an additional circulator is required to act as a shunt between the store and manifolds.

===Installation===

Installation comprises connecting the switched live ‘call for heat’ from the other central heating controls, to the pump live wire. The pump live will be pre-wired to terminal 9 in the wiring centre (neutral & earth pre-wired to the common N-E positions in the centre). The installer therefore has two options:

#Connect the Permanent Live plus Neutral and Earth of their central heating controls to the permanent L-N-E of the stores wiring centre, and connect the ‘call for heat’ from the controls to Terminal 9 in the wiring centre. This therefore means that the central heating controls as well as the thermal store & boiler controls are all supplied from and can be isolated at, the same source.
#Demount the pre-wired L-N-E connections of the pump and re-wire them into a separate wiring centre that the installer fits for the wiring of the central heating controls. This means that the central heating controls are separate from the thermal store & boiler controls for the purposes of control & isolation.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

<b>HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the pump and store wiring centre, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance. </b>

<references />
#<b>Danfoss RMT 230</b> room thermostat plus <b>TS715si</b> single channel programmer, or
#<b>Danfoss TP5000si</b> programmable room thermostat

===Component List===

===Wiring Diagram===

Heatbank Xcel Standard Assemblies

2017-03-03T16:49:26Z

Jameshorscroft:

'''CONTENTS AND HISTORY'''

This page is currently a Work In Progress. 20-02-17

This page is intended to form a repository of information for the various standard assemblies that constitute an Xcel thermal store in its various permutations. It is also intended to form a kernel of content that will form an up to date set of Installation and User Instructions for the Xcel.

==X2009-2-22==

'''Mains pressure domestic hot water via plate heat exchanger''':

===Operation===

This assembly generates domestic hot water (DHW) that is supplied to the taps and showers in the property. The assembly comprise a plate heat exchanger (PHE); a circulation pump; a flow switch; a blending (tempering valve).

It generates hot water only at the moment it is required when a tap is opened and its operation is similar to that of a combination (‘Combi’) when in hot water mode.

When a hot tap is opened, water starts flowing through the assembly and is sensed by the flow switch. This turns the circulation pump on which starts to draw primary hot water from the top of the cylinder and through one side of the PHE; simultaneously, cold mains water is flowing through the other side of the plate in the opposite direction. As the two channels of water pass each other, heat is transferred from the primary side to the secondary, cold mains side, and this cold water is transformed into domestic hot water. This passes out of the plate, through the blending valve to limit its temperature, then on out to the running outlet.

Under normal use patterns, there should always be sufficient energy stored in the top of the cylinder to provide small quantities of hot water at any time of day or night, however when taking showers or filling baths it is advisable to have the gas boiler available to provide a back up energy source. (See sections '''X2009-7; X2009-8; X2009-18A''')

===Image===

===Installation===

* Check the incoming cold mains water pressure. Although the plate heat exchanger is able to withstand static pressures of up to 10Bar, it is recommended that if the pressure is in excess of 6 Bar, that a pressure reducing valve is installed upstream of the cylinder to prevent excess pressures at the outlets in the property. Additionally, all fittings and appliances connected to the mains should be rated at 50% higher than the mains pressure.
*Although operation at lower pressure is possible, it is recommended that a minimum cold mains pressure of 1 Bar is connected to the unit to deliver satisfactory performance though its full range. Flow rate performance is relative to pressure and at lower values, poor flow rates to taps and showers may be the result.
*The characteristics of the plate will help to reduce the rate at which scaling up occurs, where the store is installed in hard water areas. However it will not ultimately prevent it; therefore it is recommended that scale inhibiting or water softening equipment is installed on the incoming supply to the property in locations where scale build up is a problem.
*A cold mains water supply pipe from the incoming supply must be installed up to the unit, such that it can be connected to the flow switch pre-plumbed to the cylinder. This pipework should be installed in 22mm copper.
* An isolating valve must be fitted to the cold mains supply upstream of the cylinder, in the vicinity of the unit (e.g. within the cupboard it is located in), and in clear sight.
* A Y-pattern strainer (supplied loose) must be fitted to the cold mains supply to the cylinder, downstream of the isolating valve and in a position to permit servicing.
* The cold mains supply pipework must be connected to the unit such that the body of the flow switch sits completely vertically, and thus permit reliable operation. If it sits out of line of the vertical, this may cause the switch to activate inconsistently and fail to run the heat exchanger pump.
* The thermostatic valve fitted to the unit is to limit the temperature of DHW that is delivered to the outlets around the property, and thus reduce the risk of scalding. Note that the design operating temperature of the unit (the temperature of primary water stored in the cylinder) is in the region of 70° – 75°C and under certain conditions, the plate can deliver DHW within a few degrees of this to the inlet of the blending valve. The valve should therefore be adjusted to deliver a maximum temperature of 55°C, or a value of the client’s preference, and can then be locked to prevent tampering.
* The plate heat exchanger pump should be set at a speed that permits adequate DHW delivery at the largest outlet in the property (or the combined outlet of the total of the largest outlets wished to be drawn simultaneously - if multiple draws are required). Note that the maximum 35 litres/min is only possible with a store held at a minimum 75°C. The faster the pump speed, the higher the potential DHW flow rate. The pump should not be set at a speed higher than is necessary, to prevent a reduction in efficiency and to permit greater draws of DHW from the store. The speed dial should be set in the right hand half of the range (constant differential pressure).

<u>image of pump face here </u>

===Performance===

Maximum DHW flow rate: 35 Litres/min <ref>Limiting factor will ultimately include factors including: the pressure drop across the blending valve and plate. At 35 L/min, this is approx. 85KPa or 0.85 Bar.</ref>
Maximum possible DHW temperature: 65°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 100KW (see attached data sheet) <br />

<references />

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Altecnic Mixcal III TMV 2</td>
<td> 70200015</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-2==

'''Mains pressure domestic hot water via plate heat exchanger – higher flow rate option''':

This assembly has the same operational and installation details as assembly [[Heatbank_Xcel_Standard_Assemblies#X2009-2-22|X2009-2-22]]: The difference is that the peak flow rate is higher at approx. 45 Litres/min. This is achieved by use of a larger blending / tempering valve.

===Performance===

Maximum DHW flow rate: 45 Litres/min <br />
Maximum possible DHW temperature: 50°C <br />
Maximum recommended DHW temperature: 55°C <br />
Minimum flow rate: 3 Litres/min <br />
Maximum heat transfer rate: 120KW (see attached data sheet) <br />

===Component List===

<html>
<table width="55%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Switch</td>
<td> Sika VKX15</td>
<td> 702307</td>
<td>  </td>

</tr>
<tr>
<td> Blending Valve</td>
<td> Reliance Solar Tempering Valve 22mm</td>
<td> 70200004</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

==X2009-5==

'''Direct boiler heat input assembly (’GX Assembly’)''':

===Operation===

This patented assembly heats the store from the top down enabling faster delivery of heat to DHW from cold and recovery rates that exceed most coil type cylinders/calorifiers.
The assembly comprises a return temperature control valve; an immersed-type cylinder thermostat; Pre-installed pipework and fittings linking the top and bottom of the store and providing connections for boiler flow and returns.
For details of this assemblies comparative performance, refer to [http://heatweb.co.uk/w/index.php?title=Why_the_HEATBANK_Xcel_beat_all_the_competition#Patented_Top-Down_Reheating_of_Stored_Water Here:]

When the cylinder thermostat calls for heat, a switched live is passed to the boiler and its pump. The boiler fires and primary heated water flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 55°C, the valve starts to act as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 55°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 55°C. The process continues, heating the store from the top down until the cylinder thermostat at the lower part of the store becomes satisfied, and the switched live to the boiler is removed.

In this base form the assembly provides a single point, full store heating/recovery option. The assembly is normally associated with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

*'''X2009-7 – Second thermostat for buffered heating operation'''
*'''X2009-8 – Economy Mode thermostat'''
*'''X2009-18A – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control'''

===Image===

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 30KW. If a larger boiler is to be connected, then assembly '''X2009-5B''' should be specified prior to purchase of the thermal store (up to 60KW).
#The assembly is designed to enable direct connection of the boiler to the thermal store, i.e. not using an interface such as a primary heating coil or plate heat exchanger. It is therefore imperative that the type of boiler being connected is compatible with the system type that the store will be installed as – e.g. if the store and heating system will be open vented, the boiler must be of a regular open vented type. If the store is to be open vented but the boiler will be of a sealed system or Combi type, then alternative, indirect boiler input assembly '''X2009-6''' must be specified, as it comprises a PHE interface.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positons: the flow connection is on a tee near the top of the store, above the mixer valve. The return connection is directly off the mixer valve, off the mixed hot/cold outlet port.
#If the store has been specified with optional fitted item '''X2009-11B''' (boiler circulation pump), this will be installed below the mixed hot / cold outlet of the valve. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this must be on the boiler return leg so that circulation is pumped away from the store.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral /Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Once the mixer valve opens up and starts heating the top of the store, monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Assembly</td>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> <b>X2009-5</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 312, 55°, G1”</td>
<td> 70200001</td>
<td>  </td>
</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
<tr>
<td> <b>X2009-5B</b></td>
<td> Return Temp Control Valve</td>
<td> Esbe VTC 511, 55°, RP1”</td>
<td> 70200002</td>
<td>  </td>

</tr>
<tr>
<td>  </td>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperfroof)</td>
<td> 7025442</td>
<td>  </td>

</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-6==

'''Indirect boiler heat input assembly''':

===Operation===

This assembly performs a similar function to assembly '''X2009-5/5B''', that is to provide top-down heating and more rapid recovery of the store, compared to conventional coil-fed indirect solutions. It is used when the boiler type and store configuration are not compatible, e.g. System boiler, open vented thermal store.

The assembly comprises a plate heat exchanger; a flow setter; A circulation pump; Pre-installed pipework and fittings linking the top and bottom of the store via one channel of the plate, and provides connections for boiler flow and returns via the second channel.

When the cylinder thermostat calls for heat it both starts the circulation pump and sends a switched live to fire the boiler and its pump. In its operation, the assembly is the much the same as the DHW one ('''X2009-2/-22'''), although in this case the boiler primary flow & return flows from top to bottom on one channel, whilst the cooler stored primary water is pumped from the base of the store upwards through the second plate channel then out and into the top of the store having been heated by the boiler. The flow setter is adjusted during commissioning such that at the boilers maximum output, a delta of approximately 15°C can be maintained across the boiler flow and returns at a lower store (secondary flow) temperature of approx. 55°C.

===Installation===

#This assembly is suitable for connection to a boiler of a maximum output of 26KW. If a larger boiler is to be connected, then assembly '''X2009-6-40KW''' should be specified prior to purchase of the thermal store (up to 40KW).
#The assembly is designed to enable indirect connection of the boiler to the thermal store, i.e. where the primary boiler water does not mix with the water in the thermal store. It is important that the type of boiler being connected is compared with the system type that the store will be installed as – e.g. if the store and heating system will be both open vented, or both sealed, then direct assembly '''X2009-5/5B''' should be specified instead.
#If a solar thermal coil is fitted to the store, the assembly will be pre-installed such that the lower return connection will be located above the top of the coil to permit a solar reserve at the base. If it is required as an option that the boiler heats the entire store volume, including the solar reserve, an additional tapping at the base should be specified prior to ordering to permit the assembly to be altered on site.
#Connect the boiler flow and returns to the store assembly at the labelled positions on the plate heat exchanger: the flow connection is the upper open connection and the return the lower one.
#If the store has been specified with optional fitted item '''X2009-11''' (boiler circulation pump), this will be fitted to the lower of the two connections mentioned above. In this case, the boiler return connection will be off the bottom of the pump. If a pump is being separately sourced and installed on site, this can be installed on site in the same location, unless Manufacturer’s Instructions state to pump the flow (In this case, if the pump is pre-installed this should be altered on site as required.
#Wiring:
#*Connect the ‘Switched Live/Call’ terminal on the boiler to Terminal 12 in the wiring centre. Also connect Permanent Live / Neutral / Earth from the boiler to Live / Neutral /Earth in the wiring centre.
#*If the boiler has or requires pump control, refer to the electrical Installation instructions of Section '''X2009-11B''' Boiler Pump. Note: If the store is not supplied with '''X2009-11B''', first connect the separately sourced pump Live to Terminal 6, (plus Neutral-Neutral and Earth-Earth) then follow these instructions.
#Once all other hydraulic and electrical connections are made, and the store is filled & bled, set up of the boiler can commence:
#*Set the boiler thermostat to maximum. Create a call for heat to the boiler (e.g. active programmer).
#*Refer to [[Heatbank_Xcel_Standard_Assemblies#Table_of_Flow_Setter_Values|Flow Setter Values]] for the correct setting of the flow setter for the rated output of the boiler, and adjust accordingly (see instructions (xxx). If necessary, also adjust the speed of the pre-installed pump on the store side to achieve the required flow.
#*Monitor the boiler primary flow and return temperatures using appropriate measuring equipment (e.g. clamp on temperature sensors/probes). The return temperature should be in the region of 55° +/- 3°C. The boiler flow temperature should be in the region of 15 – 20° higher than this.
#*If the flow temperature is not within this range, adjust the boiler pump speed as required until within range.
#*The cylinder thermostat is pre-set at the factory to 65°C Under normal circumstances this will permit full heating of the store to at least this temperature, with temperatures at the top of the store approximately 10°C higher or so. This is intended to prevent the boiler from struggling to achieve high enough upper store temperatures to satisfy the base of the store, given store stratification / temperature differential top to bottom. If necessary, the cylinder thermostat temperature, or the boiler thermostat setting can be reduced slightly.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Plate Heat Exchanger</td>
<td> SWEP IC8 x 40</td>
<td> 7066554</td>
<td>  </td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>

</tr>
<tr>
<td> Flow Setter</td>
<td> Tacanova AV23 (8-30LPM)</td>
<td> 7058302</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

===Table of Flow Setter Values===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler Output (KW)</td>
<td bgcolor="#99ffcc">Delta (°C)</td>
<td bgcolor="#99ffcc">Flow Rate (Litres/Min)</td>
</tr>
<tr>
<td> 12</td>
<td> 15</td>
<td> 12.2</td>
</tr>

<tr>
<td> 15</td>
<td> 15</td>
<td> 13.3</td>
</tr>

<tr>
<td> 18</td>
<td> 15</td>
<td> 16.2</td>
</tr>

<tr>
<td> 21</td>
<td> 15</td>
<td> 19.1</td>
</tr>

<tr>
<td> 24</td>
<td> 15</td>
<td> 21.9</td>
</tr>

<tr>
<td> 28</td>
<td> 15</td>
<td> 27.6</td>
</tr>

</tbody>
</table>

</html>

==X2009-7==

'''Second thermostat and relay for buffered boiler input control''':

<u>NOTE: This assembly Must be combined with a single thermostat boiler input assembly '''X2009-5''' or '''X2009-6'''</u>

===Operation===

The use of two thermostats linked with a relay allows them to act as a latch, with one thermostat acting as the switch on (buffer on) and the other as the switch off (buffer off). With the switch off thermostat located at approximately the level of the boiler return tapping, the switch on thermostat is positioned at a distance vertically above this.

This arrangement is used to hold off firing of the boiler until there is a known volume of water at a low enough temperature to call for the boiler to fire. After the store has been fully heated and a heat demand is placed on it, heat will be draw out of the upper part of the store, whilst cooler water is returned to the base from the heating circuit return, or DHW plate heat exchanger assembly return. This effectively causes a cooler body of water (with a boundary region where the upper, hotter water meets the cooler, lower water bodies) to move up the store as it is depleted.

When the temperature of the store at the switch on thermostat falls below its set value, as the lower cooler body reaches it, the boiler fires. The boiler then continues to fire and heat the store downwards until the temperature of the store at the switch off thermostat rises to its set value. This process permits the boiler to fire for a longer period when called than when using a single point thermostat, thus reducing cycling and increasing the potential for higher boiler efficiency operation.

This assembly is often coupled with the following additional assemblies, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-8''' - Thermostat for boiler input control – Economy Mode.

===Installation===

#These thermostat options will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostats will be preset at the factory to the following set point temperatures:
#*Buffer On thermostat: 60°C
#*Buffer Off thermostat: 65°C
#Under normal circumstances these values will result in the boiler operating in the mode described above (longer but less frequent burns, reduced cycling). However, as the particular characteristics of a heating system and boiler that the store will be connected to can vary, the installer may choose to adjust them to suit. In all cases:
#*The buffer on thermostat should be set at a lower temperature that the buffer on thermostat, and a differential of at least 5°C between the thermostats is recommended.
#*Temperatures should not be set at too low a value such as to unduly affect DHW performance.
#*The buffer off temperature should not exceed 75°C

===Component List===

<html>
<table width="65%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
<tr>
<td> Relay</td>
<td> Tyco / Scrack PTF (DPDT 230Vac, 10A) or equivalent </td>
<td> 702315</td>
<td>  </td>

</tr>

</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-8==

'''Thermostat for boiler input control – Economy Mode''':

===Operation===

This additional thermostat can be used with the top-down boiler input assembly to provide store heating to a smaller store volume. Positioned higher up the store, this allows a smaller amount of stored heat to be created, for low to medium DHW demands. Alternatively, it can be used to provide supplementary / back up heat input to another heat source in a bivalent operating mode, such as if a wood burning boiler stove is connected and is alight.

This assembly is often coupled with the following additional assembly, particularly with pre-configured Data Sheet units with boiler input option;

:: A. '''X2009-18A''' – Two channel programmer for Economy Mode (‘Summer’) or Full Store buffered Mode (‘Winter’) heating control.
:: B. '''X2009-7''' - Second thermostat and relay for buffered boiler input control.

===Installation===

#This thermostat option will be suppled pre-wired and fitted to the store from the factory (excepting bespoke ordering instructions from the client). If the unit is ordered with option '''X2009-18A''' (Two Channel Programmer) fitted, there is no additional on-site wiring required apart from connecting the electrical supply to the wiring centre.
#The thermostat will be preset at the factory to 65°C

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-9==

'''Overheat Thermostat''':

===Operation===

This thermostat is installed near the top of the store and acts as a safety device. Its purpose is to pass a switched live to a central heating pump to initiate heating of a circuit or zone once the store reaches 90° in its upper region. This thereby cools the store and prevents it overheating due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels.

The circuit that is to be enabled for heat dumping may be either radiators or underfloor heating (UFH), or even both, however see following installation notes regards controls methodology. In general the requirement is that the thermostat engages the circulation pump and overrides any programmer and valve/actuator that provides normal operation control of the circuit.

===Installation===

#Ensure that the enabled circuit for dumping of heat is capable of dispersing enough energy from the store / heat input. This will depend on the type of appliance that overheat protection is being provided for. In the case of a wood burning or multi fuel boiler stove without thermostatic control, this will be the maximum rated output of the stove to the water jacket burning the most calorific fuel it is designed for. For example, if a stove has a maximum output to water of 20KW, and there are two separate heating zones in the property of 10KW each, it will be necessary to enable both circuits from the overheat thermostat.
#If motorised valves or actuators are installed on the heating circuit/s then the overheat thermostat must be wired so as to first open the appropriate valve/s and then initiate the circulation pump.
#If for example the central heating control system comprises Programmer -> room thermostat ->motorised valve -> circulation pump, then the switched live from the overheat thermostat must be wired to bypass the programmer and room thermostat, and directly energise the motorised valve first (then the pump).
#Furthermore, ensure that any fitted radiator thermostats do not prevent heat transfer, even when rooms are up to temperature. To achieve this it may be necessary to leave some radiators without thermostatic valves.
#If dumping heat into a UFH system, it will be necessary to integrate with that system’s normal controls. It will be generally necessary to simulate a call for heat that ignores the set/target room temperature of the zone/s being dumped to, but without overriding any high limit safety functions of the UFH’s own controls. This may require additional relays and wiring.
#NOTE: In order for the pre-wired overheat thermostat to engage with the central heating controls in the property, it will be necessary to supply the permanent live/neutral/earth of those controls from the permanent supply from the wiring centre of the thermal store. Alternatively, the wiring for this thermostat may be demounted from the store’s wiring centre and connected to the wiring centre of the central heating controls, if these are installed separately.

[[File:Warning_Symbol_Danger_and_Electrical.jpg|left|100px|caption]]

HOWEVER: If this is done, it is IMPERATIVE that the installer clearly labels this information on the overheat thermostat and store, to show that that it is electrically separate from the rest of the store’s controls, and from where it can be safely isolated from for servicing / maintenance.

This assembly is often used in conjunction with option '''X2009-13''' – Overheat ‘discharge to drain’ assembly. This therefore provides two levels of overheat protection, with the overheat thermostat being the first level and the '''X2009-13''' assembly providing a secondary, back up level in the event of power or component failure.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Cylinder Thermostat</td>
<td> Danfoss ICT 100 (tamperproof)</td>
<td> 7025442</td>
<td>  </td>
</tr>
</tbody>
</table>

</html>

===Wiring Diagram===

==X2009-13==

'''Overheat ‘discharge to drain’ assembly''':

===Operation===

This assembly is installed near the top of the store and acts as a safety device. Its purpose is to pass cold mains water through a heat exchanger if the store overheats and reaches approximately 90°C: The water becomes heated by the stored energy in the cylinder, and then discharged, and must be carried to a safe termination point. This thereby cools the store and prevents it reaching boiling point due to continued heat input from uncontrolled connected sources such as wood burners, or others sources with failed controls, e.g. solar panels. This assembly is also referred to as a ‘quench coil’.

The assembly comprises a heat exchanger (‘quench’) coil installed in the upper part of the store, a thermo-mechanical safety relief valve, and a flow regulating valve. A connection from the DHW plate heat exchanger assembly ('''X2009-2/-22''') outlet is continued up the store, passes through the thermo-mechanical valve, flow regulator, and into the heat exchanger. A discharge outlet from the heat exchanger is left for the installer to connect to on site. The thermo-mechanical valve has a temperature probe which is installed in a pocket near the top of the cylinder and connects to the valve via a flexible capillary. When the store temperature reaches the activation temperature of the valve of approximately 90°C (this is factory set and cannot be adjusted), a phase change in the probe exerts pressure on the valve and opens it, allowing mains water to pass through the heat exchanger. The valve starts to open at approximately 90 °C and is fully open at 94°C.

The purpose of the flow regulating valve is to control the flow rate of water passing through the heat exchanger such as to permit, ideally, a steady flow of water and heat transfer that matches the maximum heat input of the uncontrolled device. This is to reduce the possibility of ‘cycling’ of the discharge valve when it operates. This valve is factory adjusted to allow a minimum flow rate of approximately 4 - 5 litres/min, so that it cannot be fully shut off.

===Installation===

#Connect pipework to the outlet of the quench coil to a safe termination point, via a tundish, in accordance with the requirements of Approved Document G3
#Once the cold mains water supply has been connected to the store, test the function of the control valve by pressing on the red test button: Hold the test button for approximately 20 – 30 seconds to ensure that water is discharged satisfactorily to the safe termination point; then gently release the test button.
#The minimum rate of the flow regulating valve should be sufficient to discharge heat input from stoves of up to approximately 8 – 10KW output to water. For stoves of greater output (15 – 20KW) the valve should be adjusted to flow approximately 8 – 10 litres/min.
#The operation of the safety valve should be checked again during commissioning and thereafter on an annual basis.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Safety Relief Valve</td>
<td> Esbe VST112</td>
<td> 70101675</td>
<td>  </td>
</tr>
<tr>
<td> Flow Regulator</td>
<td> Lockshield gate valve - 15mm</td>
<td> 7016968</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

==X2009-5C==

'''Direct Wood Burner Heat Input Assembly on Pumped Circulation''':

===Operation===

This assembly is generally used when gravity circulation (thermosyphon) is difficult to, or cannot be, achieved between a wood burner and the thermal store, e.g. the stove and store are on the same level and / or are some distance apart horizontally. It may also be used to assist in efficient operation of a stove and capture of energy on high output appliances, where a simple gravity install is possible and would normally be considered.

The assembly heats the store from the top down much like boiler input assembly '''X2009-5'''; It is normally assembled so as to heat the entire volume of the store from top to bottom, inclusive of any solar thermal reserve. The assembly comprises a pump; a return temperature control valve (‘back end protection’); a gravity valve (supplied loose); a flue thermostat, for pump control (supplied loose); Pre-installed pipework and fittings that provide connections for the flow and returns from the stove to be connected.

When the stove is lit and combustion established, the stove structure and the connecting flue pipe will gradually increase in temperature. When the flue pipe reaches the set point temperature of the flue thermostat, this passes a switched live to the pump. Primary heated water from the stove flows to the valve, is recirculated and back to the boiler return, without entering the store. Once the primary flow reaches 60°C, the valve starts to operate as a mixer, opening the lower store connection: This draws cold water from the base of the store to regulate the water returning to the boiler at approx. 60°C. Simultaneously, primary heated water stars flowing into the top of the store, of at least 60°C. The process continues, heating the store from the top down whilst the stove is alight. When the stove dies down after firing is complete, the flue temperature drops until the flue thermostat disengages the pump.

In conditions when the pump is not running but the stove is generating heat (e.g. during warm up / cool down, or if there is a component or power failure during normal operation), the gravity valve enables a gravity circulation path to be established to allow this heat to be transferred to the store or heatleak circuit. The valve is a swing check, or one way valve: When the pump is running, the circulation forces hold the flap shut against the gravity circulation path, shutting off that particular path. When the pump stops, this pressure is removed. This then allows gravity circulation to establish and push past the flap.

<u> Image and / or drawing </u>

The location of the valve is determined by the install configuration (see below).

===Installation===

There are two principle installation configurations that this assembly can be connected to and work with. '''It is imperative that the appropriate configuration is determined prior to any setting out of work or first fix installation to ensure that all pipework and other components will be located and installed correctly: Furthermore, establishing this is key to determining the configuration of the store prior to its purchase, to ensure that it is supplied with the appropriate assemblies pre-installed'''.<br />
These configurations are:

*Partial gravity circulation – where pumped circulation will be most effective in delivering heat to the store, but where gravity circulation to the store is possible, e.g. in a component or electrical power failure scenario.
*Fully pumped circulation – where gravity circulation to the store is not possible at all.

Depending on which configuration is appropriate, this will determine how overheat protection for the system is accommodated, and the location of key components.<br />
'''It is for the installing / commissioning engineer, consultant or other professional concerned with the installation to determine which configuration is appropriate. Therefore, Thermal Integration Ltd and Specflue Ltd does not accept responsibility for the effectiveness of an installation or system that includes our products'''.

====Partial Gravity Circulation====

Also referred to as ‘Pump Assist’ or ‘Gravity Fallback’.

*The pipework installation between the stove and the store should be undertaken in a similar way to a conventional gravity installation, i.e. minimum 28mm diameter pipework, as few elbows/changes of direction as possible, use swept bends where possible, horizontal sections to have a slight rise towards store. This is to ensure that gravity circulation can be achieved to the store when the pump is not in operation.
*The flow pipe is connected to the branch of the tee on the upper part of the pre-installed pipework. Note that although the pre-assembled pipework is in 22mm, because the distance from this tee to the store inlet is small compared to the rest of the circuit, the effect of resistance on circulation under gravity is negligible.
*Because the heat from the stove will be delivered to the store in all circumstances, a suitable circulation path must be available out of the store that bypasses the pump and back end protection valve when the pump is not running: This is achieved by fitting the gravity valve to the base of the store and then installing pipework from the pump outlet to the inlet (upper port) of the tee. The outlet (lower port) of the tee then connects to the return pipe to the stove.
*The cylinder '''must''' be provided with overheat protection: All models intended for connection to wood burning stove feature a high limit thermostat ('''X2009-9'''). Standard Data Sheet models with pumped wood burner assemblies are provided with tappings to allow a quench coil to be fitted – if the configuration is specified at the time of quotation the quench assembly will be pre-installed when the unit is ordered. Alternatively, the necessary components can be purchased separately from Thermal Integration for assembly on site; or the installer may choose to provide an alternate means of overheat protection, e.g. installation of a temperature relief, or combined temperature and pressure relief valve.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of pump assist</u>

====Fully Pumped Circulation====

*Because there is no possibility of gravity circulation to the store in this scenario, overheat protection for the stove must comprise a gravity circuit that generally rises vertically above it. This should then rise to a heatleak radiator. This pipework must be undertaken in '''minimum 22mm'''; If it is deemed necessary by the installer this should be increased to '''28mm'''.
*In order to further protect the stove and to ensure a safe installation, this gravity circuit should form the cold feed and vent paths to the header tank, continuing up above the heatleak radiator; this therefore provides a free path to the vent from the stove. This pipework should be undertaken in '''minimum 22mm''' (although the final connections to the radiator can be made in 15mm). In order to counteract the positive pressure conditions that would otherwise exist in this circuit, potentially resulting in ‘pumping over’ into the header tank, the vent and cold feed pipe should be unified in a formation known as a ‘London Loop’ or Shepherd’s Crook’ (See schematic).
*The pumped circuit to the store can be undertaken in 22mm pipe.
*The pumped flow/gravity flow/vent, and pumped return/gravity return/cold feed circuits must join to make unified flow and return connections to the stove. Where the pumped return from the store meets the gravity return for the heatleak radiator, the gravity valve needs to be installed so as to prevent circulation around the heatleak whilst the pump is running, but to allow free gravity circulation when it is not.

'''<u>NOTE:</u> The following schematics are for general guidance only and do not constitute a complete system circuit. It is the responsibility of the installation / commissioning engineer to ensure that the system is installed in such a way as to meet the requirements of the relevant Building Regulations.'''

<u>image and drawing of fully pumped – distant/same floor</u><br />
<u>image and drawing of fully pumped – stove above store</u><br />
<u>image and drawing of gravity valve install</u><br />

===Component List===

<html>
<table width="60%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Pump</td>
<td> Wilo Yonos PARA RS 25/1-6</td>
<td> 7070047</td>
<td>  </td>
</tr>
<tr>
<td> Return Mixer Valve</td>
<td> Esbe VTC 312 20-3.2, 60°, G1”</td>
<td> 70200030</td>
<td>  </td>
</tr>
<tr>
<td> Flue Thermostat</td>
<td> Esbe CTF150</td>
<td> 70200077</td>
<td>  </td>
</tr>
<tr>
<td> Gravity Valve</td>
<td> VCH brass horizontal swing check valve FxF 1"</td>
<td> 70200055</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

==X2009-4==

'''Secondary Circulation of Domestic Hot Water (DHW)''':

===Operation===

This assembly can be used in properties where there are long pipe runs between the store and the most distant outlets (‘Dead Leg’), or multiple outlets in a large, multi bathroom dwelling. Its purpose is to reduce the time and amount of cold water drawn from a hot outlet, until the outlet runs hot. This aids in conserving both water and energy. This is achieved by installing pipework from the most distant hot outlet/s back to the thermal store, thus creating a loop, with a bronze pump fitted to circulate the water round this loop.

The pump requires time control in order to operate only during periods of occupancy and higher demand. The pre-installed assembly comprises: A bronze circulation pump with pump valves (suitable for connecting to cold potable & DHW systems); A one-way/check valve. A pipe thermostat is also supplied loose.

When the bronze pump is activated, it circulates water through the plate heat exchanger (PHE) and blending valve, out towards the various hot outlets, and then back round to the pump in a continuous loop. Note however that the water in this circuit does not pass through the flow switch, therefore primary heat from the store is not transferred into the circuit in the normal way. To achieve this, the pipe thermostat monitors the circuit temperature and is wired so that if it falls below a pre-determined (by installer/client) temperature, it activates the primary PHE pump and heat is transferred into this secondary loop; when the circuit temperature reaches the target the primary pump stops but the bronze one continues. This the secondary loop is held at a temperature to allow rapid delivery of DHW when an outlet opens. When this happens, the flow switch activates as normal and DHW is created/delivered in the normal way. The check valve is installed between the bronze pump and the point at which it tees into the DHW PHE assembly: This prevents the cold mains supply forcing itself backwards round the loop and disrupting the flow of DHW.

===Installation===

*The DHW distribution pipework in the dwelling needs to be installed such that it runs from the blending value outlet on the store to the various hot outlets, as normal, continues onwards from the furthest outlet/s, and then returns back to the thermal store.
*The bronze pump and check valve are pre-installed on the store, with one open connection on the pump inlet: The return of the DHW loop is to be connected here.
*The pipe thermostat needs to be attached to this return pipe within 1 Meter of the bronze pump.
*The pipe thermostat to be wired into the store wiring centre (WC) as follows: Thermostat Common (1) to WC Terminal 2; Thermostat Break on Rise (2) WC Terminal 3.
*The pipe thermostat should be set at a temperature that the client wishes the secondary loop to be maintained at when in operation. A suggested initial setting is 38°C.
*A programmer/timer (supplied by Others) should be installed such that the client can set suitable time periods for the secondary loop to be in operation. The ’Call’ from this programmer should be wired into Terminal 2 of, and permanent Live/Neutral/Earth taken from, the store wiring centre.

===Component List===

<html>
<table width="50%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Component</td>
<td bgcolor="#99ffcc">Make / Model</td>
<td bgcolor="#99ffcc">Part Code</td>
<td bgcolor="#99ffcc">Data Sheet</td>
</tr>
<tr>
<td> Bronze Pump</td>
<td> Wilo SB30</td>
<td> 7067972</td>
<td>  </td>
</tr>
<tr>
<td> Pipe Thermostat</td>
<td> Danfoss ATF Frost Thermostat</td>
<td> 7018159</td>
<td>  </td>
</tr>
</tbody>
</table>
</html>

===Wiring Diagram===

Heatbank Xcel Standard Assemblies

2017-03-03T16:32:50Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-03T16:18:51Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-03T14:16:48Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-03T12:53:44Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-03T12:47:31Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-03T12:00:46Z

Jameshorscroft:

File:Warning Symbol Danger and Electrical.jpg

2017-03-03T11:58:14Z

Jameshorscroft: Warning Symbol Danger and Electrical

Warning Symbol Danger and Electrical

File:Warning Symbol Electrical Crop 1.jpg

2017-03-03T10:29:26Z

Jameshorscroft: Warning Symbol - Electrical

Warning Symbol - Electrical

File:Warning Symbol Danger Crop 1.jpg

2017-03-03T10:28:26Z

Jameshorscroft: Warning Symbol - Danger

Warning Symbol - Danger

Heatbank Xcel Standard Assemblies

2017-03-02T17:05:49Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T16:17:14Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T16:10:23Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T15:48:48Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T15:13:30Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T15:03:14Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T14:51:18Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T14:34:15Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T12:55:02Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-03-02T12:49:08Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-02-28T15:45:12Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-02-28T10:23:54Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-02-28T10:22:09Z

Jameshorscroft:

Heatbank Xcel Standard Assemblies

2017-02-20T17:19:42Z

Jameshorscroft: Ok

Pellet sensor kit for auger fed systems - set up and operation

2016-05-03T15:02:38Z

Jameshorscroft:

==Introduction==

This article describes the set-up, operation and problem solving
of the pellet level sensor equipment that is used in conjunction with a
remote hopper and auger installation where the auger feeds pellets from
the bulk hopper directly to the day hopper on the appliance.

<br>

* MCZ part no: 40A11013
* Specflue part no: 52ECPLS
{{IMGL|Pellet_level_sensor_kit_image.png|Pellet level sensor equipment as used with auger and adjacent bulk hopper|204}}
<br>

This equipment is designed to work with / control the 2.3 Meter auger;

* MCZ part no: 40A12004
* Specflue part no: 52PA23
{{IMGL|Pellet_auger_23M_image.png|Pellet auger 2.3 Meter for use with adjacent bulk hopper an pellet level sensor kit|201}}
<br>

The sensor equipment comprises a pre-wired box, a pair of sensors
pre-wired to a plug, and a metal support bracket. The bracket is
installed in the day hopper in the appliance, the sensors are installed
onto the bracket and the plug fits in a socket on the wiring box. The
box also has a socket for electrical plug for the auger. The internals
of the wiring box comprise an On / Off power switch, connecting terminal
blocks, and a double pole double throw relay.

<br>
The sensors are positioned on the bracket at high and low level; When
the hopper is empty, and both sensors uncovered, power is sent to the
auger which operates to fill the hopper. Once the hopper is full and
both sensors covered, the power is cut and filling stops.

<br>
The sensors are of a proximity type, which can sense the presence of
objects or material in close relation to them, or just touching them,
depending on the sensitivity to which they have been set.

<br>
They have a telltale LED light to the rear; When energised and they are covered, this light will be on (usually (but not always - see below); when uncovered this light is off.

<br>

<gallery>
20150821_154153.jpg | Sensor uncovered, with light off
20150821_154032.jpg | Sensor covered, with light on
</gallery>

<br>
The sensors are of the Normally Open type - i.e. if they are uncovered, their contacts are open and do not complete a circuit.

<br>
When the sensors are covered, they complete a circuit and are ‘closed’.

<br>
A further point to consider: The wiring arrangement inside the control
system box means that the relay that delivers current to the auger motor
is wired via the Normally Closed terminals - i.e. - when the relay coil
is not energised, the auger will run: To stop the auger from running,
the coil must be energised to break the normally closed contacts.
This can be observed by disconnecting the plug with the sensors from the
wiring box, plugging the auger motor in, and then switching the box on.
The auger will run continuously as the sensors need to be both closed
in order to energise the relay coil to cut power from the auger.

<br>

==Calibration of Sensors==

<br>
The following procedure should be carried out with the sensors freely to
hand (i.e. not in their normal working location in the hopper) to aid
easy adjustment of their sensitivity.

<br>
It is also useful to have a small container full of pellets to hand to immerse the sensors in.

<br>
NOTE: When adjusting the sensors, this must be done in small increments
of a maximum of ½ turn at a time, stopping briefly to check if the state
changes, then continuing as needed. Note the effect of turning in
either direction as follows:

<br>

* Turning clockwise increases sensitivity
* Turning anti clockwise decreases sensitivity
<br>
===Stage 1===

<br>
Connect the sensors to the wiring box and hold onto them either right by
their base or carefully by their wires at the point that they enter the
sensor base - holding onto the body may cause false readings and prevent correct set up & calibration. Ensure that they are separated from each other and from any surface by a minimum of 6” / 15cm, but preferably nearer 12”/ 30cm.

<br>
Turn the control box on: The small orange lights on the base of each sensor should Not be lit.

<br>
IF: The bottom sensor is lit whilst uncovered, this should be adjusted first.

* Turn the adjustment screw anticlockwise until it goes out.
* Then, if the top sensor is also lit whilst uncovered, adjust this in the same way.
* Ensure that these adjustments are made in increments of ½ turn maximum. Keep adjusting ½ turn at a time and observing, then adjusting again, until the light goes out.
<br>

===Stage 2===

<br>
Cover the bottom sensor and keep it covered; the light may or may not come on. At this stage it is not important either way.

<br>
Now cover the top sensor to confirm its light comes on: When doing this by hand, the light should come on just
as the hand touches the end of the sensor. If it comes on as the hand
approaches the sensor and there is still a small physical air gap
between the two, it is slightly too sensitive. Move the hand away and
now adjust the sensor by a very small amount anti clockwise (Maximum ¼ turn) and slowly:

<br>

* IF the light had stayed on, stop adjusting the moment the light goes out
<br>
Now repeat the test of covering the sensor: If still too sensitive, adjust slightly again (anticlockwise)
It is imperative that adjustments at this stage are made slowly and in very small increments.
Repeat this process until the light only comes on just as the end of the
sensor is touched, and goes out again quickly after moving it away.
The top sensor should now reliably activate as soon as it is covered
(light on) and then uncovered (light off).

<br>
===Stage 3===

<br>
Now to check that both sensors active correctly and with each other:

<br>

* Uncover the top sensor - light should go out
* Uncover the bottom sensor - light also should go out.
If the auger is connected this should now run (or check for 230Vac at the auger socket
terminals). If auger does not run and no voltage present, first cover
the bottom sensor, then the top.
* If both sensor lights come on after both are covered, then repeat the first 2 steps of uncovering them again in sequence, both lights should go out in turn and the auger should now run.
* IF the auger still does not run, cover both sensors back in turn (bottom then top). Now, uncover the bottom sensor only. If its light remains on, follow the process in STAGE 2 to reduce its sensitivity.
* If at point 2 above, the bottom sensor light did not go out when uncovered, keep both sensors uncovered and follow the process in STAGE 2 to reduce its sensitivity. At the point the light goes out, the auger should run / 230Vac present at the auger socket terminals.
<br>
===Stage 4===

<br>
Reconfirm the correct operation of the sensors using the sample
container of fuel. At this stage, both sensors should be uncovered with
their lights out.

<br>
When performing this test, a valid result will be achieved by placing
the end of the sensor onto the surface of the fuel sample, so it is in
physical contact with it.

<br>
First place the bottom, then top sensors. As the top sensor touches the
fuel, both lights should go out & auger stop. Now, uncover first the
top, then the bottom sensor. As the bottom sensor is uncovered, the
auger should start. Repeat a couple of time to ensure stable activation
either way. If confirmed the calibration process is complete.

<br>
If at this stage it is discovered that they don’t activate reliably, then repeat / follow the process in STAGEs 1 & 2 as required to further adjust calibration as needed.

Remember:

* IF TOO SENSITIVE (light stays on when uncovered) - adjust with the sensor uncovered / unobstructed.
* IF NOT SENSITIVE ENOUGH (light stays off / does not come on when placed on fuel) - adjust with sensor placed on the fuel.
* ALSO: Note that the BOTTOM sensor light will Not come on when it is covered IF the top sensor is uncovered, during the correct sequence. If it remain Off when the top is then covered, adjust as per point B AND with the top sensor covered.
<br>
Once calibration is complete, the sensors can now be installed into the hopper as per the normal Installation Instructions.

<br>
NOTE: IT is strongly recommended that the sensors are attached to their
supporting bracket such that the end of the sensor sticks out into the
hopper & is immersed into fuel as far as possible - this also
ensures that the end of the sensor is as far away from the bracket as
possible.

<br>
==Problem Solving==

<br>
If the sensors had worked initially but now do not trigger the auger,
performing the correct sequence of covering & uncovering usually
resets them. With the sensors in situ in the hopper, proceed as follows:

* Cover bottom
* Cover top
* Uncover top
* Uncover bottom
<br>
If not, then it may require observing the lights on the back come on
& off as expected by temporarily demounting them. Depending on what
is discovered, follow Stages 1 - 3 above as required.

A description of the operating logic and sequencing of the sensors is given in this document:

<br>
[http://www.heatweb.com/wiki/images/2/29/Pellet_level_sensors_-_Auger_System_-_Operating_logic.pdf ] [http://www.heatweb.com/wiki/index.php?title=File:Pellet_level_sensors_-_Auger_System_-_Operating_logic.pdf Pellet level sensors - Auger System - Operating logic]

<br>
==Wiring==

<br>

{{IMGL|Pellet_level_sensors_-_wiring_schematic.png|Wiring schematic of pellet level sensor equipment|250}}
<br>
==Sequence of Operation / Logic==

<br>

<gallery>
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Full.png | 1. Hopper Full
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Emptying.png | 2. Hopper Emptying
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Empty.png | 3. Hopper Empty
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Refilling.png | 4. Hopper Refilling
</gallery>

Pellet sensor kit for auger fed systems - set up and operation

2016-05-03T14:50:12Z

Jameshorscroft:

INTRODUCTION

This article describes the set-up, operation and problem solving
of the pellet level sensor equipment that is used in conjunction with a
remote hopper and auger installation where the auger feeds pellets from
the bulk hopper directly to the day hopper on the appliance.

<br>

* MCZ part no: 40A11013
* Specflue part no: 52ECPLS
{{IMGL|Pellet_level_sensor_kit_image.png|Pellet level sensor equipment as used with auger and adjacent bulk hopper|204}}
<br>

This equipment is designed to work with / control the 2.3 Meter auger;

* MCZ part no: 40A12004
* Specflue part no: 52PA23
{{IMGL|Pellet_auger_23M_image.png|Pellet auger 2.3 Meter for use with adjacent bulk hopper an pellet level sensor kit|201}}
<br>

The sensor equipment comprises a pre-wired box, a pair of sensors
pre-wired to a plug, and a metal support bracket. The bracket is
installed in the day hopper in the appliance, the sensors are installed
onto the bracket and the plug fits in a socket on the wiring box. The
box also has a socket for electrical plug for the auger. The internals
of the wiring box comprise an On / Off power switch, connecting terminal
blocks, and a double pole double throw relay.

<br>
The sensors are positioned on the bracket at high and low level; When
the hopper is empty, and both sensors uncovered, power is sent to the
auger which operates to fill the hopper. Once the hopper is full and
both sensors covered, the power is cut and filling stops.

<br>
The sensors are of a proximity type, which can sense the presence of
objects or material in close relation to them, or just touching them,
depending on the sensitivity to which they have been set.

<br>
They have a telltale LED light to the rear; When energised and they are covered, this light will be on (usually (but not always - see below); when uncovered this light is off.

<br>

<gallery>
20150821_154153.jpg | Sensor uncovered, with light off
20150821_154032.jpg | Sensor covered, with light on
</gallery>

<br>
The sensors are of the Normally Open type - i.e. if they are uncovered, their contacts are open and do not complete a circuit.

<br>
When the sensors are covered, they complete a circuit and are ‘closed’.

<br>
A further point to consider: The wiring arrangement inside the control
system box means that the relay that delivers current to the auger motor
is wired via the Normally Closed terminals - i.e. - when the relay coil
is not energised, the auger will run: To stop the auger from running,
the coil must be energised to break the normally closed contacts.
This can be observed by disconnecting the plug with the sensors from the
wiring box, plugging the auger motor in, and then switching the box on.
The auger will run continuously as the sensors need to be both closed
in order to energise the relay coil to cut power from the auger.

<br>

CALIBRATION OF SENSORS
<br>
The following procedure should be carried out with the sensors freely to
hand (i.e. not in their normal working location in the hopper) to aid
easy adjustment of their sensitivity.

<br>
It is also useful to have a small container full of pellets to hand to immerse the sensors in.

<br>
NOTE: When adjusting the sensors, this must be done in small increments
of a maximum of ½ turn at a time, stopping briefly to check if the state
changes, then continuing as needed. Note the effect of turning in
either direction as follows:

<br>

* Turning clockwise increases sensitivity
* Turning anti clockwise decreases sensitivity
<br>
STAGE 1
<br>
Connect the sensors to the wiring box and hold onto them either right by
their base or carefully by their wires at the point that they enter the
sensor base - holding onto the body may cause false readings and prevent correct set up & calibration. Ensure that they are separated from each other and from any surface by a minimum of 6” / 15cm, but preferably nearer 12”/ 30cm.

<br>
Turn the control box on: The small orange lights on the base of each sensor should Not be lit.

<br>
IF: The bottom sensor is lit whilst uncovered, this should be adjusted first.

* Turn the adjustment screw anticlockwise until it goes out.
* Then, if the top sensor is also lit whilst uncovered, adjust this in the same way.
* Ensure that these adjustments are made in increments of ½ turn
maximum. Keep adjusting ½ turn at a time and observing, then adjusting
again, until the light goes out.
<br>

STAGE 2
<br>
Cover the bottom sensor and keep it covered; the light may or may not come on. At this stage it is not important either way.

<br>
Now cover the top sensor to confirm its light comes on: When doing this by hand, the light should come on just
as the hand touches the end of the sensor. If it comes on as the hand
approaches the sensor and there is still a small physical air gap
between the two, it is slightly too sensitive. Move the hand away and
now adjust the sensor by a very small amount anti clockwise (Maximum ¼ turn) and slowly:

<br>

* IF the light had stayed on, stop adjusting the moment the light goes out
<br>
Now repeat the test of covering the sensor: If still too sensitive, adjust slightly again (anticlockwise)
It is imperative that adjustments at this stage are made slowly and in very small increments.
Repeat this process until the light only comes on just as the end of the
sensor is touched, and goes out again quickly after moving it away.
The top sensor should now reliably activate as soon as it is covered
(light on) and then uncovered (light off).

<br>
STAGE 3

<br>
Now to check that both sensors active correctly and with each other:

<br>

* Uncover the top sensor - light should go out
* Uncover the bottom sensor - light also should go out.
If the auger is connected this should now run (or check for 230Vac at the auger socket
terminals). If auger does not run and no voltage present, first cover
the bottom sensor, then the top.
* If both sensor lights come on after both are covered, then repeat the first 2 steps of uncovering them again in sequence, both lights should go out in turn and the auger should now run.
* IF the auger still does not run, cover both sensors back in turn (bottom then top). Now, uncover the bottom sensor only. If its light remains on, follow the process in STAGE 2 to reduce its sensitivity.
* If at point 2 above, the bottom sensor light did not go out when uncovered, keep both sensors uncovered and follow the process in STAGE 2 to reduce its sensitivity. At the point the light goes out, the auger should run / 230Vac present at the auger socket terminals.
<br>
STAGE 4

<br>
Reconfirm the correct operation of the sensors using the sample
container of fuel. At this stage, both sensors should be uncovered with
their lights out.

<br>
When performing this test, a valid result will be achieved by placing
the end of the sensor onto the surface of the fuel sample, so it is in
physical contact with it.

<br>
First place the bottom, then top sensors. As the top sensor touches the
fuel, both lights should go out & auger stop. Now, uncover first the
top, then the bottom sensor. As the bottom sensor is uncovered, the
auger should start. Repeat a couple of time to ensure stable activation
either way. If confirmed the calibration process is complete.

<br>
If at this stage it is discovered that they don’t activate reliably, then repeat / follow the process in STAGEs 1 & 2 as required to further adjust calibration as needed.

Remember:

* IF TOO SENSITIVE (light stays on when uncovered) - adjust with the sensor uncovered / unobstructed.
* IF NOT SENSITIVE ENOUGH (light stays off / does not come on when placed on fuel) - adjust with sensor placed on the fuel.
* ALSO: Note that the BOTTOM sensor light will Not come on when
it is covered IF the top sensor is uncovered, during the correct
sequence. If it remain Off when the top is then covered, adjust as per
point B AND with the top sensor covered.
<br>
Once calibration is complete, the sensors can now be installed into the hopper as per the normal Installation Instructions.

<br>
NOTE: IT is strongly recommended that the sensors are attached to their
supporting bracket such that the end of the sensor sticks out into the
hopper & is immersed into fuel as far as possible - this also
ensures that the end of the sensor is as far away from the bracket as
possible.

<br>
PROBLEM SOLVING

<br>
If the sensors had worked initially but now do not trigger the auger,
performing the correct sequence of covering & uncovering usually
resets them. With the sensors in situ in the hopper, proceed as follows:

* Cover bottom
* Cover top
* Uncover top
* Uncover bottom
<br>
If not, then it may require observing the lights on the back come on
& off as expected by temporarily demounting them. Depending on what
is discovered, follow Stages 1 - 3 above as required.

A description of the operating logic and sequencing of the sensors is given in this document:

<br>
[http://www.heatweb.com/wiki/images/2/29/Pellet_level_sensors_-_Auger_System_-_Operating_logic.pdf ] [http://www.heatweb.com/wiki/index.php?title=File:Pellet_level_sensors_-_Auger_System_-_Operating_logic.pdf Pellet level sensors - Auger System - Operating logic]

<br>
WIRING

<br>

{{IMGL|Pellet_level_sensors_-_wiring_schematic.png|Wiring schematic of pellet level sensor equipment|250}}
<br>
SEQUENCE OF OPERATION / LOGIC

<br>

<gallery>
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Full.png | 1. Hopper Full
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Emptying.png | 2. Hopper Emptying
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Empty.png | 3. Hopper Empty
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Refilling.png | 4. Hopper Refilling
</gallery>

Pellet sensor kit for auger fed systems - set up and operation

2016-05-03T14:31:10Z

Jameshorscroft:

INTRODUCTION

This article describes the set-up, operation and problem solving
of the pellet level sensor equipment that is used in conjunction with a
remote hopper and auger installation where the auger feeds pellets from
the bulk hopper directly to the day hopper on the appliance.

<br>

* MCZ part no: 40A11013
* Specflue part no: 52ECPLS
{{IMGL|Pellet_level_sensor_kit_image.png|Pellet level sensor equipment as used with auger and adjacent bulk hopper|204}}
<br>
This equipment is designed to work with / control the 2.3 Meter auger;

* MCZ part no: 40A12004
* Specflue part no: 52PA23
{{IMGL|Pellet_auger_23M_image.png|Pellet auger 2.3 Meter for use with adjacent bulk hopper an pellet level sensor kit|201}}
<br>

The sensor equipment comprises a pre-wired box, a pair of sensors
pre-wired to a plug, and a metal support bracket. The bracket is
installed in the day hopper in the appliance, the sensors are installed
onto the bracket and the plug fits in a socket on the wiring box. The
box also has a socket for electrical plug for the auger. The internals
of the wiring box comprise an On / Off power switch, connecting terminal
blocks, and a double pole double throw relay.

<br>
The sensors are positioned on the bracket at high and low level; When
the hopper is empty, and both sensors uncovered, power is sent to the
auger which operates to fill the hopper. Once the hopper is full and
both sensors covered, the power is cut and filling stops.

<br>
The sensors are of a proximity type, which can sense the presence of
objects or material in close relation to them, or just touching them,
depending on the sensitivity to which they have been set.

<br>
They have a telltale LED light to the rear; When energised and they are covered, this light will be on (usually (but not always - see below); when uncovered this light is off.

<br>

<gallery>
20150821_154153.jpg | Sensor uncovered, with light off
20150821_154032.jpg | Sensor covered, with light on
</gallery>

<br>
The sensors are of the Normally Open type - i.e. if they are uncovered, their contacts are open and do not complete a circuit.

<br>
When the sensors are covered, they complete a circuit and are ‘closed’.

<br>
A further point to consider: The wiring arrangement inside the control
system box means that the relay that delivers current to the auger motor
is wired via the Normally Closed terminals - i.e. - when the relay coil
is not energised, the auger will run: To stop the auger from running,
the coil must be energised to break the normally closed contacts.
This can be observed by disconnecting the plug with the sensors from the
wiring box, plugging the auger motor in, and then switching the box on.
The auger will run continuously as the sensors need to be both closed
in order to energise the relay coil to cut power from the auger.

<br>
CALIBRATION OF SENSORS

<br>
The following procedure should be carried out with the sensors freely to
hand (i.e. not in their normal working location in the hopper) to aid
easy adjustment of their sensitivity.

<br>
It is also useful to have a small container full of pellets to hand to immerse the sensors in.

<br>
NOTE: When adjusting the sensors, this must be done in small increments
of a maximum of ½ turn at a time, stopping briefly to check if the state
changes, then continuing as needed. Note the effect of turning in
either direction as follows:

<br>

* Turning clockwise increases sensitivity
* Turning anti clockwise decreases sensitivity
<br>
STAGE 1

<br>
Connect the sensors to the wiring box and hold onto them either right by
their base or carefully by their wires at the point that they enter the
sensor base - holding onto the body may cause false readings and prevent correct set up & calibration. Ensure that they are separated from each other and from any surface by a minimum of 6” / 15cm, but preferably nearer 12”/ 30cm.

<br>
Turn the control box on: The small orange lights on the base of each sensor should Not be lit.

<br>
IF: The bottom sensor is lit whilst uncovered, this should be adjusted first.

* Turn the adjustment screw anticlockwise until it goes out.
* Then, if the top sensor is also lit whilst uncovered, adjust this in the same way.
* Ensure that these adjustments are made in increments of ½ turn
maximum. Keep adjusting ½ turn at a time and observing, then adjusting
again, until the light goes out.
<br>
STAGE 2

<br>
Cover the bottom sensor and keep it covered; the light may or may not come on. At this stage it is not important either way.

<br>
Now cover the top sensor to confirm its light comes on: When doing this by hand, the light should come on just
as the hand touches the end of the sensor. If it comes on as the hand
approaches the sensor and there is still a small physical air gap
between the two, it is slightly too sensitive. Move the hand away and
now adjust the sensor by a very small amount anti clockwise (Maximum ¼ turn) and slowly:

<br>

* IF the light had stayed on, stop adjusting the moment the light goes out
<br>
Now repeat the test of covering the sensor: If still too sensitive, adjust slightly again (anticlockwise)
It is imperative that adjustments at this stage are made slowly and in very small increments.
Repeat this process until the light only comes on just as the end of the
sensor is touched, and goes out again quickly after moving it away.
The top sensor should now reliably activate as soon as it is covered
(light on) and then uncovered (light off).

<br>
STAGE 3

<br>
Now to check that both sensors active correctly and with each other:

<br>

* Uncover the top sensor - light should go out
* Uncover the bottom sensor - light also should go out. If auger
connected this should now run (or check for 230Vac at the auger socket
terminals). If auger does not run and no voltage present, first cover
the bottom sensor, then the top.
* If both sensor lights come on after both are covered, then repeat
the first 2 steps of uncovering them again in sequence, both lights
should go out in turn and the auger should now run.
* IF the auger still does not run, cover both sensors back in turn
(bottom then top). Now, uncover the bottom sensor only. If its light
remains on, follow the process in STAGE 2 to reduce its sensitivity.
* If at point 2 above, the bottom sensor light did not go out when
uncovered, keep both sensors uncovered and follow the process in STAGE 2
to reduce its sensitivity. At the point the light goes out, the auger
should run / 230Vac present at the auger socket terminals.
<br>
STAGE 4

<br>
Reconfirm the correct operation of the sensors using the sample
container of fuel. At this stage, both sensors should be uncovered with
their lights out.

<br>
When performing this test, a valid result will be achieved by placing
the end of the sensor onto the surface of the fuel sample, so it is in
physical contact with it.

<br>
First place the bottom, then top sensors. As the top sensor touches the
fuel, both lights should go out & auger stop. Now, uncover first the
top, then the bottom sensor. As the bottom sensor is uncovered, the
auger should start. Repeat a couple of time to ensure stable activation
either way. If confirmed the calibration process is complete.

<br>
If at this stage it is discovered that they don’t activate reliably, then repeat / follow the process in STAGEs 1 & 2 as required to further adjust calibration as needed.

Remember:

* IF TOO SENSITIVE (light stays on when uncovered) - adjust with the sensor uncovered / unobstructed.
* IF NOT SENSITIVE ENOUGH (light stays off / does not come on when placed on fuel) - adjust with sensor placed on the fuel.
* ALSO: Note that the BOTTOM sensor light will Not come on when
it is covered IF the top sensor is uncovered, during the correct
sequence. If it remain Off when the top is then covered, adjust as per
point B AND with the top sensor covered.
<br>
Once calibration is complete, the sensors can now be installed into the hopper as per the normal Installation Instructions.

<br>
NOTE: IT is strongly recommended that the sensors are attached to their
supporting bracket such that the end of the sensor sticks out into the
hopper & is immersed into fuel as far as possible - this also
ensures that the end of the sensor is as far away from the bracket as
possible.

<br>
PROBLEM SOLVING

<br>
If the sensors had worked initially but now do not trigger the auger,
performing the correct sequence of covering & uncovering usually
resets them. With the sensors in situ in the hopper, proceed as follows:

* Cover bottom
* Cover top
* Uncover top
* Uncover bottom
<br>
If not, then it may require observing the lights on the back come on
& off as expected by temporarily demounting them. Depending on what
is discovered, follow Stages 1 - 3 above as required.

A description of the operating logic and sequencing of the sensors is given in this document:

<br>
[http://www.heatweb.com/wiki/images/2/29/Pellet_level_sensors_-_Auger_System_-_Operating_logic.pdf ] [http://www.heatweb.com/wiki/index.php?title=File:Pellet_level_sensors_-_Auger_System_-_Operating_logic.pdf Pellet level sensors - Auger System - Operating logic]

<br>
WIRING

<br>

{{IMGL|Pellet_level_sensors_-_wiring_schematic.png|Wiring schematic of pellet level sensor equipment|250}}
<br>
SEQUENCE OF OPERATION / LOGIC

<br>

<gallery>
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Full.png | 1. Hopper Full
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Emptying.png | 2. Hopper Emptying
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Empty.png | 3. Hopper Empty
Pellet_level_sensors_-_Operating_Logic_-_Hopper_Refilling.png | 4. Hopper Refilling
</gallery>

Amazon HXIN Unvented DHW Cylinder

2016-04-26T14:16:55Z

Jameshorscroft: /* Plumbing */

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|none|500px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most convention indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - which can be a feature of conventional single thermostat systems - and thus aids in boiler efficiency.

When the cylinder temperature at the Buffer Off position drops below its set point, it in turn energises the buffer on thermostat; If this is simultaneously calling for heat, it turns on the plate heat exchanger pump. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel, is heated, and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate, in order to maintain the stored DHW at the required set point; As the DHW flowing away from the plate approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied with the plate heat exchanger and bronze pump pre-plumbed, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder Manufacturer’s Instructions. Expansion and Temperature / Pressure relief valves should be connected to discharge pipework (via the tundish) that is installed in accordance with Building Regulations Document G, as described in the cylinder Manufacturer’s Instructions.

Consideration must be given by the installer to the primary flow and return temperature delta and flow rates of the boiler plant or primary heat source that is to be connected. The set up and operation of the unit assumes a delta on the CWMS in / DHW out side of the plate of 50°C in a single pass. The resultant delta on the primary side can be in the region of 40 - 45°C and flow rates of 15 - 35 Litres/min., dependent on the power of the heat source and its flow temperature. If the connected plant or heat source cannot operate with these deltas or flow rates, suitable bypass and flow regulation equipment must be sourced and fitted by the installer upstream of the plate heat exchanger to accommodate this.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base, and a further connection made between the two push fit fittings seen at mid level on each cylinder using the pipework & flows setter assembly (supplied loose).

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual.jpg|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. Note that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) should all be taken from the wiring centre in order to achieve electrical balance with the switched live outputs to both the boiler when called, and zone control for space heating.

==Set up & commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}

Amazon HXIN Unvented DHW Cylinder

2016-04-25T16:38:16Z

Jameshorscroft:

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|none|500px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most convention indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - which can be a feature of conventional single thermostat systems - and thus aids in boiler efficiency.

When the cylinder temperature at the Buffer Off position drops below its set point, it in turn energises the buffer on thermostat; If this is simultaneously calling for heat, it turns on the plate heat exchanger pump. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel, is heated, and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate, in order to maintain the stored DHW at the required set point; As the DHW flowing away from the plate approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied pre-plumbed with the plate heat exchanger and bronze pump, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder Manufacturer’s Instructions. Expansion and Temperature / Pressure relief valve should be connected to discharge pipework (via the tundish) that is installed in accordance with Building Regulations, as described in the cylinder Manufacturer’s Instructions.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base, and a further connection made between the two push fit fittings seen at mid level on each cylinder using the pipework & flows setter assembly (supplied loose).

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual.jpg|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. Note that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) should all be taken from the wiring centre in order to achieve electrical balance with the switched live outputs to both the boiler when called, and zone control for space heating.

==Set up & commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}

Amazon HXIN Unvented DHW Cylinder

2016-04-25T16:36:13Z

Jameshorscroft: /* Set up & commissioning of DHW controls */

==Labelled Cylinder Drawing==

[[File:Amazon HXIN labelled cylinder drawing.jpg|none|500px]]

==System Overview==

The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and recovery times than possible with most convention indirect coil type cylinders, as the full output of the boiler or primary heat source can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.

The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants

==Principle of Operation==

The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating of the cylinder. The ‘Buffer On’ thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a ‘high limit’ overheat cut-out facility). The ‘Buffer Off’ thermostat is tee’d into the plate heat exchanger assembly. This dual thermostat arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - which can be a feature of conventional single thermostat systems - and thus aids in boiler efficiency.

When the cylinder temperature at the Buffer Off position drops below its set point, it in turn energises the buffer on thermostat; If this is simultaneously calling for heat, it turns on the plate heat exchanger pump. In parallel, this calls for heat from the boiler or heat source via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other channel, is heated, and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both the buffer thermostats are satisfied.

A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the plate, in order to maintain the stored DHW at the required set point; As the DHW flowing away from the plate approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.

A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be necessary to adjust the plate heat exchanger pump speed as required.

==Plumbing==

The cylinder will be supplied pre-plumbed with the plate heat exchanger and bronze pump, and pre-wired with the buffering and safety thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the cylinder Manufacturer’s Instructions. Expansion and Temperature / Pressure relief valve should be connected to discharge pipework (via the tundish) that is installed in accordance with Building Regulations, as described in the cylinder Manufacturer’s Instructions.

For twin cylinder variants Only:
Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet connections at their base, and a further connection made between the two push fit fittings seen at mid level on each cylinder using the pipework & flows setter assembly (supplied loose).

==Wiring==
[[File:Amazon HXIN Wiring for Install Manual.jpg|center|500px]]

Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired. Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. Note that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) should all be taken from the wiring centre in order to achieve electrical balance with the switched live outputs to both the boiler when called, and zone control for space heating.

==Set up & commissioning of DHW controls==

Having completed the installation of the cylinder as per the manufacturer’s instructions, and filled it, the set up of the temperature and flow controls can be undertaken as follows:

# The two cylinder thermostats should be set as follows:
#* Dual thermostat on cylinder: 50°C
#* ICT thermostat tee’d off heat exchanger: 55°C
# Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
#* The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic control of the DHW temperature being produced – see attached data sheets for further identification.
#* The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
#* Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow setter:
#*; Adjustment of the Taconova Flow Setters.
#: “The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle float."
# The DHW temperature control valve (RAVK or AVTB) is to be set such that 60°C is observed at the DHW outlet from the heat exchanger, entering the cylinder (where the capillary tube from the valve is fitted). This equates to a setting on the adjustment knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the flowsetter.

==Tables of Flow Setter values==

<b>TABLE A: DHW flow setter values Vs. Boiler output - 50KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 10</td>
<td> 50</td>
<td> 2.9</td>
</tr>
<tr>
<td> 15</td>
<td> 50</td>
<td> 4.3</td>

</tr>
<tr>
<td> 20</td>
<td> 50</td>
<td> 5.7</td>

</tr>
<tr>
<td> 25</td>
<td> 50</td>
<td> 7.1</td>

</tr>
<tr>
<td> 30</td>
<td> 50</td>
<td> 8.6</td>

</tr>
<tr>
<td> 35</td>
<td> 50</td>
<td> 10</td>

</tr>
<tr>
<td> 40</td>
<td> 50</td>
<td> 11.4</td>

</tr>
<tr>
<td> 45</td>
<td> 50</td>
<td> 12.9</td>

</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>

</tr>
</tbody>
</table>

</html>

<b>TABLE B: DHW flow setter values Vs. Boiler output - 100KW version</b>

<html>
<table width="40%" cellspacing="0" cellpadding="5" border="1">
<tbody>
<tr>
<td bgcolor="#99ffcc">Boiler output (KW)</td>
<td bgcolor="#99ffcc">Temperature rise</td>
<td bgcolor="#99ffcc">Flow rate (L/min)</td>
</tr>
<tr>
<td> 50</td>
<td> 50</td>
<td> 14.3</td>
</tr>
<tr>
<td> 55</td>
<td> 50</td>
<td> 15.7</td>

</tr>
<tr>
<td> 60</td>
<td> 50</td>
<td> 17.1</td>

</tr>
<tr>
<td> 65</td>
<td> 50</td>
<td> 18.6</td>

</tr>
<tr>
<td> 70</td>
<td> 50</td>
<td> 20</td>

</tr>
<tr>
<td> 75</td>
<td> 50</td>
<td> 21.4</td>

</tr>
<tr>
<td> 80</td>
<td> 50</td>
<td> 22.9</td>

</tr>
<tr>
<td> 85</td>
<td> 50</td>
<td> 24.3</td>

</tr>
<tr>
<td> 90</td>
<td> 50</td>
<td> 25.7</td>

</tr>
<tr>
<td> 95</td>
<td> 50</td>
<td> 27.1</td>

</tr>
<tr>
<td> 100</td>
<td> 50</td>
<td> 28.6</td>

</tr>
</tbody>
</table>

</html>

==Data Sheets==

{{F|RAVK Data Sheet.pdf|RAVK Data Sheet}}
{{F|Danfoss AVTA Datasheet.pdf|AVTB Data Sheet}}
{{F|Taconova AV23 Inline Flow Setter.pdf|Flow Setter Data Sheet}}
{{F|Wilo SB30 Bronze Pump.pdf|Wilo SB30 Bronze Pump}}