joule Cyclone Installation & Maintenance Manual

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Direct & Indirect Unvented Cylinder Installation & Maintenance Manual

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Table of Contents

Introduction 9 General Requirements 14 Direct Technical Speci cation

15 Direct Installation Mechanical Diagram 19 Indirect Technical Speci cation 20 2 Port Mechanical Diagram 21 2 Port Electrical Diagram 22 3 Port Mechanical Diagram 23 3 Port Electrical Diagram 24 Electronic Controls 25 Discharge Agreement 29 Maintenance 31 Taking The Cylinder Out Of Use 32 Spare Parts 33 Trouble Shooting 34 Guarantee

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INTRODUCTION

The instructions are an integral part of the appliance and must be given to the end user on completion of the installation in order to comply with the current regulation.

It is important to carefully read the manual to understand all the information to enable safe installation, use and servicing. These instructions consist of details for instal-

lation, servicing, fault  nding and replacement of parts for the cylinder purchased.

JOULE will not accept any liability in the event of damage for not complying with the guidance in this instruction manual.

The instructions for this installation manual apply to the range of JOULE Cyclone Indirect Unvented Cylinders.

Safety is paramount when installing unvented hot water systems and the following instructions must be adhered to:

Only certi ed competant installers can install, commission and service the equipment supplied. The cylinder must be used for potable hot water only. Any other applications will be considered incorrect use and JOULE will not be held liable for any losses resulting from such use.

All installation and maintenance instructions must be observed to ensure the correct operation of the equipment.

The electric immersion must not be switched on unless the cylinder is completely full of water. Domestic hot water may be stored at temperatures exceeding 60°C. Preventative measures should be put in place to negate the possibility of scalding.

A maintenance schedule should be put in place with a competent person to service the equipment annually to comply with the warranty conditions. When servicing the system the mains supply to the cylinder should be isolated.

Only genuine spare parts should be used. A full list of items with relevant codes can be found on page 23 .

The installation must be carried out by a person competent to install unvented hot water systems. The installation must be carried out in accordance with the following recommendations:

All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L1 Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department UK Water Regulations/Byelaws (Scotland) Health & Safety Document No. 635 (The Electricity At Work Regulations 1989) The installation should also be in accordance with the following British Standard Codes of Practice:

BS 5449:1990 Forced circulation hot water systems BS 5546:2000 Installation of hot water supplies for domestic purposes BS 5918:1989 Solar heating systems for domestic hot water BS 6700:2006 Design, installation, testing and maintenance of services supplying water.

Failure to install this appliance correctly could lead to prosecution and will invalidate the guarantee. It is in your own interest and that of safety to ensure that the law is complied with.

HANDLING

Care must be taken when transporting, storing and installing the equipment:

At least two people should lift the cylinder to prevent injuries. The cylinder must be stored in a dry area and must never be set the cylinder down hard during handling.

Packaging should only be removed at the installation location. The cylinder must be installed on a level  oor with the required load bearing capability. Installation, servicing, maintenance and repair must be carried out by a competent person.

All electrical wiring must be carried out by a quali ed electrician and be installed in accordance with current I.E.E Wiring Regulations. A lack of safety devices can lead to potentially fatal injuries, all necessary safety devices must be installed correctly in the system. The use of an electric immersion may lead to the build up of electrical potential in the water. This can in turn cause corrosion of the immersion. To prevent this, ensure the immersion heater, and the hot and cold pipework are correctly bonded and connected to the earth line.

If plastic pipes are used they must be approved temperature resistant to 95°C at a pressure of 10 Bar.

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WHAT IS BENCHMARK?

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations.

The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit www.centralheating. co.uk

WATER SUPPLY

The performance of any unvented system is only as good as the mains water supply

available. To this e ect the maximum possible water demand should be assessed, with the knowledge that the mains supplies both hot and cold services simultaneously.

The water heater itself operates at a pressure of 3 bar, controlled by the inlet control set, and is capable of delivering over 50 litres per minute. The high quality inlet control set has been designed to make the most of the  ow rates available.

The water supply should be checked to ensure it can meet these requirements. If necessary, consult the local water authority regarding the likely pressure and  ow rate availability.

Consideration should be given to upgrading existing ½” (15mm) cold mains pipework to a larger size if the recommended minimum pressure/ ow rate is not being achieved. JOULE recommend that primary pipework used has a minimum diameter of 22mm to ensure low pressure loss.

Note: A high static (no  ow) mains pressure is no guarantee of good  ow availability. In a domestic installation 1.5 bar and 25 l/min. should be regarded as the minimum. The maximum mains pressure that the inlet control set can cope with is 10 bar.

CHANGE OF WATER SUPPLY

The changing or alternating from one water supply to another can have a detrimental e ect on the operation and / or life expectation of the water heater storage cylinder, pressure temperature relief valve and heating unit.

Where there is a changeover from one water supply to another, e.g. a rainwater tank supply, bore water supply, desalinated water supply, public reticulated water supply or water brought in from another supply, then water chemistry information should be sought from the supplier or it should be tested to ensure the water supply meets the requirements given in these guidelines for the Joule warranty to apply.

WATER CHEMISTRY

This water heater must be installed in accordance with this advice to be covered by the Joule warranty. This water heater is manufactured to suit the water conditions of most public reticulated water supplies. However, there are some known water chemistries which can have detrimental e ects on the water heater and its operation and / or life expectancy. If you are unsure of your water chemistry, you may be able to obtain information from your local water supply authority. This water heater should only be connected to a water supply which complies with these guidelines for the JOULE warranty to apply.

WATER CHEMISTRY LEVELS AFFECTING WARRANTY

The JOULE warranty of this water heater will not cover resultant faults on components including the storage cylinder where water stored in the storage cylinder exceeds at any time any of the following levels:

Components Maximum Permitted Levels

Total Dissolved Solids 600 mg/Litre

Total Hardness 200 mg/Litre

Chloride 300 mg/Litre

Magnesium 10 mg/Litre

Calcium 20 mg/Litre

Sodium 150 mg/Litre

Iron 1 mg/Litre

Maximum pH 9.5

Minimum pH 6.5

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TOTAL DISSOLVED SOLIDS (TDS)

Some water analysis reports may state the conductivity of the water rather than the level of total dissolved solids. Conductivity, measured in microsiemens per centime-

tre (µS / cm), is directly proportional to the TDS content of the water. TDS, in mg/L, is approximately 70% of the conductivity in µS / cm.

The JOULE warranty will not cover resultant faults to the storage cylinder if this water heater is connected at anytime to a water supply where the TDS content of the water exceeds 600 mg/L. 16 In locations where TDS approaches 600 mg/L, e.g. due to sediment, we strongly recommend  tting an appropriate  lter to ensure water entering or in the water heater does not exceed this level at any time i.e. due to sediment build up.

FEATURES OF THE UNVENTED CYLINDER

- Made from Duplex Stainless Steel for excellent corrosion resistance.

- Strong rust-proofed steel case.

- Insulation is by means of an approved CFC/HCFC free polyurethane foam with an ozone depletion factor of zero.

- Available in a variety of sizes to suit - 125L, 150L, 170L, 200L, 250L, 300, 400 and 500 litres.

- All models including Solar models are available in Twin or Triple versions Supplied complete with all the necessary safety and control devices needed to connect to cold water mains

- All safety and control devices are pre-set.

- High quality controls selected that combine high  ow rate performance with min imum pressure drop which gives fantastic performance in all areas, with great improvements in areas with poor water pressure.

WELLMASTER CYLINDERS

Only JOULE Wellmaster cylinders may be installed on a well, private water scheme or any water source that does not come from the public mains. Water that has been softened using salts or any other treatment may not be supplied to any Joule cylinder. Un-softened water only must be supplied to the cylinder. Softened water may be used to supply the rest of the property but not the cylinder. A de-scaler on the cold water feed may be used if required.

If any of the water parameters are higher than set out in the table including Total Hardness regardless of whether or not it is fed from a main water connection a JOULE Wellmaster cylinder must be used.

GENERAL REQUIREMENTS

SITING THE UNIT

This unit can supply outlets above it or at some distance from it but any outlets above the unit will reduce the available outlet pressure by 0.1 bar for every 1m of height

di erence. The maximum length of the “dead leg” should be as stated in the Water Supply (Water Fittings) Regulations 1999 G18.7, in particular to the area of most frequent use.

Particular attention is needed if sitting in a garage or outbuilding as the unit should be protected from frost. All exposed pipework must be insulated. The unit must be installed UPRIGHT on a  at base capable of supporting its weight when full (please see the technical speciﬁcation section for weights).

Su cient access to allow maintenance of the valves should be considered. In addition the immersion heaters are 400mm in length and this distance should be considered to allow withdrawal for servicing if required. The discharge pipework from the safety valves should fall continuously and terminate safely.

Negative pressure may form in cylinders installed very high in a building. To counteract this, an anti-vacuum valve can be installed to prevent damage to the cylinder. The

anti-vacuum valve ensures that pressure compensation as a result of air  owing into the cylinder.

CONNECTING TO THE CYLINDER

All of the pipework connections on the cylinder are female threaded. Upon ﬁlling / commissioning, ensure all connections are completely watertight.

Note: No control or isolation valve should be ﬁtted between the expansion relief valve and the storage cylinder. The relief valve connections should not be used for any other purpose.

COLD MAINS PIPEWORK

Run the cold main through the building to the place where is to be installed. Take care not to run the cold pipe near hot water or heating pipe work so that the heat pick-up is minimized. Identify the cold water supply pipe and  t an isolating valve (not supplied). A 22mm BS1010 stopcock can typically be used but a 22mm quarter turn full bore valve would be better as it does not restrict the  ow as much. Do not use “screwdriver slot” or similar valves.

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Make the connection to the cold feed of the cylinder and incorporate a drain valve. Position the inlet control just ABOVE the Temperature & Pressure Relief Valve (TPRV) mounted on the side of the cylinder. This ensures that the cylinder does not have to be drained down in order to service the inlet control set. Ensure that the arrow points in the direction of the water  ow. Select a suitable position for the expansion vessel.

Mount it to the wall using the bracket provided. Use the  exible hose provided to connect to the inlet control group.

BALANCED COLD CONNECTION

If there are to be showers, bidets or monobloc taps in the installation then a balanced cold supply is necessary. There is a 22mm balanced connection on the inlet control set.

FITTING THE INLET CONTROL GROUP

Excess pressure can lead to the cylinder bursting. The inlet control set supplied has an expansion relief valve with a 15mm connection to allow it to be connected to the tundish. Make sure that there is su cient space for future maintenance and also for

connection of the discharge pipe for the expansion relief valve.

It is essential that this connection is not covered or closed. The hot water expansion vessel can be  tted to the inlet control group using the supplied expansion vessel  exible hose.

HOT WATER PIPEWORK

Run the ﬁrst part of the hot water distribution pipework in 22mm. This can be reduced to 15mm and 10mm as appropriate for the type of tap etc. Your aim should be to reduce the volume of the hot draw-o pipework to a practical minimum so that the time taken for the hot water is as quick as possible.

Do not use monobloc mixer tap or showers if the balanced cold connection is not provided. Outlets of this type can back pressurise the unit and result in discharge.

EXPANSION VESSEL

The expansion vessel receives the increased water volume when expansion takes place as the system heats up and it maintains a positive pressure in the system. The expansion vessel contains a  exible diaphragm, which is initially charged on one side with nitrogen, but can be topped up with air when required.

Select a suitable position for the expansion vessel. Mount it to the wall using the bracket provided and connect to the inlet control set with the  exible hose provided. Ensure that the top of the vessel is accessible for servicing. The pipe connecting the expansion vessel to the system should have a diameter of not less than 15mm and must not contain any restrictions.

Prior to connecting the expansion vessel to the system the pipework should be  ushed and tested. When the vessel is connected the system should be pressurised when cold. If the initial system water pressure is too high, the diaphragm will be displaced too far into the vessel. This will leave the vessel unable to accommodate the volume of expansion water. The result of this is an increase in system pressure and the safety valve will lift.

PRIMARY COIL CONNECTIONS

Connect the primary connections (Indirect only). The primary circuit must be positively pumped. Either primary connection may be used as the primary  ow. Reheat times are identical either way. The primary circuit can be open vented or sealed, with up to a maximum pressure of 3.5 bar. If you seal the primary circuit an additional expansion vessel and safety valve is required.

The boiler may be Gas, Electric or Oil but must be under e ective thermostatic control. Uncontrolled heat sources such as some AGA’s, back boilers, solid fuel stoves, etc. are NOT SUITABLE. Please contact our Technical department for guidance. Connect the two port zone valve (indirect only) into the primary  ow pipework. The direction of  ow arrow should be towards the primary  ow connection.

INSTALLING THE TWO PORT MOTORISED VALVE

The function of the Two Port Motorised Valve prevents the cylinder from overheating. It can be installed on either horizontal or vertical pipework.

If it is mounted onto horizontal pipework the valve head must face upwards. The direction of  ow is marked on the body of the valve with arrows.

THERMOSTATIC MIXER

When installing a solar system with an unvented JOULE Cyclone twin coil cylinder, a thermostatic mixing valve should be installed. Its function is to act as an anti scald protection. The thermostatic mixer is to be set to a temperature of between 300C and 600C and is supplied by the installer.

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UNVENTED KIT COMPONENTS

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Inlet Control Group Inlet Control Group

Tundish Tundish

T & P Valve ( tted) T & P Valve ( tted)

3kW Immersion ( tted) 3kW Immersion ( tted)

Expansion Vessel Expansion Vessel

Expansion Vessel Hose Expansion Vessel Hose

Dual Cylinder Stat

2 Port Zone Valve

SECONDARY CIRCULATION

On larger installations long pipe runs to draw-o points can cause signi cant volumes

of water to be drawn o before an acceptable temperature can be reached. Secondary pumped circulation using a stainless steel or a bronze pump, and combined with e ective time and temperature controls can overcome this problem. Where secondary return circulation is required the pipework should be run in 15mm pipe. A suitable WRAS approved stainless steel or bronze circulation pump must be used. A check valve must also be installed to prevent back ow.

On large secondary circulation systems it may be necessary to incorporate an extra expansion vessel into the circuit to accommodate the increased system water volume. Secondary circulation should be avoided on Direct electrically heated units being used on o -peak electricity tari s. It should be noted that the use of a secondary circulation circuit can increase running costs as there will be circulation pipe losses. High levels of insulation on secondary pipework are required to keep energy losses to a minimum.

DEAD LEGS

The length of hot water draw o to taps and other outlets should be kept to a minimum to reduce the amount of cold water drawn o before the hot water arrives. The maximum recommended dead leg lengths are shown in  gure 2.b. Where there is more than one size of pipe on a dead leg, the equivalent length and size should be estimated.

Where the dead leg length exceeds the recommended maximum, secondary circulation should be installed. It should be controlled by a time switch and incorporate a motorized valve that can prevent gravity circulation in the circuit.

Pipe Size (mm) Maximum Length (m)

10, 12 20

15, 22 12

28 8

35 and above 3

SYSTEM NOISE

Noise in pipework may occur as a result of expansion of pipework over joists or where the pipe has been left touching other pipes or a part of the building structure. Care must be taken to ensure that the pipework is correctly bracketed, is not in tension or compression, and does not carry the weight of components such as a circulation pump.

SETTING THE HOT WATER TEMPERATURE

The hot water temperature is set on the dual thermostat by the competent person during the installation. The dual thermostat should be set to 60°C. If you are heating

water in the cylinder for the  rst time, or the time controls for the DHW zone have been o for a prolonged period of time, the cylinder may take additional time to heat up.

WARNINGS Inappropriate adjustments can lead to the damages in the system. If any changes are made to the cylinder, the controls, the water and power supply lines or the expansion relief components there is a risk of steam escaping or rupture to the system.

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Technical Speci cation Direct

B GC ED F

15°

30°

Mechanical Diagram Direct Installation

Balanced Cold

Connection

Secondary Flow

Secondary

Return

Cold Main

LEGEND

01 Bronze Pump

02 Non Return Valve (Not Supplied)

03 Inlet Control Group

04 Temperature & Pressure Relief Valve

05 Isolation Valve (Not Supplied)

06 Expansion Vessel With Wall Bracket

07 Two Port Zone Valve

08 Three Port Zone Valve (Not Supplied)

09 Drain Valve (Not Supplied)

10 Tundish

11 Heating Circulation Pump (Required where boiler has no internal pump)

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FITTING THE IMMERSION HEATER

Always check the immersion for signs of leakage before wiring commences. The immersion heater must be completely submerged in water with a minimum of 200mm of water above the top of the immersion.

WARNING: DO NOT OPERATE THE IMMERSION HEATERS UNTIL THE CYLINDER HAS BEEN FILLED WITH WATER

Wire the immersion through a double pole fused spur. The contact separation must be no less than 3mm with a minimum breaking capacity of 16A.

20 Amp Fused Double Pole Isolating Switch

230 V AC - 50Hz

Install the immersion using rigid cable, 2m long max, with 2.5 mm2 cross-section and a temperature resistance of at least 85°C.

The Cable should be rubber insulated HOFR sheathed, complying with BS6141 Table

8. It must be fully earthed. Ensure all terminal connections are securely made. Do not however use excessive force when tightening the terminal screws.

Ensure that the power supply is disconnected prior to making any electrical connections. Provide 90mm length of cable for each of the Live and Neutral cables with 8mm of bare cable for connection to the Immersion terminals. Provide 110mm length of cable for the Earth cable with 20mm of bare cable for connection to the Earth stud.

Make a circle with the bare Earth cable and tighten securely using the washer to the Earth stud. Fit the Live and Neutral cables to the Immersion thermostat. Ensure all terminal connections are properly tightened prior to commissioning

For installations with high water demands, or areas with hard water, Titanium immersions should be  tted.

The thermostat should be set so that the water is heated to a temperature between 600C and 650C. Water stored at temperatures below 600C can result in bacteria growth and temperatures above 650C can cause scalding.

The immersion stat has an integrated high limit stat which If the primary thermostat fails the limit thermostat takes over and shuts the element o before the water can boil in the cylinder.

TESTING

If there is no hot water you can carry out several tests with your multimeter to decide which component is faulty. First remove the cover for the wiring and then check for voltage across the live and neutral terminals on the element. If you get a reading the element is faulty (power going through thermostat so stat is working). Next, check whether the thermostat is working by connecting your multimeter to the live out of the thermostat, if there is no reading the thermostat is faulty.

NOTE: IF THE WATER IS GETTING EXTREMELY HOT THEN THE THERMOSTAT IS STUCK IN THE “ON” POSITION AND WILL NEED TO BE REPLACED.

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SAFETY

Disconnect the immersion from the mains electrical supply before removing any covers.

Do not attempt to replace the immersion heater(s) with alternatives to those recommended by JOULE.

Do not bypass the Thermal Cut-Out(s) in any circumstances.

REPLACING THE IMMERSION

First task is to isolate the power. Immersion heaters are rated at 3Kw and require their

own 20amp double pole isolation switch. Turn o the power from the isolation switch and remove the fuse. Next turn o the water to the tank.

Drain the water from the tank via the drain cock using a hose. Remove the immersion using an immersion spanner. Thread in the replacement immersion heater creating the seal using a rubber o-ring or  bre washer. Slot the immersion heater into the hole

with the washer and make sure the threads are lined up correctly. Tighten with whichever spanner you are using, taking care not to over tighten and risk damaging the cylinder.

Open the taps up and turn the cold water supply back on. When water starts to come

out of the taps shut them o and check for leaks. If all is good wire up the immersion heater, checking that your connections are good. Fit the cap on the immersion and turn the power back on.

If the immersion is connected to a booster switch turn it on and check that it heats up. Economy 7 immersion heaters will only turn on at set times during the night and cannot be altered so check the following morning to see if the water has heated up properly.

Technical Speci cation Indirect

B C D E F G H I J

15°

30°

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Mechanical Diagram

2 x Two Port Zone Valves (S-Plan) Variant Dual Thermostat

Dual Stat

High Limit

Stat

Secondary Flow

Boiler

Secondary Return

Balanced Cold Connection

Cold Main

01 Bronze Pump

02 Non Return Valve (Not Supplied)

03 Inlet Control Group

04 Temperature & Pressure Relief Valve

05 Isolation Valve (Not Supplied)

06 Expansion Vessel With Wall Bracket

07 Two Port Zone Valve

08 Three Port Zone Valve (Not Supplied)

09 Drain Valve (Not Supplied)

10 Tundish

11 Heating Circulation Pump (Required where boiler has no internal pump)

LEGEND

Electrical Diagram

2 x Two Port Zone Valves (S-Plan) Variant Dual Thermostat

Standard

Boiler

2 Channel Time Clock

DHW Dual

Cylinder Stat

DHW Zone Valve

230 VAC - 50Hz

Junction Box

Room Stat

Pump

CH Zone Valve

1 2 3 4 5 6 7 8 9 10

High Limit

Control

5 Amp

Blue

Brown

Orange

Grey

Earth

C 1 2 C 1 2

DHW

SLNNL

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Mechanical Diagram

Three Port Mid Position Valve (Y-Plan) + Two Port Valve

Variant Dual Thermostat

Cold Main

Balanced Cold Connection

Boiler

Secondary Flow

High Limit

Stat Dual Stat

Secondary Return

Boiler Primary Flow

Boiler Return Flow

01 Bronze Pump

02 Non Return Valve (Not Supplied)

03 Inlet Control Group

04 Temperature & Pressure Relief Valve

05 Isolation Valve (Not Supplied)

06 Expansion Vessel With Wall Bracket

07 Two Port Zone Valve

08 Three Port Zone Valve (Not Supplied)

09 Drain Valve (Not Supplied)

10 Tundish

11 Heating Circulation Pump (Required where boiler has no internal pump)

LEGEND

Electrical Diagram

Three Port Mid Position Valve (Y-Plan) + Two Port Valve

Variant Dual Thermostat

Room Stat

Pump

230 VAC - 50Hz

5 Amp

1 2 3 4 5 6 7 8 9 10

Junction Box

2 Channel Time Clock

DHW Dual

Cylinder Stat

High Limit

Control

C 1 2 C 1 2

DHW Zone Valve

Blue

Brown

Orange

Grey

Earth

3 Port Valve

Blue

Brown

Orange

Grey

Earth

SL N PL

SLN L

ON OFF

DHW

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ELECTRONIC CONTROLS

ELECTRICAL CONTROLS

Suitable time and temperature controls should be installed to allow the cylinder to operate at it’s maximum e ciency. All electrical work carried out must comply with

IEE Wiring Regulations (BS 3456). Products must also be installed as per the regulations in G3 of the Building Regulations. A boiler interlock should be in place and is a wiring arrangement where the boiler cannot  re unless there is a demand for hot water generation.

TYPICAL WIRING DIAGRAMS

These diagrams relate only to the components listed. Others may vary in their wiring requirements, particularly thermostats. Always refer to manufacturers’ instructions which may override the detail in order to function correctly.

EXAMPLE

The link must be installed between the adjustable thermostat and the safety cut-out thermostat as shown above. The working thermostat which controls the temperature of the domestic hot water is adjustable. A safety cut out is also incorporated within the thermostat and will operate at 85°C ± 3°C. Both thermostats should run in series. To reset the safety cut-out and the motorised valve the reset button must be pressed in.

JOULE cannot be responsible if alternative wiring plans are used.

Important: Before resetting the safety cut-out or altering the thermostat setting isolate electrical supply to the unit before removal of the cover.

DHW Zone Valve

Adjustable Thermostat

Safety Cut

Out Thermostat

C C

2 Channel Time Clock

L N CH

O

(Installer Link)

DHW Dual Cylinder Stat

2 1 2 1

DHW

Brown

Blue

Earth

Grey

Orange

DISCHARGE PIPEWORK

The inlet control group should be positioned so that the discharge from both safety valves can be combined via a 15mm end feed Tee, as in the diagram below. Connect the tundish and route the discharge pipe which must be routed in accordance with Building regulation - Part G3 of schedule 1.

When operating normally water will not be discharged. Water discharge from the two safety valves will only occur under fault conditions. The tundish should be vertical, located in the same space as the unvented hot water storage system and be ﬁtted as close as possible, within 500mm of the safety device e.g. the temperature relief valve.

The position of the tundish must be that when installed it is visible to the occupants of the premises. When positioning the tundish, the drain valves and motorised valve ensure that these items are positioned away from any electrical devices. The discharge pipe (D2) coming from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, be of metal and:

Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger, and so on.

Bends must be taken into account in calculating the  ow resistance. Refer to diagram 1, Table 1 and the worked example. An alternative approach for sizing discharge pipes would be to follow BS6700 Speciﬁcation for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

Have a vertical section of pipe at least 300mm long, below the tundish before any elbows or bends in the pipework.

Be installed with a continuous fall.

It is preferable for the discharge to be visible at both the tundish and the  nal point of discharge. Where this is not possible or practically di cult, there should be clear

visibility at one or other of these locations

DISCHARGE AGREEMENT

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EXAMPLES OF ACCEPTABLE DISCHARGEMENT ARRANGEMENTS

Ideally below the ﬁxed grating and above the water seal in a trapped gulley.

Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that where children play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.

Discharges at a high level; e.g. in to 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 and 3m from any plastic guttering systems that would collect such discharges (tundish available).

Where a single pipe serves a number of discharges, such as in blocks of  ats, 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 larger than the largest individual discharge pipe to be connected. If unvented hot water storage systems are installed where discharges from safety devices may not be apparent, i.e. in dwellings occupied by blind, in rm or disabled people, consideration should be

given to the installation of an electronically operated device to warn when discharge takes place.

WORKED EXAMPLE

The example on the next page is for G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.

Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is: 9.0m. Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m. Therefore the maximum permitted length equates to: 5.8m. 5.8m is less than the actual length of 7m, therefore calculate the next largest size.

Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief valve equates to: 14m. As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

Size of discharge pipework

Maximum length of straight pipe (no bends or elbows)

Deduct the  gure below from the maximum length for each bend or elbow in the discharge pipe

22m Up to 9m 0.8m

28mm Up to 18m 1m

35mm Up to 27m 1.4m

Table 4.a - Sizing of copper discharge pipe (D2) for a temperature relief balbe with a G1/2 outlet size (as supplied)

Figure 4.b

Note: It is not acceptable to discharge straight into a soil pipe.

Note: The discharge will consist of scalding water and steam. Asphalt, roo ng felt and non-metallica rainwater goods may be damaged by such discharges.

Metal discharge pipe (D2) from

temperature relief valve to tundish.

Tundish

Metal discharge pipe (D2) from

tundish, with continous fall. See 3.56,

Table 1 and worked example.

Trapped Gulley

Fixed Grating

Discharge below  xed

grating (3.61gives

alternative points of

discharge.)

Safety Device

(temperature relief

valve.)

600mm Maximum

300mm

Minimum

Direct & Indirect

FILLING

First you must ensure that the pressure in the expansion vessel is the same as the setting of the pressure reducing valve i.e. 3 bar (45PSI). The valve is of the Schrader car tyre type. Check all the connections for water tightness including any factory made connections such as the immersion heater and the temperature and pressure relief valve. Prior to ﬁlling, open the hot tap furthest away from the cylinder to expel air. Open the cold main isolation valve and allow the unit to  ll.

Once the cylinder has been fully commissioned it should be heated to its normal operating temperature. Draw o secondary hot water to each outlet and allow hot water to  ow from each outlet for at least 30 seconds to remove any  ux residue from the pipe work within the secondary hot water system. Then fully drain the cylinder and re- ll to ensure that all  ux residues is removed from the system.

INDIRECT UNITS

Fill the primary circuit according to the boiler manufacturers’ commissioning instructions. Any additives used in the heating system water circulating through the cylinder coil must be compatible for use with stainless steel cylinders.

Ensure the lever on the two port valve is set to the ﬁlling position. When full, move the lever back. Switch the programmer to Domestic Hot Water (DHW) and allow the unit to start to heat. Adjust the dial of the dual thermostat to between 30°C and 70°C as required.

STORAGE TEMPERATURE

60-65°C is the recommended storage temperature for both direct and indirect cylinders. In hard water areas consideration should be given to reducing this to 50-55°C. In many healthcare applications the guidance on Legionella control and safe water delivery temperatures will require storing the water at 60-65°C, distributing at 5055°C and using thermostatic mixing valves to control the  nal temperature. For details consult the NHS Estates Guidance on safe hot water temperatures.

DISCHARGE ARRANGEMENT

MAINTENANCE

GENERAL

Servicing should only be carried out by competent installers and any spare parts used must be purchased from JOULE.

NEVER bypass any safety devices or operate the unit without them being fully

operational.

DRAINING

Switch the electrical power o (important to avoid damage to element). Isolate boiler from the unit. Turn o the cold water supply valve. Open hot water tap. Open the drain valve. The unit will drain.

WARNING: WATER DRAINED OFF MAY BE VERY HOT!

ANNUAL MAINTENANCE

The water heaters require annual servicing in order to ensure safe working and optimum performance. It is essential that the following checks are performed by a competent installer on an annual basis. This is commonly done at the same time as the annual boiler service.

Twist the cap of the expansion relief valve on the inlet control set and allow water to  ow for 5 seconds. Release and make sure it resets correctly.

Repeat with the pressure / temperature relief valve. In both cases check that the discharge pipework is carrying the water away adequately. If not, check for blockages etc. and clear.

Check that any immersion heaters ﬁtted are working correctly and that they are controlling the water at a temperature between 55°C and 65°C.

Check the pressure in the expansion vessel is charged to 3 bar. Turn o the water supply to the unit and open a hot tap ﬁrst. The air valve on expansion vessel is a Schrader (car tyre) type. Air or CO2 may be used to charge the expansion vessel. Unscrew the head on the inlet control set and clean the mesh  lter within.

The Service Log Book supplied with this unit should be updated at each service.

Direct & Indirect

YOUR GUARANTEE MAY BE VOID IF YOU CANNOT PRODUCE PROOF OF ANNUAL SERVICING

IMMERSION HEATER REPLACEMENT

If the thermal cut out on the Immersion heater operates contact a competent installer. If the thermal cut out fault occurs again the immersion will need to be replaced.

Prior to installing the replacement Immersion, ensure the o-ring is correctly positioned on the head of the Immersion and lubricate the threads before  tting.

Thread the Immersion by hand until it is hand tight and then tighten gently to allow the o-rings to create a water tight seal.

INSPECTION

Where internal inspection of the cylinder is required an endoscope can be used. Inspection can be carried out by draining down the cylinder and removing a component that is  tted to a wet connection in the cylinder.

SAFETY VALVE CHECKS

rom either the temperature/pressure relief valve or the expansion relief valve indicates a problem.

Check your discharge pipework is free from debris and is carrying water away to waste e ectively. Next hold both of these safety valves open, allowing as much water as possible to  ow through the tundish. Release the valves and check that they reseat correctly. Completion of the Benchmark checklist on pages 36-37

MUST be adhered to by the

installer.

GUIDANCE IN THE EVENT OF A PROBLEM

If you have a problem in the ﬁrst year, contact the plumber who ﬁtted the unit. Thereafter contact the plumber who carries out the annual servicing for you. If your cylinder develops a leak we will supply you with a new one. We ask for a nominal upfront payment to prevent fraud and we will require the original unit to be returned to us for inspection along with a copy of your Service Log Book. If it is conﬁrmed that it has failed within the terms of the guarantee your upfront payment will be refunded.

If a component part fails within the guarantee period, we will send you a new one without any upfront charge. Credit card details may be taken to prevent fraud.

We ask you to post the faulty part back to us within one month by recorded delivery.

If you do not return the part we will charge you for it and for the postage and packing. If your part fails after the guarantee period, we will ask for upfront payment.

LOG BOOK

The installer must comply with all of the installation instructions contained within this installation manual. On completion of the initial installation and after each subsequent annual service the Benchmark Log Book must be completed and signed by the competent person who has worked the unit.

The purpose of Benchmark is to ensure that customers have the correct equipment for their requirements installed in accordance with the manufacturer’s installation instructions. The equipment must be installed by installers who have completed an accredited competent person’s scheme and who install, commission and service the equipment in accordance with the manufacturer’s instructions.

All installations must comply with the appropriate Building Regulations and the Benchmark Log Book should be provide to the customer. The Benchmark Log Book can also be used to show that all equipment is installed in accordance with the relevant Building Regulations.

TAKING THE CYLINDER OUT OF USE

SHUTTING DOWN

Ensure the cold water supply is isolated and at least two hot water draw o points are

open prior to draining the cylinder.

One of the hot water draw o points should be as close as possible to the height of cylinder in draw o terms. Where applicable use the drain valve at the cold water inlet to drain the contents of the cylinder. Isolate the coil from the main heating system. If necessary blow out the coil prior to moving the cylinder.

RECYCLING AND DISPOSAL

The cylinder or any of its components must not be disposed of in domestic rubbish. The material in the cylinder, packaging and components contain recyclable materials and they should be disposed of properly and in accordance with national regulations.

Direct & Indirect

SPARE PARTS

TROUBLESHOOTING

Your stainless system is automatic in normal use and requires only annual servicing. You should employ a competent installer to perform the annual servicing. Normally this is timed to coincide with the annual boiler service.

IF WATER IS FLOWING FROM THE SAFETY VALVES THROUGH THE TUNDISH THIS INDICATES A FAULT CONDITION AND ACTION IS NEEDED.

If this water is hot, turn the boiler and / or the immersion heater o . Do not turn o the water until the discharge runs cool. The discharge may also stop.

CALL OUT A COMPETENT PLUMBER TO SERVICE THE UNIT.

Tell them you have a fault on an unvented cylinder. We stock all the spare parts they may need and JOULE can be contacted via telephone numbers on back page.

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GUARANTEE

JOULE CYCLONE

The JOULE Cyclone stainless steel vessel carries a fully transferable 25-year guarantee against faulty materials or manufacture provided that:

• It has been installed in the United Kingdom or the Republic of Ireland as per the instructions provided in the installation manual provided with the cylinder and in accordance with all of the relevant standards, regulations and codes of practice in force at the time.

• It has not been modiﬁed in any way, other than by JOULE

• It has not been misused, tampered with or subjected to neglect.

• The system is fed from the public mains water supply.

• It has only been used for the storage of potable water.

• It has not been subjected to frost damage.

• The unit has been serviced annually.

• The Service Log Book has been completed after each annual service.

• The warranty card is  lled in and a copy is sent by email to warranty@joule.ie

EXCLUSIONS

The guarantee does not cover cylinders a ected by the following;

• The e ects of scale build up on the cylinder.

• Any labour charges associated with replacing the unit or its parts.

• Any consequential losses caused by the failure or malfunction of the unit.

Please note that invoices for servicing may be requested to prove that the unit has been serviced annually UNVENTED KIT The expansion vessel and cold water controls supplied with JOULE models carry a 2-year guarantee. All other components that are ﬁtted to, or supplied, with the unit carry a 2-year guarantee.

JOULE WELLMASTER

The JOULE Wellmaster stainless steel vessel carries a fully transferable 10-year guarantee against faulty materials or manufacture provided that:

Notes

_________________________________________________________ ________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________

• It has not been modiﬁed in any way, other than by JOULE

• It has not been misused, tampered with or subjected to neglect

• It has only been used for the storage of potable water.

• The sacri cial anode is removed for inspection within 3 months of the cylinder installation. If there are signs of corrosion on the anode it must be replaced

• A replacement schedule for the anode must be put in place based on the  ndings of the initial 3 month inspection.

• Maximum interval between anode inspections is 12 months.

• The warranty card is  lled in and a copy is sent by email to warranty@joule.ie

EXCLUSIONS The guarantee does not cover cylinders a ected by the following;

• Wellmaster cylinders where the anode has not been routinely maintained.

• Any labour charges associated with replacing the unit or its parts.

• Any consequential losses caused by the failure or malfunction of the unit.

Please note that invoices for servicing may be requested to prove that the unit has been serviced annually

Joule fully endorse the Benchmark scheme and the code of practice can be obtained from www.centralheating.co.uk

Direct & Indirect

This Comissioning Checklist is to be completed in full by the competent person who commised the storage system as a means of demonstrating compliance with the appropriate building regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invali-

date the warranty but does not a ect statutory rights.

Customer Name Telephone Number Address

Cylinder Make & Model Cylinder Serial Number Commissioned by (print name) Registered Operative ID Number Company Name Telephone Number Company Address

Commisioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certi cate*: Building Regulations Noti cation Number (if applicable)

MAINS PRESSURE HOT WATER STORAGE

SYSTEM COMMISSIONING CHECKLIST

ALL SYSTEMS

What is the incoming static cold water perssure at the inlet to the system? bar Has a strainer been cleaned of installation debris (if  tted)? Is the installation in a hard water area (above 200ppm)? If yes, has a water scaled reducer been  tted? What type of scale reducer has been  tted? What is the hot water thermostat set temperature? °C

What is the maximum hot water  ow rate at set thermostat temperature (measuered at high  ow outlet)? L/min Time and temperature controls have been  tted in compliane with Part L of the Building Regulations? Type of control system (if applicable) Is the cylinder solar (or other renewable) compatible? What is the hot water temperature at the nearest outlet? °C

All appropriate pipes have been insulated up to 1 metre or the point where they become concealed.

UNVENTED SYSTEMS ONLY

Where is the pressure reducing valve situated (if  tted) ? bar What is the pressure reducing valve setting? Has a combinded temperature and pressure releif balve and expansion valve been  tted and discharge tested? The tundish and the discharge pipework have been connected and terminated to Part G of the Building Regulations Are all energy sources  tted with a cut out device? Has the expansion bessel or internal air space been checked

ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)

Is the primary circuit a sealed or open vented system?

What is the maximum primary  ow temperature? °C

What store temperature is achievable? °C What is the maximum hot water temperature? °C

THERMAL STORES ONLY

ALL INSTALLATIONS

The hot water system compiles with the appropriate building regulations The system has been installed and commisioned in accordance with the manufacturer’s instructions The system controls have been demonstrated to and understood by the customer The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer.

Commissioning Engineer’s Signature

Customer’s Signature

(to con rm satisfactory demonstrationg and receipt of manufacturer’s literature)

* All installations in England and Wales must be noti ed

to Local Authority Building Control (LABC) either directly

or through a Competent Persons Scheme.

A Building Regulations Compliance Certi cate will then

be issued to the customer.

Direct & Indirect

SYSTEM RECORD

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.