Joule Direct, Twin solar cylinder Installation & Maintenance Manual

Joule Direct, Twin solar cylinder Installation & Maintenance Manual

Below you will find brief information for solar cylinder Direct, solar cylinder Twin. The document outlines the installation process, maintenance requirements, troubleshooting tips, and warranty information for these solar cylinders.

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Joule Solar Cylinder Direct, Twin Installation & Maintenance Manual | Manualzz

Direct & Twin Solar

Cylinder Installation

& Maintenance Manual

Direct & Twin Sol

Please register your product online at www.jouleuk.co.uk

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Address

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Product

Cylinder

Solar Thermal

Solar PV

Air Source Heat

Pump

Integrated Heat

Pump and Cylinder

Underfl oor Heating

Direct Gas Fire

Cylinder

Product

Installed

(Check)

Serial Number

Located in Cylinder badge

Taken From Solar

Controller

One Ser. No. from String

/ Micro Inverter

Located on External Heat

Pump Badge

Located on Cylinder

Badge

Project Ref. on Supplied

Schematic

Located on Cylinder

Badge

Installation

Date

Installer

Address

2

Contact Tel.

Contact Email

Joule Advance Installer

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Table of Contents

4

Introduction

9 General Requirements

15 Spare Parts

19 ErP Product Information

20 Direct Solar Technical Specifi cation

22 Direct Installation Mechanical Diagram

24 Indirect Technical Specifi cation

26 2 Port Mechanical Diagram

27 2 Port Electrical Diagram

28 3 Port Mechanical Diagram

29 3 Port Electrical Diagram

30 Electronic Controls

31 Discharge Agreement

34 Commissioning

35 Maintenance

37 Taking The Cylinder Out Of Use

39 Trouble Shooting

41 Guarantee

44 Benchmark Log Book

46 System Record

3

Direct & Twin Sol

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 fi 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 certifi 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 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 fl 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 qualifi 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.

5

Direct & Twin Sol

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 eff 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 fl 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 fl ow rate availability.

Consideration should be given to upgrading existing ½” (15mm) cold mains pipework to a larger size if the recommended minimum pressure/fl 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 fl ow) mains pressure is no guarantee of good fl 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.

6

CHANGE OF WATER SUPPLY

The changing or alternating from one water supply to another can have a detrimental eff 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 eff 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

Total Dissolved Solids

Total Hardness

Chloride

Magnesium

Calcium

Sodium

Iron

Maximum pH

Minimum pH

Maximum Permitted Levels

600 mg/Litre

200 mg/Litre

300 mg/Litre

10 mg/Litre

20 mg/Litre

150 mg/Litre

1 mg/Litre

9.5

6.5

7

Direct & Twin Sol

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 fi tting an appropriate fi 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 - 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 fl ow 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 diff 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 fl at base capable of supporting its weight when full (please see the technical specification section for weights). 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 fl 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 fi 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 fl ow as much. Do not use “screwdriver slot” or similar valves.

9

Direct & Twin Sol

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 fl ow. Select a suitable position for the expansion vessel.

Mount it to the wall using the bracket provided. Use the fl 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 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 fi tted to the inlet control group using the supplied expansion vessel fl 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-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 fl exible 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 fl 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 fl 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 fl 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 eff 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 fl ow pipework. The direction of fl ow arrow should be towards the primary fl 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 fl 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.

11

Direct & Twin Sol

SOLAR COIL CONNECTIONS

The solar circuit is the lower coil in the cylinderand must be connected to a pumped solar circuit. It is not suitable for use with an uncontrolled heat source. Either solar connections may be used as the solar fl ow. Reheat times are identical either way. The solar circuit can be open vented or sealed, with up to a maximum pressure of 3.5 bar. If you seal the solar circuit an additional solar expansion vessel and safety valve is required. A dual line pump station must be installed onto thesolar pipework which includes a solar rated pressure and temperature relief valve, an expansion vessel connection, a solar discharge vessel connection, and a pressure gauge. The fl uid used in the solar pipework must be safe for use and be a propylene glycol with organic inhibitors.

DISCHARGED FLUID FROM THE SOLAR DUAL LINE PUMP STATION CAN REACH TEM-

PERATURES IN EXCESS OF 100°C.

A clear solar discharge vessel should be installed to contain any discharge from the solar pipework. The discharge vessel must be manufactured from a transparent material capable of withstanding the discharge temperatures from the solar system. Refer to the solar system supplier for guidance.

NSTALLING THE SOLAR TWO PORT MOTORISED VALVE

A Two Port Motorised Valve must be installed on either horizontal or vertical pipework between the solar system and the cylinder. If it is mounted onto horizontal pipework the valve head must face upwards. The direction of fl ow is marked on the body of the valve with arrows.

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 fi 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.

12

UNVENTED KIT COMPONENTS

Direct

Inlet Control Group

Tundish

T & P Valve (fi tted)

3kW Immersion (fi tted)

Expansion Vessel

Expansion Vessel Hose

Indirect

Inlet Control Group

Tundish

T & P Valve (fi tted)

3kW Immersion (fi tted)

Expansion Vessel

Expansion Vessel Hose

Dual Cylinder Stat

2 Port Zone Valve

SECONDARY CIRCULATION

On larger installations long pipe runs to draw-off points can cause signifi cant 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 eff 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 backfl 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 off -peak electricity tariff 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.

13

Direct & Twin Sol

Pipe Size (mm)

10, 12

15, 22

28

35 and above

Maximum Length (m)

20

12

8

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 fi rst 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.

WIRING THE SOLAR ZONE VALVE

To prevent the cylinder from overheating a high limit thermostat and a 2 port motorised valveshould be wired in series between the solar controller and the solar pump.

In the event of overheating from the solar system, the high limit thermostat will shut off power to the solar coil zone valve and the solar pump. All components on the mechanical system must be rated for use at elevated temperatures and pressures.

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

Capacity (L)

Expansion

Vessel

Dual Stat

Primary Coil 2

Port Zone Valve

Inlet Group

100

T&P Relief Valve

Immersion

Tundish

125 150 170

TV-P-000019L

200 250 300 400 500

TV-P-000024L TV-P-000035L TV-P-000050L

TZC-D-000000Z

TZM-I-00022MM

TZG-3.0-0.75L

TZG-3.0-0001L

TZ9-4.0-000.75

TZ9-4.0-0000.5

TI-I-L-14-3-1

TZU-000015X22 TZU-0000022X1

Direct & Twin Sol

L

N

20 Amp Fused Double

Pole Isolating Switch

L

N

230 V AC - 50Hz

L

N

20 Amp Fused Double

Pole Isolating Switch

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.

16

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 fi 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 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.

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Direct & Twin Sol

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 fi 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 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.

18

Twin Solar

Hot Water Storage Tank Volume (L)

Standing Loss (W)

Solar Direct

Hot Water Storage Tank Volume (L)

Standing Loss (W)

150L

-

-

-

148

55

B

165

68

C

168

66

C

170L 200L

(1150x600)

193

200L

(1490x530)

193

80

C

83

C

250L

(1400x600)

244

250L

(1815x530)

244

300L

(1600x600)

287

89

C

91

C

96

C

194

78

C

196

81

C

244

89

C

247

89

C

290

92

C

400L

387

102

C

390

102

C

500L

492

115

C

494

115

C

Direct & Twin Sol

ØB

Direct Solar

20

A J I H G F E D C

Technical Specifi cation

Capacity

A (mm)

B (mm)

C (mm)

D (mm)

E (mm)

F (mm)

G (mm)

H (mm)

I (mm)

J (mm)

Solar Coil Surface (m²) kW Rating

Heat Up Time - Coil

(mins)

Heat Up Time (Mins)

Weight - Empty (kg)

Weight - Full (kg)

Operating Pressure

Max Water Supply

Pressure

Max Primary Working

Pressure

Immersion Heater

150L 170L 200L 200L 250L 250L 300L 400L 500L

1190 1310 1150 1490 1400 1815 1600 1570 1900

530 530 600 530 600 530 600 710 710

196 196 218 196 218 196 218 225 225

246 246 268 246 268 246 268 275 275

346 346 368 386 438 416 438 430 430

446 446 468 486 538 516 538 615 615

511 511 533 551 603 581 603 680 680

636 731 668 821 833 931 968 915 1150

762 882 768 981 968 1271 1153 1190 1440

911 1031 883 1211 1133 1531 1333 1290 1640

0.58

0.58

0.67

0.67

0.77

0.77

0.77

1.15

1.28

16

23

16

24

18

28

18

28

22

34

22

34

22

39

30

48

35

54

23

39

24

43

28

46

28

47

34

56

34

57

39

64

48

71

54

87

187 210 243 244 302 303 360 471 589

3 bar

10 bar

3 bar

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 fl ow temperature of 60°C and a tempertature rise from 15°C to 60°C.

21

Direct & Twin Sol

Mechanical Diagram

LEGEND

05

06

07

08

09

10

01

02

03

04

11

12

Bronze Pump

Non Return Valve (Not Supplied)

Inlet Control Group

Temperature & Pressure Relief Valve

Isolation Valve (Not Supplied)

Expansion Vessel With Wall Bracket

Two Port Zone Valve

Three Port Zone Valve (Not Supplied)

Drain Valve (Not Supplied)

Tundish

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

Solar Dual Line Pump Station

13 Solar Expansion Vessel

Note: The pressure reducing valve, non-return valve and expansion relief valve are combined together in the inlet control set.

22

23

Direct & Twin Sol

ØB

Twin Solar

24

A L K J I H G F E D C

Technical Specifi cation

Capacity

A (mm)

B (mm)

C (mm)

D (mm)

E (mm)

F (mm)

G (mm)

H (mm)

I (mm)

J (mm)

K (mm)

L (mm)

Solar Coil Surface (m²) kW Rating

Boiler Coil Surface (m²) kW Rating

Heat Up Time (Mins)

Weight - Empty (kg)

Weight - Full (kg)

Operating Pressure

Max Water Supply Pressure

Max Primary Working

Pressure

Immersion Heater

Expansion Vessel Charge

Pressure

170L 200L 200L 250L 250L 300L 400L 500L

1310 1150 1490 1400 1815 1600 1570 1900

530 600 530 600 530 600 710

196 218 196 218 196 218 225

710

225

246 268 246 268 246 268 275

346 368 386 438 416 438 430

446 468 486 538 516 538 615

275

430

615

511 533 551 603 581 603 680

576 598 616 668 646 668 745

680

745

681 688 756 798 786 810 888 888

826 768 906 1053 1031 1053 1130 1130

882 848 981 968 1271 1153 1180 1440

1031 883 1211 1133 1531 1333 1280 1640

0.58

0.58

0.58

0.67

0.67

0.67

0.77

0.77

16 16 16 18 18 18 22 22

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

16

15

16

21

16

21

16

27

16

27

16

32

16

42

49 50 50 59 60 67 74

219 246 247 307 308 364 476

16

49

87

589

3 bar

10 bar

3 bar

3kW/240V - 1.75” - 14” Long

2.7 bar

Note: Heat and reheat times are a guide and are based on a primary fl ow temperature of 60°C and a tempertature rise from 15°C to 60°C.

25

Direct & Twin Sol

Mechanical Diagram

LEGEND

05

06

07

08

09

10

01

02

03

04

11

12

Bronze Pump

Non Return Valve (Not Supplied)

Inlet Control Group

Temperature & Pressure Relief Valve

Isolation Valve (Not Supplied)

Expansion Vessel With Wall Bracket

Two Port Zone Valve

Three Port Zone Valve (Not Supplied)

Drain Valve (Not Supplied)

Tundish

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

Solar Dual Line Pump Station

13 Solar Expansion Vessel

Note: The pressure reducing valve, non-return valve and expansion relief valve are combined together in the inlet control set.

26

Electrical Diagram

27

Direct & Twin Sol

Mechanical Diagram

LEGEND

05

06

07

08

09

10

01

02

03

04

11

12

Bronze Pump

Non Return Valve (Not Supplied)

Inlet Control Group

Temperature & Pressure Relief Valve

Isolation Valve (Not Supplied)

Expansion Vessel With Wall Bracket

Two Port Zone Valve

Three Port Zone Valve (Not Supplied)

Drain Valve (Not Supplied)

Tundish

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

Solar Dual Line Pump Station

13 Solar Expansion Vessel

Note: The pressure reducing valve, non-return valve and expansion relief valve are combined together in the inlet control set.

28

Electrical Diagram

29

Direct & Twin Sol

Electronic Controls

ELECTRICAL CONTROLS

Suitable time and temperature controls should be installed to allow the cylinder to

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 fi 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

2 Channel Time Clock DHW Dual Cylinder Stat

C 2 1 C 2 1

L N

DHW

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.

30

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 fl 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 fi nal point visibility at one or other of these locations

31

Direct & Twin Sol

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 fl 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, infi 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.

32

Size of discharge pipework

22m

28mm

35mm

Maximum length of straight pipe (no bends or elbows)

Up to 9m

Up to 18m

Up to 27m

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

0.8m

1m

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.

600mm M aximum

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 fi xed 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, roofi ng felt and non-metallica rainwater goods may be damaged by such discharges.

33

Direct & Twin Sol

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 fi ll.

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 fl ow from each outlet for at least 30 seconds to remove any fl ux residue from the pipe work within the secondary hot water system. Then fully drain the cylinder and re-fi ll to ensure that all fl 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 50-

55°C and using thermostatic mixing valves to control the fi nal temperature. For details consult the NHS Estates Guidance on safe hot water temperatures.

34

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 fl 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 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 fi lter within.

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

35

Direct & Twin Sol

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 fi 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 fi 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 eff ectively. Next hold both of these safety valves open, allowing as much water as possible to fl ow 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.

36

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.

37

Direct & Twin Sol

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.

38

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 INDI-

CATES 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.

39

Direct & Twin Sol

Fault

Water escaping from the case unit.

Cold water at hot tops.

Water discharges from expansion relief valve

Water discharges from temperature & pressure relief valve

Milky / cloudy water

Possible Cause

Compression fi tting on hot - draw off not sealing.

Immersion heater not switched on or cutout has triggered.

Indirect - Boiler not working.

Solution

Check / remake joint sealing paste.

Check / reset.

Indirect - motorized valve fault.

Indirect - cutout in dual stat has operated.

If continual - pressure reducing valve (part of inlet control set ) mayno tbe operating correctly.

If continual - expansion relief valve seat may be damaged.

If intermittent - expansion vessel charge may have reduced / bladder perished.

Unit is being back pressurized.

Unit has overheated - thermal controls have failed.

Oxygenated Water.

Cold main off .

Check boiler - consult boiler manufactures’ instructions.

Check plumbing / wiring motorized valve.

Check outlet pressure from inlet control set is 3 bar.

Check outlet pressure from inlet control set is 3 bar.

Remove cartridge - check seat and renew if necessary.

Check pressure in expansion bessel. Recharge to 3 bar if necessary. If bladder perished replace vessel.

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.

Switched off power to boiler and immersion heaters. Leave water supply on. Wait until discharges stops. Isolate water supply and replace if faulty.

Water from any pressurized system will release oxygen bubbles when fl owing. The bubbles will settle out.

Check and open stopcock.

No hot water fl ow

Strainer blocked in pressure reducing valve.

Inlet control set may be fi tted incorrectly.

Isolate water supply and clean.

Check and refi t 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.

40

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 cyl-

inder and in accordance with all of the relevant standards, regulations and

codes of practice in force at the time.

• It has not been modifi ed 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 aff ected by the following;

The eff 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 fi tted 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 cyl-

inder and in accordance with all of the relevant standards, regulations and

codes of practice in force at the time.

• It has not been modifi ed 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.

41

Direct & Twin Sol

• The sacrifi 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

fi ndings 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 aff 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

[email protected]

Tel: 02523552094

Registration can be made by logging online to www.jouleuk.co.uk

/ www.joule.ie

Notes

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42

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

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_________________________________________________________

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_________________________________________________________

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_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

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_________________________________________________________

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_________________________________________________________

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43

Direct & Twin Sol

Mains Pressure Hot

44

Water Storage System Commisioning Checklist

45

Direct & Twin Sol

46

Service Record

47

Direct & Twin Sol mail tel fax eml web

JOULE IE

Kylemore Park West, Ballyfermot, Dublin 10

+353 (1) 623 7080

+353 (1) 626 9337 [email protected]

www.joule.ie

mail tel fax eml web

JOULE UK

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

mail tel fax eml web

JOULE PL

23-200 Kraśnik, ul. Towarowa 34.

+48 (0) 128811171

+48 (0) 814709046 [email protected]

www.joule-pl.pl

48

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Key Features

  • Duplex Stainless Steel for corrosion resistance
  • CFC/HCFC free polyurethane foam insulation
  • Available in a variety of sizes
  • Pre-set safety and control devices
  • High quality controls for efficient operation
  • Suitable for a range of heating sources
  • Wellmaster cylinders for alternative water sources
  • Thermostatic mixing valve for scalding protection

Frequently Answers and Questions

What are the maximum permitted levels for water chemistry in the cylinder?
The maximum permitted levels for various water chemistry parameters are listed in the document, including Total Dissolved Solids, Total Hardness, Chloride, Magnesium, Calcium, Sodium, Iron, and pH. Refer to the document for specific values.
How do I set the hot water temperature?
The hot water temperature is set on the dual thermostat during installation and should be set to 60°C. Do not adjust the thermostat without consulting a competent person.
How do I replace the immersion heater?
To replace the immersion heater, first isolate the power and water supply to the tank. Drain the water from the tank and remove the immersion heater using a spanner. Install the replacement immersion heater, ensuring the threads are lined up correctly and the connection is watertight. Re-connect the water and power supply, checking for leaks before turning the power back on.

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