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Installation Instructions
Troubleshooting
SureCal Horizontal Calorifier Connection Instructions
Calorifier Connection Instructions
Connection Instructions
First, select a suitable location for your new Surecal calorifier. Place the calorifier in position and secure down using it’s four fixing feet.
The calorifier is fitted with a temperature mixing valve (1). To set the valve turn anti clockwise to the maximum, this will give a maximum water temperature of 65°C. When the knob is fully closed i.e clockwise it is set to 30°C.
The hot out, cold in, optional second coil and PRV are made for 15mm push fit plastic plumbing, Hep20 or speed fit. Hot out must be at 12 o’clock (ie at the highest point) and cold in at 6 o’clock (the lowest point).
Push on your plastic plumbing or compression fitting to the mixer valve (1) for your hot water supply.
Push on your cold feed to the lowest fitting (2) to supply pump pressure cold water to the calorifier.
Engine connections, to the coil (3) – Use heater hose from the engine and pass over the barbed fittings and fix with jubilee clips.
Pipe the outlet of the pressure release valve to the bilges (4). The pressure release valve can be used as a drain by holding open.
Immersion heater(5) instructions contained on ‘Immersion Connection Instructions’ sheet.
An expansion bottle should be fitted on the hot supply between the thermostatic mixer and first take off (i.e. Taps) This will relieve the increased pressure caused by hot water expansion.
Only competant individuals should attempt to install the calorifier, incorrect installation will void warranty and no liability shall be taken by Surejust Ltd.
When deciding on the position of installation, care must be taken to ensure access can be obtained for future servicing and/or removal.
Whilst the insulation used for SureCal calorifiers ensures exceptional heat retention, the exterior can be easily scratched, it is recommended that the calorifer is positioned such that minimal contact with other equipment is ensured, in addition, the calorifier should not be positioned in contact with equipment that can reach a high operating temperature.
Calorifier Connections
SureCal Vertical Calorifier Connection Instructions
Calorifier Connection Instructions
Connection Instructions
The calorifier is fitted with a temperature mixing valve (1). To set the valve turn anti clockwise to the maximum, this will give a maximum water temperature of 65°C. When the knob is fully closed i.e clockwise it is set to 30°C.
The hot out, cold in, optional second coil and PRV are made for 15mm push fit plastic plumbing, Hep20 or speed fit.
Push on your plastic plumbing or compression fitting to the mixer valve (1) for your hot water supply.
Push on your cold feed to the lowest fitting (2) to supply pump pressure cold water to the calorifier and tee off to the mixer valve and connect a cold feed in.
Engine connections (15mm barbed), to the coil (3) – Use heater hose from the engine and pass over the barbed fittings and fix with jubilee clips.
Pipe the outlet of the pressure release valve to the bilges (4) and drain. The pressure release valve can be used as a drain by holding open.
Immersion heater (5) instructions contained on ‘Immersion Connection Instructions’ sheet.
An expansion bottle should be fitted on the hot supply between the thermostatic mixer and first take off (i.e. Taps) This will relieve the increased pressure caused by hot water expansion.
When deciding on the position of installation, care must be taken to ensure access can be obtained for future servicing and/or removal.
Whilst the insulation used for SureCal calorifiers ensures exceptional heat retention, the exterior can be easily scratched, it is recommended that the calorifer is positioned such that minimal contact with other equipment is ensured, in addition, the calorifier should not be positioned in contact with equipment that can reach a high operating temperature.
Calorifier Connections
Immersion Connection Instructions
Immersion Connection Instructions
Thermostat Information
To maintain safety and operation, any replacement thermostat must be of the same type.
Electrical Information
- This unit should be connected by a suitably qualified electrician in accordance with the latest I.E.E. regulations.
- Ensure the electrical supply is switched off before making any connection to the unit.
- The immersion heater must be wired through a double pole isolating switch with contact separation of at least 3mm in both poles.
- The immersion heater must be wired with a heat resistant flexible cord with a minimum T rating of “T-80” and with a minimum cross-section area of 1.5mm2.
- Ensure that the terminal screws are not over tightened as this could result in the terminations being broken off.
Wiring
- Earth connection (green & yellow) should be made firmly to the earth post (marked “E”) using the terminals attachments provided.
- The Live Supply (brown) from the mains supply cable to the thermostat terminal marked “L”.
- The neutral connection (blue) from the mains supply to the thermostat terminal marked “N”.
Immersion Replacement Information
- Check your mains power voltage matches the voltage rating indicated on the label of the plastic terminal cover.
- The immersion heater screws into a (2 ¼” BSP) thread boss.
- The immersion heater must be fixed to the cylinder using the O ring provided. Please ensure that the unit is not over tightened into the tank boss.
The appliance is not to be used by children or persons with reduced capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Immersion Layout
The thermostat has a safety resettable cut out mechanism which prevents excessive temperatures.
The unit is able to disconnect both supply conductors (live and neutral) by a single initiating action. In case the normal sensing device fails the over temperature safety device will act to limit the water over temperature.
To reset the thermostat after an intervention of the safety device:
- Switch off the heater by isolating the power supply
- Allow the water in the cylinder to cool down sufficiently
- Remove the cover and press the button on the top of the thermostat
NB: This cut out is a safety device, if this is found to be operating frequently then we recommend to consult a qualified electrician to investigate the nature of the problem as the thermostat may need to be replaced. It may be helpful to lower the thermostat setting to avoid unnecessary cut offs.
Surecal 12v/240v Motorhome Water Heater Calorifier Installation Instructions
Calorifier Connection Instructions
Connection Instructions
The calorifier is fitted with a temperature mixing valve (1). To set the valve turn anti clockwise to the maximum, this will give a maximum water temperature of 65°C. When the knob is fully closed i.e clockwise it is set to 30°C.
The hot out and PRV are made for 15mm push fit plastic plumbing, Hep20 or speed fit. Hot out must be at 12 o’clock (ie at the highest point) and cold in at 6 o’clock (the lowest point).
Push on your plastic plumbing or compression fitting to the mixer valve (1) for your hot water supply.
Push on your cold feed (2) to supply pump pressure cold water to the calorifier.
Immersion electrical connections, (5) – Connect to both 12 volt supply and mains supply.
Pipe the outlet of the pressure release valve to a suitable discharge point, please note this water will be hot.
Immersion heater(5) instructions contained on ‘Immersion Connection Instructions’ sheet.
It is advised that an expansion bottle be fitted on the hot supply between the thermostatic mixer and first take off (i.e. Taps). This will relieve the increased pressure caused by hot water expansion.
When deciding on the position of installation, care must be taken to ensure access can be obtained for future servicing and/or removal.
Whilst the insulation used for SureCal calorifiers ensures exceptional heat retention, the exterior can be easily scratched, it is recommended that the calorifer is positioned such that minimal contact with other equipment is ensured, in addition, the calorifier should not be positioned in contact with equipment that can reach a high operating temperature.
Calorifier Connections
Surecal 12v/240v Motorhome Water Heater Immersion Connection Instructions
Immersion Connection Instructions
Thermostat Information
To maintain safety and operation, any replacement thermostat must be of the same type.
Electrical Information
Wiring (240v only)
- Earth connection (green & yellow) should be made firmly to the earth post (marked “E”) using the terminals attachments provided.
- The Live Supply (brown) from the mains supply cable to the thermostat terminal marked “L”.
- The neutral connection (blue) from the mains supply to the thermostat terminal marked “N”.
Immersion Replacement Information
- Check your mains power voltage matches the voltage rating indicated on the label of the plastic terminal cover.
- The immersion heater screws into a (2 ¼” BSP) thread boss.
- The immersion heater must be fixed to the cylinder using the O ring provided. Please ensure that the unit is not over tightened into the tank boss.
If the heater is switched on when the water level is not fully covering the heating element there may be serious damage incurred to the heater, property or persons.
The appliance is not to be used by children or persons with reduced capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Immersion Layout
Notes
- This 12v feed can either be taken directly to the battery ‘+’ (as shown here) or can be taken to the vehicles alternator ‘trigger wire’. If powered from the alternator trigger wire, the heater will only operate when the engine is running. If taken directly to the battery then the heater can be operated with the engine off.
- Ensure the correct gauge wire is used and de-rated accordingly. A 300w heater at 12v will draw ~25a; therefore a 30a fuse is required. The wiring needs to be rated higher than the fuse rating once de-rated. 11 awg (4 mm^2) wire is recommended
- This end would be in the form of a normal 3-pin mains plug fitted with a 13a fuse
- The 240v ac thermostat is wired differently to the 12v thermostat. This is because both thermostats are rated for 20a max. – at 240v the current required for the 700w heater is ~3a; therefore the thermostat can safely be wired in series with the heater as shown.- at 12v the current required for the 300w heater is ~25a; therfore the thermostat cannot be wired in series and a relay is needed as shown.
- The thermostat must be used for safety.
- Make sure a 12v led/indicator is used. These have resistors built in and do not require an external resistor
- When selecting the correct relay, a 12v coil is needed and the contacts must have a higher rating than the fuse that is protecting it (greater than 30a).
Advice and Troubleshooting
Expansion Tanks
Expansion Tanks are an essential feature on any hot water system. They need to be installed on the hot water supply after the hot water heater. Anywhere on the hot side of the system, but preferably as near to the hot water heater as is reasonably possible. It can be fitted in any orientation.
The tanks are pre set at our factory for most systems, however the pressure is worth checking as some installations are set up with different pump pressures. In general the required pressure setting for an expansion bottle is 5psi above your pump pressure. If you do not know your pump pressure then set the expansion tank to 30 psi.
Surejust accumulator and expansion tanks are supplied complete with mounting bracket and plumbing fitting, ready to connect into your system.
Expansion/Accumulator Tank Size Chart
| Calorifier Size | Recommended Expansion Tank Size |
|---|---|
| 0-22 Litres | 2 Litres |
| 22-55 Litres | 5 Litres |
| 55-80 Litres | 8 Litres |
| 80-120 Litres | 12 Litres |
| 120-200 Litres | 24 Litres |
| Expansion/Accumultor Tank Size | Physical Size of Expansion / Accumulator Tank | ||
|---|---|---|---|
| Width | Height | Depth | |
| 2 Litres | 120mm | 300mm | 150mm |
| 5 Litres | 180mm | 380mm | 190mm |
| 8 Litres | 220mm | 410mm | 230mm |
| 12 Litres | 270mm | 400mm | 280mm |
| 24 Litres | 260mm | 600mm | 280mm |
Connections to the tank
The hot out, cold in and PRV are made for plastic plumbing Hep 2 or speed fit. Use a straight connector or elbow to snap on to the brass fitting. Hot out must be at 12 o’clock (ie at the highest point) and cold in at 6 o’clock (the lowest point).
Troubleshooting
Normally the P.R.V will be factory set at 3 or 4 bar, this can be checked by looking at the pressure rating indicator on the face of the red knob.
⍰ Do the dimensions of the cylinders include all fittings and insulation?
Yes, insulation and all fittings suppled as standard with our calorifiers are included within the dimensions stated.
⍰ Is an accumulator tank necessary?
An accumulator tank is usually necessary, we would advise the installation of an accumulator tank as it will help look after the pressure pump and provides a small volume of water to use before your pump kicks in.
⍰ How long does water take to heat up to a usable temperature?
Lots of factors will determine the actual heat up time of the water in your calorifier, however as a rule of thumb a 1 KW immersion will take 30 minutes to heat up 10 liters of water to a usable temperature. When using the engine or diesel heaters the entire tank will generally heat up in approximatley 30 minutes.
⍰ Can an expansion bottle be fitted upside down and where should it be fitted?
An expansion bottle can be fitted in any orientation, the bottle should be installed after the mixer valve.
⍰ The immersion heater isn’t working!
Make sure the manual safety reset button hasn’t popped out. If so identify why this has happened and then reset.
⍰ How do you adjust the output water temeperature?
This can be altered by turning the thermostatic mixing valve to a comfortable temperature fully closed (clockwise is 30 °C or fully open (anticlockwise) 65 °C.
⍰ Do I need a twin or single coil calorifier?
If you only have one heat source (i.e. one or two engines) then a single coil should be used. If you have more than one heat source (i.e. an engine and a diesel heater) then you would use a twin coil.
⍰ My P.R.V keeps dripping or releasing water?
You need an expansion tank fitted or, if you already have an expansion tank, the tank pressure needs altering. When altering the pressure in an expansion or accumulator tank, first switch your pump off and open your taps (cold taps for an accumulator, hot for an expansion tank).