Direct & Indirect Installation Manual

Direct & Indirect Installation Manual
Direct & Indirect
Unvented Cylinder
Installation & Maintenance
Manual
1
Direct & Indirect
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2
Table of Contents
4
9
15
16
17
18
21
22
23
24
25
26
27
30
31
33
35
37
38
40
42
Introduction
General Requirements
ErP Product Information
Direct Technical Specification
Direct Installation Mechanical Diagram
Testing
Indirect Technical Specification
2 Port Mechanical Diagram
2 Port Electrical Diagram
3 Port Mechanical Diagram
3 Port Electrical Diagram
Electronic Controls
Discharge Arrangement
Commissioning
Maintenance
Taking The Cylinder Out Of Use
Troubleshooting
Guarantee
Notes
Benchmark Log Book
System Record
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Direct & Indirect
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 installation, servicing, fault finding 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 certified 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 13 .
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:
4
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 floor 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 qualified 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.
5
Direct & Indirect
A thermostatic mixer should be installed in the system to prevent the risk of scalding.
If there are leaks found in the system, shut off the cold water stop valve from the main
supply and contact a competent person immediately.
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 effect 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 flow 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 flow rate
availability.
Consideration should be given to upgrading existing ½” (15mm) cold mains pipework to a larger size if the recommended minimum pressure/flow 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 flow) mains pressure is no guarantee of good flow 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.
6
CHANGE OF WATER SUPPLY
The changing or alternating from one water supply to another can have a detrimental
effect 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 effects 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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Direct & Indirect
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 centimetre (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 fitting an appropriate filter 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 - 100L, 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 flow rate performance with
minimum 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.
8
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
difference. 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 flat base capable of supporting its weight when full (please
see the technical specification section for weights).
Sufficient 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 flowing 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 fit 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 flow as much. Do not use “screwdriver slot” or similar valves.
9
Direct & Indirect
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 flow. Select a suitable position for the expansion vessel.
Mount it to the wall using the bracket provided. Use the flexible 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 sufficient 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 fitted to the inlet control group using the supplied expansion vessel
flexible 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-off 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 flexible diaphragm, which is initially charged on one side
with nitrogen, but can be topped up with air when required.
10
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 flexible 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
flushed 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 flow. 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 effective 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 flow pipework. The direction
of flow arrow should be towards the primary flow 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 flow 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 30°C and
60°C and is supplied by the installer.
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Direct & Indirect
UNVENTED KIT COMPONENTS
Direct
Indirect
Inlet Control Group
Inlet Control Group
Tundish
Tundish
T & P Valve (fitted)
T & P Valve (fitted)
3kW Immersion (fitted)
3kW Immersion (fitted)
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-off points can cause significant volumes
of water to be drawn off before an acceptable temperature can be reached. Secondary pumped circulation using a stainless steel or a bronze pump, and combined with
effective 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 backflow.
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 off-peak electricity tariffs. 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.
12
Capacity (L)
Expansion
Vessel
100
125
150
170
200
250
TV-P-000019L
300
400
500
TV-P-000024L
TV-P-000035L
TV-P-000050L
Dual Stat
TZC-D-000000Z
Primary Coil 2
Port Zone Valve
TZM-I-00022MM
Inlet Group
T&P Relief Valve
Immersion
TZ9-4.0-0000.5
TZG-3.0-0001L
TZ9-4.0-000.75
TI-I-L-14-3-1
TZU-000015X22
TZU-0000022X1
13
Spare Parts
Tundish
TZG-3.0-0.75L
Direct & Indirect
DEAD LEGS
The length of hot water draw off to taps and other outlets should be kept to a minimum to reduce the amount of cold water drawn off before the hot water arrives. The
maximum recommended dead leg lengths are shown in figure 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 first time, or the time controls for the DHW zone have
been off 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.
14
100L
125L
150L
175L
200L
200L
250L
250L
300L
300L
400L
500L
Load Profile
L
L
L
L
L
L
L
L
XL
XL
XXL
XXL
Energy Efficiency Class
C
C
C
D
D
D
D
D
D
D
D
D
Energy Efficiency (%)
37
37
37
36
36
35
35
35
37
36
37
36
2740
2773
2785
2830
2875
2892
2908
2928
4565
4610
5805
5999
Sound Power Level (dB)
16
16
16
16
16
16
16
16
16
16
16
16
Thermostat Temperature Setting (°C)
60
60
60
60
60
60
60
60
60
60
60
60
Hot Water Storage Tank Volume
96
124
148
168
194
196
247
247
290
289
390
494
Standing Loss
44
52
55
66
78
81
87
89
92
103
102
115
Energy Efficiency Class
B
B
B
C
C
C
C
C
C
D
C
C
Direct
Anuual Electrcity Consumption (kWh)
Indirect
Indirect
Horizontal
15
170L
(1205x530)
200L
(1085x600)
250L
(1135x600)
300L
(1535x600)
Load Profile
L
L
L
L
XL
Energy Efficiency Class
D
D
D
D
D
Energy Efficiency (%)
36
35
35
35
36
2818
2901
2933
2949
4614
Sound Power Level (dB)
16
16
16
16
16
Thermostat Temperature Setting (°C)
60
60
60
60
60
Hot Water Storage Tank Volume
148
168
194
247
290
Standing Loss
63
69
89
97
104
Energy Efficiency ClassC
C
C
D
D
D
Anuual Electrcity Consumption (kWh)
ErP Product Information
Direct
Horizontal
150L
(1140x530)
Direct Technical Specification
Direct & Indirect
ØB
A G F E D C
Capacity
100L
125L
150L
170L
200L
200L
250L
250L
300L
300L
400L
500L
A (mm)
950
1030
1190
1310
1150
1490
1400
1815
1600
2040
1570
1900
B (mm)
500
530
530
530
600
530
600
530
600
530
710
710
C (mm)
188
196
196
196
218
196
218
196
218
196
225
225
D (mm)
203
211
211
211
233
211
233
211
233
211
240
240
E (mm)
468
511
561
631
553
701
653
861
733
1001
740
840
F (mm)
628
651
786
881
768
981
968
1271
1153
1551
1180
1440
G (mm)
743
751
911
1031
883
1211
1133
1531
1333
1811
1280
1640
Heat Up Time (Mins)
52
62
76
96
119
119
140
140
166
166
225
260
Weight - Empty (kg)
36
30
34
37
40
41
49
49
56
55
62
89
Weight - Full (kg)
135
155
184
207
240
241
299
299
356
355
462
587
Operating Pressure
3 bar
Max Water Supply
Pressure
10 bar
Max Primary Working
Pressure
3 bar
Immersion Heater
3kW/240V - 1.75” - 14” Long
Expansion Vessel
Charge Pressure
2.7 bar
Note: Heat and reheat times are a guide and are based on a primary flow temperature
of 60°C and a tempertature rise from 15°C to 60°C.
16
Horizontal Direct Technical Specification
X
Y
Y
X
Capacity
150L
170L
200L
250L
300L
A (mm)
1085
1205
1085
1335
1535
B (mm)
530
530
600
600
600
Heat Up Time (Mins)
76
96
119
140
166
Weight - Empty (kg)
34
37
40
49
56
Weight - Full (kg)
184
207
240
299
356
Operating Pressure
3 Bar
Max Water Supply Pressure
10 Bar
Max Primary Working Pressure
3 Bar
17
Direct & Indirect
Mechanical Diagram
LEGEND
18
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)
Testing
20 Amp Fused Double
Pole Isolating Switch
L
N
L
N
230 V AC - 50Hz
20 Amp Fused Double
Pole Isolating Switch
L
N
L
N
230 V AC - 50Hz
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.
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Direct & Indirect
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 fitted.
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 off 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.
20
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 off the power from the isolation switch
and remove the fuse. Next turn off 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 fibre 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 off 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.
21
Indirect Technical Specification
Direct & Indirect
ØB
A H G F E D C
Capacity
100L
125L
150L
170L
200L
200L
250L
250L
300L
300L
400L
500L
A (mm)
950
1030
1190
1310
1150
1490
1400
1815
1600
2040
1570
1900
B (mm)
500
530
530
530
600
530
600
530
600
530
710
710
C (mm)
188
196
196
196
218
196
218
196
218
196
225
225
D (mm)
333
211
341
341
423
336
383
361
383
361
405
455
E (mm)
478
511
486
486
538
516
608
586
608
586
675
745
F (mm)
543
651
551
551
603
581
673
651
673
651
740
810
G (mm)
628
751
786
881
768
981
968
1271
1153
1551
1180
1440
H (mm)
743
751
911
1031
883
1211
1133
1531
1333
1811
1280
1640
Heat Up Time (Mins)
14
23
26
27
31
31
37
37
42
42
52
54
Weight - Empty (kg)
39
35
39
43
46
47
56
57
64
65
71
87
Weight - Full (kg)
135
158
187
210
243
244
302
303
360
361
471
589
Operating Pressure
3 bar
Max Water Supply
Pressure
10 bar
Max Primary Working
Pressure
3 bar
Immersion Heater
3kW/240V - 1.75” - 14” Long
Expansion Vessel
Charge Pressure
2.7 bar
Note: Heat and reheat times are a guide and are based on a primary flow temperature
of 60°C and a tempertature rise from 15°C to 60°C.
22
Horizontal Indirect Technical Specification
X
Y
Y
X
Capacity
150L
170L
200L
250L
300L
A (mm)
1140
1205
1085
1335
1535
B (mm)
530
530
600
600
600
Heat Up Time (Mins)
26
27
31
37
42
Weight - Empty (kg)
39
43
46
56
64
Weight - Full (kg)
187
210
243
302
360
Operating Pressure
3 Bar
Max Water Supply Pressure
10 Bar
Max Primary Working Pressure
3 Bar
23
Direct & Indirect
Mechanical Diagram
LEGEND
24
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)
Electrical Diagram
25
Direct & Indirect
Mechnical Diagram
LEGEND
26
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)
Electrical Diagram
27
Electronic Controls
Direct & Indirect
ELECTRICAL CONTROLS
Suitable time and temperature controls should be installed to allow the cylinder to
operate at it’s maximum efficiency. 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 fire 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
DHW
L
N
C
21
C
Orange
Grey
Earth
Blue
DHW Dual Cylinder Stat
Brown
2 Channel Time Clock
21
CH On Off
DHW Zone Valve
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.
28
Discharge Arrangement
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 flow 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 final point
of discharge. Where this is not possible or practically difficult, there should be clear
visibility at one or other of these locations
29
Direct & Indirect
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 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 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, infirm 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.
30
Size of discharge
pipework
Maximum length of
Deduct the figure below from the
straight pipe (no bends or maximum length for each bend
elbows)
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)
Metal discharge pipe (D2) from
temperature relief valve to tundish.
600m
m Max
imum
Tundish
Safety Device
(temperature relief
valve.)
300mm
Minimum
Metal discharge pipe (D2) from
tundish, with continous fall. See 3.56,
Table 1 and worked example.
Discharge below fixed
grating (3.61gives
alternative points of
discharge.)
Fixed Grating
Trapped Gulley
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, roofing felt and
non-metallica rainwater goods may be damaged by such discharges.
31
Direct & Indirect
Commissioning
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 fill.
Once the cylinder has been fully commissioned it should be heated to its normal operating temperature. Draw off secondary hot water to each outlet and allow hot water
to flow from each outlet for at least 30 seconds to remove any flux residue from the
pipe work within the secondary hot water system. Then fully drain the cylinder and
re-fill to ensure that all flux 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 final temperature. For details
consult the NHS Estates Guidance on safe hot water temperatures.
32
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 off (important to avoid damage to element). Isolate boiler from the unit. Turn off 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
flow 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 off 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 filter within.
The Service Log Book supplied with this unit should be updated at each service.
33
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 fitting.
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 fitted 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 effectively. Next hold both of these safety valves open, allowing as much water
as possible to flow through the tundish. Release the valves and check that they reseat
correctly.
Completion of the Benchmark checklist on pages 40-41 MUST be adhered to by the
installer.
34
Taking The Cylinder Out Of Use
SHUTTING DOWN
Ensure the cold water supply is isolated and at least two hot water draw off points are
open prior to draining the cylinder.
One of the hot water draw off points should be as close as possible to the height of
cylinder in draw off 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.
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.
35
Direct & Indirect
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.
36
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 off. Do not turn off
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.
37
Direct & Indirect
Fault
Possible Cause
Solution
Water escaping from the case
unit.
Compression fitting on hot draw off not sealing.
Check / remake joint sealing
paste.
Cold water at hot tops.
Immersion heater not switched
on or cutout has triggered.
Check / reset.
Indirect - Boiler not working.
Check boiler - consult boiler
manufactures’ instructions.
Indirect - motorized valve fault.
Check plumbing / wiring
motorized valve.
Indirect - cutout in dual stat has
operated.
Check outlet pressure from inlet
control set is 3 bar.
If continual - pressure reducing
valve (part of inlet control set )
mayno tbe operating correctly.
Check outlet pressure from inlet
control set is 3 bar.
If continual - expansion relief
valve seat may be damaged.
Remove cartridge - check seat
and renew if necessary.
If intermittent - expansion vessel
charge may have reduced /
bladder perished.
Check pressure in expansion
bessel. Recharge to 3 bar if
necessary. If bladder perished
replace vessel.
Unit is being back pressurized.
With cylinder cold check pressure in cylinder. If this is the
same as the incoming mains
pressure then you are getting
backfeed. Install a balanced cold
supply.
Water discharges from temperature & pressure relief valve
Unit has overheated - thermal
controls have failed.
Switched off power to boiler and
immersion heaters. Leave water
supply on. Wait until discharges
stops. Isolate water supply and
replace if faulty.
Milky / cloudy water
Oxygenated Water.
Water from any pressurized system will release oxygen bubbles
when flowing. The bubbles will
settle out.
No hot water flow
Cold main off.
Check and open stopcock.
Strainer blocked in pressure
reducing valve.
Isolate water supply and clean.
Inlet control set may be fitted
incorrectly.
Check and refit required.
Noise during hot water draw off typically worse in the morning
Loose airing cupboard pipework.
Install extra clips.
Hot or warm water from cold tap
If tap runs cold after a minute
or so the pipe is picking up heat
from heating pipework.
Insulate/re-route.
Water discharges from expansion relief valve
38
Guarantee
CYCLONE GUARANTEE – CC/001 – 13/10/15
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.
Exclusions
The guarantee does not cover cylinders affected by the following;
•
The effects 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 20-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.
•
It has only been used for the storage of potable water.
39
Direct & Indirect
•
•
•
•
The sacrificial 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
findings of the initial 3 month inspection.
Maximum interval between anode inspections is 22 months.
The Service Log Book has been completed after each annual service.
Exclusions
The guarantee does not cover cylinders affected 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
[email protected]
Tel: 02523552094
Registration can be made by logging online to www.jouleuk.co.uk / www.joule.ie
Notes
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41
Direct & Indirect
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43
Direct & Indirect
44
Mains Pressure Hot
Water Storage System Commisioning Checklist
45
Direct & Indirect
46
Service Record
47
Direct & Indirect
JOULE IE
mail
tel
fax
eml
web
Kylemore Park West, Ballyfermot, Dublin 10
+353 (1) 623 7080
+353 (1) 626 9337
[email protected]
www.joule.ie
JOULE UK
mail
tel
fax
eml
web
Unit 17C&D Power Road, Plantation Bus. Pk.
Bromborough, Wirral, CH62 3RN
+44 (0) 1513 551 094
+44 (0) 1513 568 336
[email protected]
www.jouleuk.co.uk
JOULE PL
mail
tel
fax
eml
web
48
23-200 Kraśnik, ul. Towarowa 34.
+48 (0) 128811171
+48 (0) 814709046
[email protected]
www.joule-pl.pl
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