EnergyMaster Manual

INTEGRATED RENEWABLE & HEATING SOLUTIONS

underfloor heating
ground source heat pumps
air source heat pumps
solar thermal
rainwater harvesting
v01 Nu-Heat
ENERGYMASTER THERMAL STORE MANUAL
Nu-Heat
U N D E R F L O O R & R E N E W A B L E S
INTRODUCTION
It is a condition of the warranty that the Commissioning Certificate included in the Handover Pack is completed and
returned to Nu-Heat once the system is fully commissioned.The annual maintenance record at the back of the
EnergyMaster User Guide must also be completed at each yearly inspection.
This manual gives all the information needed to install your Nu-Heat EnergyMaster Thermal Store.
Building control must be notified of the fitting of this unvented thermal store.
Installation of an unvented thermal store must be carried out by a Competent Person or, failing that, the local building
control authority must be notified of the proposed work before commencement and the completed installation must be
inspected by a Competent Person.
In order for the process to be achieved quickly and easily the principle of operation should be understood. The following
pages have comprehensive diagrams showing the purpose of each component and its position in the installation.
Parts supplied are listed - please note that pipework and some sundry fittings will be site supplied.
Attention to the advice given in this manual will help to ensure a trouble-free and effective installation. The requirements
of the relevant British Standards and IEE Wiring Regulations should always be met.
bs7671: 2008. requirements for electrical installations, iee wiring regulations, building
regulations electrical safety (part p)
Electrical installation must be carried out by a Competent Person or, failing that, the local building control Authority
must be notified of the proposed work before commencement and the completed installation must be inspected by a
Competent Person.
optional additional equipment
Where connections are shown to equipment that is not supplied by Nu-Heat, this is for guidance only. In all such cases
the suppliers installation information should be checked before fixing and connecting the equipment.
Attention to the advice given in this manual will help to ensure a trouble-free and effective installation. The requirements
of the relevant British Standards, Water Regulations and other regulations should always be met.
If there is any aspect of the installation that you do not understand, please contact Nu-Heat Technical Support, quoting
your system reference number, for advice.
In line with the company policy of product development, Nu-Heat reserves the right to supply different components to
those shown.
This manual is the copyright of Nu-Heat. All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise
without prior written permission of Nu-Heat.
EnergyMaster Manual
page contents
2 Introduction
4 Cylinder storage on site
4 Positioning the cylinder
4 Cylinder connections
5 Performance
5 Mains water supply
5 Pipework
6 Components
9 Temperature/pressure relief valve discharge
10 Immersion heater control
10 Thermal cut-outs
11 Connection position of secondary hot water loop
12 EnergyMaster hot water supply
13 Cleansing, filling, flushing and commissioning the cylinder
15 Draining the cylinder
15 Hard water precautions
15 Troubleshooting, warranty and servicing requirements
CYLINDER STORAGE ON SITE
The cylinder should be stored under cover, in a dry place. It may be tilted for
handling around site, but beware of laying the cylinder horizontally as this could
inadvertently cause damage to the connection tappings.
POSITIONING THE CYLINDER
The cylinder location will have been discussed as part of the system design
process, and the agreed position will be noted on the A3 System Illustration and
Manifolds. Space must be provided for access to allow any future maintenance
and replacement work
Please note the cylinder weight in order to ensure that the floor on which it sits
is structurally sufficient.
EnergyMaster 210 litre 260 kg
EnergyMaster 210 litre solar 263 kg
EnergyMaster 300 litre 365 kg
EnergyMaster 300 litre solar 368 kg
EnergyMaster 400 litre solar 474 kg
CYLINDER CONNECTIONS
Please see the A3 System Illustration and Manifolds supplied for the overall
plumbing scheme.
A Product Data Sheet is provided in the Handover Pack show all the fittings
supplied and the purpose of each tapping.
The cylinder relief valve shall not be used for any other purpose
Note: Push fit fittings must not be connected to the stainless steel tails as the
grab ring will not grip the stainless steel.
EnergyMaster Manual
PERFORMANCE
The EnergyMaster cylinder is designed to provide the following maximum flow
rates when raising mains cold water through 40C at full duty:
EnergyMaster 210 litre (incl. solar) 27 litres/minute
EnergyMaster 300 litre (incl. solar) 40 litres/minute
EnergyMaster 400 litre solar 40 litres/minute
MAINS WATER SUPPLY
The cylinder should take its mains water feed after the supply to the kitchen, but
before all other cold water draw-offs, above the stop cock. If the mains pressure
exceeds 3.5-bar it should be limited to this figure by a pressure reducing valve
(not supplied) equal to the size of the connecting pipework, fitted after the
incoming stopcock and the supply to the kitchen and before any draw-off points.
A mains water input of up to the maximum performance figures stated above
(or double for dual cylinders) is required at minimum static pressure of 2-bar.
Where the supply is inadequate but the incoming mains pressure is over 2-bar
it can be boosted with a purpose designed accumulator vessel. Please contact
Nu-Heat for details. A non-return valve and expansion vessel is supplied to
meet water regulations.
PIPEWORK
The minimum size of copper pipework to be used for mains water connections
to and from the cylinder is:
EnergyMaster 210 litre (incl. solar) 22mm
Dual EnergyMaster 210 litre (incl. solar) 22mm
EnergyMaster 300 or 400 litre (incl. solar) 28mm
Dual EnergyMaster 300 or 400 litre (incl. solar) 35mm
COMPONENTS
energymaster cylinder
Please refer to your A3 System Illustration and Manifolds for your specific
plumbing schematic.
Please note: installation of the EnergyMaster thermal store is notifiable work.
The EnergyMaster cylinder stores water for both the floor heating and the
production of domestic hot water. If the temperature of the water in the
cylinder falls below the level set on the cylinder thermostat, the boiler is turned
on and hot water is circulated into the body of the cylinder to replenish the
store. A secondary over-temperature cut out protects against failure of the
dual cylinder thermostat/primary over-temperature cut-out.
If installed with a solar thermal system, the solar pump will be brought on to
heat the cylinder when the hot water temperature in the cylinder drops. If there
is any shortfall this will be made up by the boiler which is called on by the
cylinder thermostat.
In larger properties either a larger cylinder, or twin cylinders may be recommended
to ensure an adequate supply of hot water.
1. Automatic air vent
2. Secondary over-temperature cut out
3. Pressure relief valve (factory fitted)
4. Chrome pipework assembly (trim to length)
5. Hot water blending valve
6. Flow switch
7. Dual cylinder thermostat/primary over-temperature cut-out
8. 3kW immersion heater
expansion vessel
The EnergyMaster cylinder is supplied with a 2 litre expansion vessel. This vessel
absorbs the small amount of expansion in the domestic hot water pipework
when the system is hot and must be checked and set to 4-bar when the
system is cold, at commissioning stage.
non-return valve
A non-return valve is supplied to comply with the water regulations and prevent
backflow. It must be positioned in the flow to the EnergyMaster cylinder after
the cold tee off to the kitchen, in line with water regulations. See A3 System
Illustration and manifolds for details.
25
45
65
1
2
3
4
5
6
7
8
COMPONENTS cont.
auto air vent operation and maintenance
For rapid venting when filling the cylinder remove both caps and depress the
valve under the red cap with a screwdriver. Replace the red cap when the
system is full.
During normal operation the cylinder is vented by leaving the black bleed cap
loose, this allows stray pockets of air to escape automatically and should be
checked regularly.
Important: to prevent cylinder collapse when draining down the system ensure
the rapid venting valve is depressed or the air vent connections loosened.
pressure relief valve
If, in the unlikely event of failure of all other safety devices, the cylinder
reaches excessively high pressure then water will be discharged by this valve.
The outlet from this valve should be safely taken to waste via copper pipe
(see Temperature/pressure relief valve discharge section). The valve should be
manually operated during the annual servicing by turning the knob in order to
check that it is free to function.
shunt pump, valves and bends
Mounted on the EnergyMaster cylinder and controlled by the flow switch, this
pump circulates stored boiler water through the domestic hot water heat exchanger
giving mains-pressure hot water on demand. Important: Arrow indicates direction
of water flow.
flow switch
The flow switch detects the flow of water into the EnergyMaster cylinders internal
heat exchanger. The switch operates the shunt pump, ensuring that the heat
exchanger can work at its maximum capacity. The flow switch must be fitted in
the orientation shown, with the arrow pointing upwards.
isolating valve and strainer
The in-line 22mm isolating ball valve with filter is fitted on the cold mains supply
to the EnergyMaster cylinder. It prevents grit getting into the cylinder and enables
the cold water supply to the cylinder to be shut off if necessary. It must be fitted
with the trap below the pipework. Restrict the incoming mains cold water flow rate
to between 22 and 27 litres/min. for 210 litre cylinders, 36 and 40 litres/min. for 300
and 400 litre cylinders. For dual cylinders the flow must be equal to each cylinder.
EnergyMaster Manual
Rapid vent
screw
Bleed screw
Pressure
relief valve
Shunt pump,
valves and
bends
Flow switch
Isolating valve
and strainer
COMPONENTS cont.
cylinder zone valves
Two cylinder zone valves are supplied, and both must be fitted. One is controlled
by the dual cylinder thermostat/over-temperature cut-out. The second is controlled
by the secondary over-temperature cut-out at the top of the cylinder. It is a
requirement of building regulation G3 that, with unvented thermal stores, there
are two independent over-temperature cut-outs, and they must each operate an
independent valve.
expansion vessel and filling loop assembly
The expansion vessel forms part of the filling loop assembly. It accommodates
boiler and cylinder water expansion when the system is hot. Use in addition to
any internal system boiler expansion vessels to accommodate the additional
expansion of the EnergyMaster cylinder water volume. It is important to note:
before fitting the expansion vessel the air pressure must be reset.
Refer to A3 System Illustration and Manifolds.
1. Connection to boiler primaries
2. Pressure gauge
3. Pressure relief valve
4. Discharge to waste
5. Non-return valve
6. Isolating valves (2)
7. 15mm cold mains in
8. 15mm Pressure reducing valve adjusted to 1-bar maximum fill pressure
9. Air valve connection (for charging and checking pre-charged air pressure)
10. Expansion vessel
9 10
6 8
1 2 3 4 5 6
7
EnergyMaster Manual
PRESSURE RELIEF VALVE DISCHARGE
The pipe work that takes any discharge from the pressure relief valve should be
fitted in copper.
The pipe outlet should be taken to a safe place, as any water/steam released is a
scald hazard. Such a safe place would be below a fixed grate to a trapped gully.
Note that the discharge will be either very hot water or steam that will cause
damage to certain plastics or asphalt, etc.
The pipe work should be sized so as not to restrict the discharge. The diameter
of pipe connected to the pressure relief valve (D1) should be at least as large as
the outlet of the valve, and the pipe run must be no more than 600mm length
before the tundish. The pipe should drop continuously away from the valve.
The tundish outflow should be made in at least the next largest size up from the
inlet. If the length of pipe is greater than 9m then the next size up is required (i.e.
if a 22mm outflow, then 28mm pipe work), and if longer than 18m then two sizes
larger, and so-on. Any bends and elbows also present a pressure drop, and these
must be accounted for by assigning an equivalent pipe length as given in the
table below.
1/2 Valve Pipe size (mm)
22
28
35
Max. pipe length based
on straight length (m)
9
18
27
Equivalent resistance of
bend or elbow (m)
0.8
1.0
1.4
There must be a straight drop of
300mm below the tundish. Safety device
(e.g. temperature
relief valve) 600mm
max.
300mm min.
Metal discharge pipe (D2) from
tundish with continuous fall
Metal discharge pipe (D1) from
temperature relief valve to tundish
Tundish
Discharge below fixed grating
or suitable alternative
Fixed grating
Trapped gulley
IMMERSION HEATER CONTROL
An immersion heater is supplied with the cylinder to provide a back-up in case,
say, of oil or LPG running out. Please see the A3 Underfloor Heating Control
Systemdrawings for wiring information.
The immersion heater must be installed with a fuse as rated by the manufacturer,
and comply with the relevant electrical standards.
Note: The immersion heater supplied is fitted with a thermal cut-out. This is
an essential safety requirement, and immersion heaters without thermal
cut-outs must not be used.
THERMAL CUT-OUTS
All cylinders are provided with a dual stat with over-temperature cut-out, and
a second over-temperature cut-out thermostat (high limit stat) to prevent the
cylinder from exceeding 90 C. These must operate two separate cylinder zone
valves in order to comply with Part G of the building regulations.
EnergyMaster Manual
CONNECTION POSITION OF SECONDARY HOT WATER LOOP
25
45
65
Auto air vent
Hot water to taps
Mains cold water
Underfloor heating
Immersion
heater
Drain-off
Flow
Return
Secondary Hot Water Loop return
supplied separately
NRV
NRV
ENERGYMASTER HOT WATER SUPPLY
domestic hot water temperature blending valve
The domestic hot water blending valve should be fitted to the EnergyMaster
cylinder. It is supplied pre-set to 43C however BS6700 recommends that water
be distributed at no less than 45C. If a hot water loop is to be used then the
HSCs Legionnaires disease: The control of legionella bacteria in water systems
Approved Code of Practice and Guidance says that this temperature should be
50C or more.
If the temperature of circulation necessary to achieve this poses a significant risk
of scalding then the temperature should, in addition, be blended down as close
to the output as possible, especially at bath taps which must be limited to 48C
according to Building Regulations Part G3. These additional blending valves are
not supplied by Nu-Heat.
In order to set a different temperature, do as follows:
Remove the screw securing the knob to the valve.
Remove both the knob and the locking ring.
Replace the knob temporarily.
Open a tap and adjust the set temperature of the valve as required
(anti clockwise to increase and clockwise to decrease).
Remove the knob and refit the locking ring.
Locate the tab on the inner face of the knob.
maintenance of the domestic hot water blending valve
The valve should be checked and cleaned annually. If the cylinders domestic
hot water pipe is hot and the blending valve outlet pipe is cold it is possible that
there is a build up of scale within the valve. To strip down the valve and clean:
Drain the domestic hot water system.
Isolate the valve and remove the knob and locking ring.
Unscrew the large hexagonal cap and slide out the interior parts of the valve.
(Note the orientation of the parts to aid reassembly).
After cleaning and reassembling, the valve should be reset and tested.
Domestic hot water temperature
blending valve (210 litre)
35
MIN
MAX
65
Domestic hot water temperature
blending valve (300 litre)
EnergyMaster Manual
CLEANSING, FILLING, FLUSHING AND COMMISSIONING THE CYLINDER
Once installation is complete the system must be cleansed to remove any solder or flux residues, or any other foreign
matter. Cleansing of the DHW system will not require a significant volume of fluid.
Any cleansing agent must not have a chlorine level exceeding 250mg/litre. This solution must be thoroughly
flushed through, as high levels of chlorine are corrosive to the cylinder.
Filling the domestic hot water side:
Before filling, check expansion vessel charge is at 3.5bar.
Open all outlets on the domestic hot water circuit. Open the main supply to the unit.
Flush the unit through until all air is expelled.
Close hot outlets and open all cold outlets connected after the pressure reducing valve for the incoming mains. Flush
through until all air is expelled.
The domestic water side of the system is now full of water. Check for any leaks on pipework or joints. It is the installers
responsibility to check all fittings, including those that are fitted to the unit.
Filling the main cylinder volume:
The boiler filling loop can be used to fill the cylinder. Whilst filling the cylinder it is important that the fast purge valve
under the red cap of the Automatic Air Vent is depressed. Alternatively the air vent may be removed until the cylinder is
nearly full, and then the fast purge should be used.
CLEANSING, FILLING, FLUSHING AND COMMISSIONING THE CYLINDER
commissioning the energymaster cylinder
System settings
25
45
65
1. Set the boiler thermostat to a mini-
mum of 75C so that it is higher than
the cylinder thermostat. Ensure the
boiler output rating is set to
maximum. If resetting is necessary,
please refer to manufacturers
instructions.
2. Set the cylinder thermostat to 65C
(maximum).
3. Set the cylinder shunt pump to
constant curve speed 3 if using an
UPS2 pump (see below). If using
a Magna pump, set to 3m head (see
below for details).
4. Set the boiler pump to maximum.
Note: When the system has been
running for at least 60 minutes, the
temperature difference between the
flow and return pipework at the boiler
should be approximately 11C. If it is
much higher than this, check that the
boiler pump is set to maximum, (if using
a system boiler the pump will be inside
the boiler and may not be adjustable).
If it remains high, please call Nu-Heat
Customer Support for advice.
The cylinder must be thoroughly
checked in accordance with the
Commissioning Checklist and Warranty
Application form in the Handover
Pack. This must be fully completed
during the commissioning process and
returned to Nu-Heat for registration.
No warranty can be issued without
the return of the completed
Commissioning Checklist to Nu-Heat.
Pump model
Grundfos UPS2

Grundfos
Magna
Press to cycle through
the options until constant
pressure mode is lit
Press to cycle through
the options until III is lit
continuously (fixed speed
mode, speed III)
Optimum setting
Then use and to set
the pressure to 3 (3m head)
2. 3. 4.
EnergyMaster Manual
DRAINING THE CYLINDER
Draining the Domestic Hot Water side of the cylinder:
Ensure that the mains is isolated
Open a tap, or to release the pressure from the system use a tap that is higher in the property than the cylinder.
Leaving the tap open, and using a bucket to collect the water, carefully remove the blanking cap from the isolating valve
and strainer on cold mains inlet and use this to drain the hot water side. Remember to close the butterfly valve to
prevent flow of fresh water from the mains.
Once the cylinder is empty remember to close the tap.
Refill as per filling instructions.
Draining the main cylinder volume:
Be aware that boiler water flows directly into the cylinder.
If required, isolate manifolds and all other circuits to prevent draining down of whole system.
Note: It is essential during draining that either the red cap fast purge on the auto air vent is depressed, or the auto
air vent completely removed from the cylinder.
Failure to do so may collapse the cylinder under the weight of water.
Connect a hose to the cylinder drain off valve. Open the valve and drain the cylinder to waste.
Refill via the boiler filling loop as per previous instructions. The inhibitor levels in the system will need to be checked
after re-filling.
HARD WATER PRECAUTIONS
If the property is in a hard water area (where Ca CO3 exceeds 200ppm), a softener should be used to prolong the life of the
cylinder heat exchanger. If the cylinder heat exchanger should scale up, a proprietary flushing solution should be used with
a flushing pump between the cold mains in and the hot outlet. Make sure that the flushing agent is fully dispersed afterwards.
Any cleansing agent must not have a chlorine level exceeding 250mg/litre. This solution must be thoroughly flushed
through, as high levels of chlorine are corrosive to the cylinder.
TROUBLESHOOTING, WARRANTY AND SERVICING REQUIREMENTS
The EnergyMaster cylinder features a 25 year warranty. In order to validate the warranty, the EnergyMaster must be serviced
annually. For full details of the EnergyMaster troubleshooting, servicing requirements and a maintenance log, please refer
to the EnergyMaster Cylinder User Guide.
Heathpark House, Devonshire Road,
Honiton, Devon EX14 1SD
Tel: 01404 549770
Fax: 01404 549771
Web: www.nu-heat.co.uk
Email: info@nu-heat.co.uk
Nu-Heat
U N D E R F L O O R & R E N E W A B L E S
If there is any aspect of the installation that you do not understand, please
contact Nu-Heat Technical Support for advice.
All illustrations and diagrams in this manual are the property of Nu-Heat.
All rights reserved. No part of this publication may be reproduced, stored
in a retrieval system, or transmitted in any form or by any means electronic,
mechanical, photocopying, recording or otherwise without prior written
permission of Nu-Heat.
DESIGN | INNOVATION | EXPERTISE | SERVICE