Wolf CSW-120 Installation Instructions Manual

Brand: Wolf

Model: CSW-120

Type: Installation Instructions Manual

This manual is also suitable for

TSW-120

Wolf CSW-120 is a domestic hot water cylinder designed to provide a constant supply of hot water for your home. It features a dual enamel coating on its internal cylinder walls and indirect coils for enhanced corrosion protection, making it suitable for use with various water conditions and types of pipework. With a capacity of 115 liters, it can deliver up to 29-710 kW-ltrs./h of hot water, with a maximum operating pressure of 7 bar for DHW and 12 bar for heating water.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Installation instructions

DHW cylinders TSW-120/CSW-120

for gas-fired condensing boilers and

conventional gas-fired boilers

Part no. 30 48 420 07/07 GB

Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. 08751/74-0 · Fax 08751/741600 · Internet: www.wolf-heiztechnik.de

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Index

Index.................................................................................................................. Page

General information .................................................................................................2

Safety notice / DHW cylinders / Standards and regulations ....................................3

Specification .............................................................................................................4

Dimensions..............................................................................................................5

Layout .......................................................................................................................6

Positioning / Installation dimensions ...................................................................... 7

Installation ................................................................................................................8

Installation of the tundish ................................................................................... 9-11

Installation of the domestic water connection .......................................................12

Final assembly .......................................................................................................14

Circulation / Commissioning ........................................................................... 15-16

Maintenance ..................................................................................................... 17-18

This manual is an integral and essential part of the product. Please

read carefully the instructions and notices about the appliance

contained in this manual, as they provide important information

regarding the safe installation, use and maintenance of the

cylinder. Failure to do so may invalidate the guarantee.

General information

Handle and store

Don’t stack the packages. Don’t transport lying.

Keep the packages in dry conditions.

Delivery

The CSW-120 range is supplied as following;

1) The cylinder with factory fitted temperature & pressure

relief valve.

2) Box containing

- reducing valve

- expansion valve with check valve

- tundishes

- pipes

- connection supplies

3) Box containing expansion vessel

Installation instructions DHW cylinders TSW-120/CSW-120

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Safety notice / DHW cylinders / Stan-

dards and regulations

Standards and

regulations

Observe the following instructions during the installation of the

DHW cylinders:

- BS 6920

- BS 7206

- DIN 1988 - Technical regulations for DHW installations

- DIN 4708 - Centralised DHW systems

- VDE requirements

- Requirements by public water suppliers

Safety notice

• Installation must be carried out by a suitably qualified installer

and in accordance with current regulations and codes of

practice.

• Only the safety valves supplied with the cylinder should be

used.

• The cylinder must not be used without the safety valves and

expansion vessels.

• The cylinder must not be used with a boiler without thermostatic

control.

• The cylinder and ancillary controls must be adequately

maintained.

• The installation must have a sufficient and constant supply of

mains fed cold water.

• No valve should be fitted between the expansion relief valve

and the storage cylinder.

• Only Wolf approved replacement parts should be used.

• The discharge pipe must be terminated where it is visible and

will not cause danger to people in the vicinity of the discharge.

Note: The discharge could consist of scalding water and steam.

DHW cylinders, type TSW-120 / CSW-120, made from steel with

top flange and pipework connections for gas-fired boilers.

Corrosion protection through dual enamel coating on internal

cylinder walls and indirect coils, acc. to DIN 4753 pt. 3.

Additional corrosion protection through magnesium anode. Suitable

for all water conditions and any type of pipework.

DHW cylinders

Domestic hot water cylinder

TSW-120

Domestic hot water cylinder

CSW-120

Installation instructions DHW cylinders TSW-120/CSW-120

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Specification

Warning to the user

a) Do not remove adjust any component part of this unvented

water heater: Contact the installer

b) If this unvented water heater develops a fault, such as a flow

of hot water from the discharge pipe, switch the heater off and

contact the installer.

Note to the installer

Leave the manual with the householder after installation.

The safety system of the DHW cylinder TSW-120/CSW-120 is

attuned to use only in combination with Wolf boiler TGG-18, TGG-

24 and TGB-20.

a) This installation is subject to building regulation approval, notify

the Local Authority of intention to install.

b) Use only manufacturer´s recommended replacement parts.

c) Installed by: Name:

Adress:

Tel.No.:

Completion date

Warning to the

installer

Type of DHW cylinder TSW/CSW -120

Cylinder capacity litres 115

Const. DHW cyl. rating (80/60 - 10/45°C) kW-ltrs./h 29-710

Standby consumption at 60

°C kWh/24h 1.5

Performance factor N

L60

1.0

Max. supply temperature °C 60

Heating up time with 25kW min 22

Re heat time with 25kW min 15

Max. operating pressure - DHW bar 3.5

Max. operating pressure - heating water bar 12

Max. permissible DHW cylinder temperature °C 95

Max. permissible heating water temperature °C 110

P+T-valve opening temperature °C 95

P+T-valve opening pressure bar 7

Max. water supply pressure bar 16.0

Expansion valve setting bar 6.0

Expansion vessel charge pressure bar 4.0

Weight (empty) kg 75

Weight of the full cylinder kg 190

Connections Cold water R ¾”

Hot water R ¾”

DHW flow R ¾”

DHW return R ¾”

DHW circulation R ¾”

Sensor well Ø mm 14

Specification

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

542

595

542

810810

Sensor well

DHW circulation

DHW return

Filling and draining

for TSW-120 below the

decorative panel

DHW cylinder flow

Domestic hot water

Cold water

Fig.: TSW-120 Fig.: CSW-120

Dimensions

Installation instructions DHW cylinders TSW-120/CSW-120

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Layout

Gas-fired boiler control unit

Domestic hot water

DHW circulation

DHW

circulation

pump

DHW cylinder sensor

connection (blue plug)

Expansion vessel

Expansion valve with

discharge outlet to tundish

Check valve

Stop valve

Pressure reducing valve

Drain

Cold water to

DHW

cylinder

Cold water

supply according

to British

Standards

Please note:

The layout is provided to provide a general overview, not a piping

prescription.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Positioning / Installation dimensions

Installation of wall hung

appliance an hot water

storage tank

notch for

water

pipes

270-420

790

810

1800-1950

CSW

mounting

bracket

centered!

Please note when using

the pipe cover:

The installation dimensions apply to TSW-120 as well as CSW-120.

If you intend installing the DHW cylinder with a pipe cover, check the

fit (dimension 300 mm) with the pipe cover prior to commencing the

pipe installation. The adjustable cylinder feet can compensate a

max. of ±10 mm.

Please note the fixing hole position on the installation template

when using a fixing bracket (accessory).

Install the DHW cylinder only in a frost protected location, otherwise

drain, if there is a risk of frost.

Consider the total weight of a full DHW cylinder when selecting

the installation location.

Adjustable feet allow you to compensate for uneven floors.

The DHW cylinder ...SW-120 may be installed in a top or bottom

cupboard or free-standing.

Positioning

270-420790

480

344

400

810

1800-1950

TSW without covering panel

notch for water pipes

mounting

bracket

780-800 300

480

344

400

1835

mounting

bracket

notch for water pipes

TSW with covering panel

Install appliance as described in Installation Instructions.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Installation

Connection of

DHW cylinder flow

DHW cylinder return

Remove the dummy plug from the heating return of the gas-fired

boiler. Remove the elbow from the heating flow of the gas-fired boiler

and insert the three-way changeover valve with a union nut and flat

gaskets. Trim the DHW cylinder flow and return pipes to size. Secure

the installation with compression fittings on the DHW cylinder ...SW

as well as with flat gaskets and union nut on the gas-fired boiler.

Bend

HVL

HRL

Dummy plug

Three-way

changeover

valve

HVL

HRL

Flow pipe Return pipe

Note

Because of heat expansion, water may during heating be discharged

from the safety valve. Never shut off the blow-off line. Safeguard

the drainage to the drain funnel via a drain pipe.

The selection of pipework material (i.e. connection fittings on site)

has to be in accordance with the rules of engineering and possible

electro-chemical reactions have to be taken into account (mixed

component installation).

If copper connections are used, utilise compression fittings made

from brass or bronze to prevent contact corrosion at the DHW

cylinder connections. Cylinder relief valve connections should not

be used for any other purpose.

Pipework on finished walls

Siphon

max. 420

SVL

SRL

GAS

HVL

HRL

HVL : Central heating flow

HRL : Central heating return

SVL : DHW flow

SRL : DHW return

WW : DHW connection

KW : Cold water inlet

Z : DHW circulation

Lower edge

casing

Upper

edge

DHW

cylinder

Please note:

When installing the pipe bezel,

the dimension between the

bottom edge of the casing and

the top edge of the cylinder

must not be a min. of 240 mm

and a max. of 420 mm, but

instead must be 300 mm.

DHW cylinder

temperature sensor

Remove the blue dummy plug from the control unit and connect

with the socket of the DHW cylinder temperature sensor. Insert the

sensor into the sensor well until it bottoms out.

Connection of

Three-way changeover

valve

Remove the dummy plug at the control unit and connect with the

socket of the three-way changeover valve.

Installation instructions DHW cylinders TSW-120/CSW-120

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Installation of the tundish

1. The tundish must be vertical and fitted within 500mm of the

temperature & pressure relief valve and must be located with

the cylinder. The tundish must also be in a position visible to the

occupants, and positioned away from any electrical devices.

The discharge pipe from the tundish should terminate in a safe

place where there is no risk to persons in the vincinity of the

discharge and to be of metal.

2. Discharge pipes from the temperature & pressure relief and

expansion relief valve may be joined together.

3. The pipe diameter must be at least one pipe size larger than the

nominal outlet size of the safety device unless it’s total

equivalent hydraulic resistance exceeds that of a straight pipe

9m long. i.e. Discharge pipes between 9m and 18m and

27 m at least 3 larger, and so on.

Bends must be taken into account in calculating the flow

resistance. Typical discharge pipe arrangement on page 10.

4. The discharge pipe must have a vertical section of pipe at least

300mm in length, below the tundish before any elbows or

bends in the pipework.

5. The discharge pipe must be installed with a continous fall.

6. The discharge must be visible at both the tundish and the final

point of discharge, but where this is not possible or practically

difficult; there should be clear visibility at one or other of these

locations. Examples of acceptance are:

i) Ideally below a fixed grating and above the w a t e r

seal in a trapped gully.

ii) Downward discharges at a low level; i.e. up t o

100mm above external surfaces such as c a r

parks, hard standings, grassed areas etc. Thes e

are acceptable providing that where children may play or

otherwise come into contact with discharges, a wire cage

or similar guard is positioned to prevent contact, whilst

maintaining visibility.

iii) Discharges at high level; l.e. into a metal hopper and metal

down pipe with the end of the discharge pipe clearly visible

(tundish visible or not). Or onto a roof capable of

withstanding high temperature discharges of water 3 m

from any plastic guttering systems that collect would such

a discharge (tundish visible).

iv) Where a single pipe serves a number of discharges, such

as in blocks of flats, the number served should be limited

to not more than 6 systems so that any installation can be

traced reasonably easily. The single common discharge

pipe should be at least one pipe size large than the largest

individual discharge pipe to be connected. If unvented hot

water storage systems re-installed where discharges

from safety devices may not be apparent l.e. in dwellings

occupied by the blind, infirm or disable people, consideration

should be given to the installation of an electronically

operated device to warn when discharge takes place.

Note: The discharge will consist of scalding water and

steam. Asphalt, roofing felt and non-metallic rainwater

goods may be damaged by such discharges.

Discharge pipework

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Installation of the tundish

Typical discharge

pipe arrangement

metal discharge pipe (D1) from

temperature relief valve to tundish

safety device

(eg.

temperature

relief valve)

300 mm

minimum

500 mm maximum

metal discharge pipe (D2) from

tundish, with continous fall,

see table an worked example

tundish

discharge below fixed

grating or as para 1 (b)

fixed louvred grating

trapped gully

Sizing of copper discharge pipe ‘D2’ for common temperature relief valve outlet sizes

Valve Minimum Minimum Maximum resistance Resistance

outlet size of size of allowed, expressed created by

size discharge discharge as a length of each elbow

pipe D1* pipe D2* straight pipe (ie. or bend

from tundish no elbows or bends)

28 mm up to 9 m 1.0 m

G½ 22 mm 35 mm up to 18 m 1.4 m

42 mm up to 27 m 1.7 m

* See Worked examples and scheme above

Worked example

The example below is for a G½ temperature

relief valve with a discharge pipe (D2) having 4

No. elbows and length of 7 m from the tundish

to the point of discharge.

From Table

Maximum resistance allowed for a straight length

of 22 mm copper discharge pipe (D2) from a G½

temperature relief valve equates to: 9 m

Subtract the resistance for 4 No. 22 mm elbows

at 0.8 m each = 3.2 m

Therefore the maximum permitted length equates

to: 5.8 m.

5.8 m is less than the actual length of 7 m

therefore calculate the next largest size.

Maximum resistance allowed for a straight

length of 28 mm pipe (D2) from a G½

temperature relief valve equates to: 18m

Subtract the resistance for 4 No. 28 mm

elbows at 1 m each = 4 m

Therefore the maximum permitted length

equates to: 14 m

As the actual length is 7 m, a 28 mm (D2)

copper pipe will be satisfactory.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

expansion

valve with

check

valve

pressure

reducing

valve

passed expansion

vessel

domestic

cold

water

always use copper

inserts

wall plug Ø 10mm

wall mounted pipe clip

plug

Installation of the tundish

tundish

DO NOT USE THIS TUNDISH

WITH THE P+T-VALVE

hold a distance of 25mm

between the tundish and the

pipe end.

threaded rod 8 x

160

reduce

compression

fitting 22/18

Installation of the pipes

domestic water

connecting set

Between storage tank and safety valve no other valves

or sieves must be installed.

The discharge pipe from the tundish should terminate in a safe

place where is no risk to person in the vicinity of the discharge.

Position the tundish where it can be readily seen.

Position the tundish away from any electrical devices.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

View of complete

mounted DHW cylinder

with tundish, domestic

water connection and

connection accessory

to the boiler

Installation of the domestic water connetoin

View of complete

mounted DHW cylinder

with tundish and

domestic water

connection

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Installation

Pressure reducing

valve

Generally, we would recommend the installation of a pressure

reducer. On the DHW side, the DHW cylinder may be operated

with a max. pressure of 10 bar. Install a pressure reducer if the

supply system delivers a higher pressure. To avoid flow noise

inside of buildings, regulate the pipe pressure to approx. 3.5 bar.

Provide a centralised pressure reducer, if mixer taps are used.

Exceeding the permissible operating pressure may

cause leakages and destruction of the storage tank.

Drinking water filter

We recommend the installation of a drinking water filter into the

cold water supply, as foreign bodies introduced into the system

can block fittings and may lead to pipe corrosion.

Check valve

The check valve is included into the expansion valve.

Expansion valve

Install a type-tested safety valve into the cold water supply. The

installation of dirt traps or other restrictions into the supply pipe

to the safety valve is not permitted.

Note: Do not fit a valve between the expansion valve and the

DHW cylinder.

Expansion vessel

Install the expansion vessel with the T-piece directly into the line,

that a flow through is guaranteed

Drain

Install the DHW cylinder so that it can be removed without

dismantling. The TSW-120 is provided with a drain below the

decorative panel.

DHW connection -

free-standing DHW

cylinder ...SW-120

When installing the DHW cylinder ...SW below the gas-fired

boiler, use the Wolf accessory “DHW cylinder connection set for

subsurface installation“ or the “DHW cylinder connection set for

surface installation“.

Secondary return

A secondary return may be fitted (consult the lavel on the face

of the unit for the correct location). A non-return valve (not

supplied) must be fitted to prevent back-flow and a bronze pump

will be needed in conjunction with a pipe thermostat to circulate

the hot water (both not supplied).

Note: An extra expansion vessel may be required where the

additional volume of the secondary return exceeds the capacity

of the expansion vessel supplied.

Connection set ...SW-120 for surface installation (accessory)

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Final assembly

After the installation, locate the pipe cover (accesory) on the DHW

cylinder ...SW-120 and push back.

Pipe cover

White plastic plugs

On CSW-120 use the white plastic plugs supplied to close the four

holes in the front panel and the three holes in each of the l.h./r.h.

rear side panels. Please note: Two white plastic plugs are surplus

and should be retained as spare parts.

On TSW-120 use the white plastic plugs supplied to close the three

holes in each of the l.h./r.h. rear side panels.

Black plastic clip

Decorative panel

TSW-120

For TSW-120 the following final steps must be completed:

Press the black plastic clips (4 pieces) into the corners of the

decorative panel. Clip the decorative panel with the pre-assembled

plastic clips into the fixing holes of the DHW cylinder front panel.

Please note: Six black plastic clips are surplus and should be retained

as spare parts.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Only an approved contractor must install and commission this

equipment; this contractor is also responsible for the appropriate

equipment level.

Thoroughly flush the pipes and the DHW cylinder after completing

the installation. Check for obvious signs of damage to the cylinder

and controls and also that the controls fitted correspond with the

references quoted in these instructions.

Ensure that the Drain Cock at the base of the appliance is closed

before commencing.

1)Open all outlet taps;

2)Turn on mains water supply and allow the water heater to fill;

3)Close taps in turn after having purged the system of air;

4)Check for leaks around the controls and immersion heaters and

again after the unit has heated up.

5)Check that no water is passing to waste through the relief

valves;

6)Test the operation of the temperature and pressure relief and

expansion valves by lifting/turning the manually operated test

lever/cap and observing that water flows through freely and

safely to waste.

Commissioning

Circulation / Commissioning

You may connect an optional DHW circuit at the circulation connector.

The DHW circuit should be connected only, if the draw-off points

are located a fair distance away and should be installed with a DHW

circulation pump with time switch control.

Implement the electrical connection in accordance with the following

wiring diagram.

DHW circulation

Netz Z FV

L1 N L N NLLL1

230VAC

DHW circulation pump

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Circulation / Commissioning

Fill the heating system at a low water pressure (approx. 1 bar).

During filling, open the three-way changeover valve several times

manually if the system includes a gas-fired boiler. On gas-fired

condensing boilers, open the air vent valve in the DHW cylinder

flow. Check whether the lid on the quick-action air vent valve is

loose. Briefly start up the boiler (circulation pump).

Demonstrate operation to user, including operation of temperature

and relief valve and what to do if it operates.

Give this manual to the user to retain for future reference and make

the customer aware that periodic checks of the equipment are

essential for safety.

When using digital control accessories DRT, DWT or DWTM for Wolf

gas-fired boilers, the cylinder loading time for the CSW-120 DHW

cylinder may be selected via a two-channel time switch CSW-120.

The loading times can be freely selected via the day/week program.

Programming the cylinder loading times is detailed in the control unit

operating instructions.

Selecting the DHW

cylinder loading times

Adjust the DHW cylinder temperature on the Wolf gas-fired boiler

between 15 - 70 °C using the cylinder thermostat. For reasons of

economy, thermostat setting 7 (approx. 60 °C) is recommended. For

regular pasturisation, a DHW cylinder thermostat setting of 70 °C

(position 9) may be selected. This setting is only intended for brief

and supervised operation.

In hard water areas we recommend thermostat setting 7 (approx.

60°C) to prolong element life.

The DHW cylinder temperature can be read off at the display if a Wolf

gas-fired boiler is connected to digital control accessories DRT, DWT

or DWTM, (see operating instructions of the respective control unit).

Selecting the DHW

cylinder temperature

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Checking the protective

anode

The integral magnesium anode can be sacrificed through electrical

reaction to protect the DHW cylinder from corrosion. Therefore check

and, if necessary, replace the anode every two years.

Remove the connection cable between the anode and the hand hole

cover. To check the protective anode, connect an ammeter between

earth and the anode. Replace the protective anode if the actual value

falls below 0.1 mA.

Maintenance

Fully release the DHW cylinder pressure, switch OFF the boiler and

the DHW circulation pump, and open a hot water tap in your house.

A hose nozzle is factory-fitted below the fill and drain cock cover.

On TSW-120, the decorative panel must first be removed by slightly

lifting and pulling it forward.

Draining the DHW

cylinder

Replacing the

protective anode

Remove the six nuts on the hand hole cover. Remove the cover,

together with the protective anode. Remove the locking nut and fit

a new protective anode.

Installation in reverse order.

Access trap to be fitted with new seal only, torque of nuts 20-25 Nm.

Fill the system and check for leaks.

Hose connection

Filling/draining aperture

Earth = hand hole cover

Protective anode

Nuts

Hand hole cover

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Maintenance

Unvented Controls

Check controls as per the following:

1)Line strainer - with the water supply turned off remove screen

from strainer and clean of any detritus;

2)Expansion vessel - with the water supply turned off and taps

open, check expansion vessel pressure and top up as necessary;

3)Temperature and pressure relief valve - with the water supply

turned on; check manually by lifting the test lever/turning the test

knob (ensure valve closes after testing);

4)Expansion relief valve - check manually by turning the test knob

(ensure valve closes after testing);

5)Discharge pipes - from both temperature and pressure relief and

expansion relief valve for obstructions;

6)Tundish and discharge pipe - open either valve gradually to

produce a full bore discharge into tundish without any back

pressure;

7)Pressure reducing valve - check that the correct outlet pressure

is being maintained by recording the pressure at an in-line termi-

nal fitted i.e. tap.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Notice

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707

Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. 08751/74-0 · Fax 08751/741600 · Internet: www.wolf-heiztechnik.de

Wolf CSW-120 Installation Instructions Manual

Brand: Wolf

Model: CSW-120

Type: Installation Instructions Manual

This manual is also suitable for

TSW-120

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Wolf CSW-120 Installation Instructions Manual

This manual is also suitable for

Wolf CSW-120 Installation Instructions Manual

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