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joule Cyclone Air Installation & Maintenance Manual

Direct, indirect, solar & high gain unvented cylinde
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Cyclone Air Direct, Indirect, Solar &
High Gain Unvented Cylinder
Installation & Maintenance Manual
REGISTER THIS PRODUCT
ONLINE WITHIN 28 DAYS OF
COMMISSIONING
IRELAND
www.joule.ie/register-a-product
UNITED KINGDOM
www.jouleuk.co.uk/register-a-product
JL-AIR-INS-008-09-2018
1
Cyclone Direct / Indirect Installation Guide

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  • Page 1 Cyclone Air Direct, Indirect, Solar & High Gain Unvented Cylinder Installation & Maintenance Manual REGISTER THIS PRODUCT ONLINE WITHIN 28 DAYS OF COMMISSIONING IRELAND www.joule.ie/register-a-product UNITED KINGDOM www.jouleuk.co.uk/register-a-product JL-AIR-INS-008-09-2018 Cyclone Direct / Indirect Installation Guide...
  • Page 2 • The fixed wiring must be protected due to exces- sive heat produced by the appliance • Max. inlet water pressure 7bar (0,7MPa) • Min. inlet water pressure 3bar (0,3MPa) www.jouleuk.co.uk | www.joule.ie...
  • Page 3 Was a Pre-Plumbed If installed, please fi ll out the Heat Pump Commissioning cylinder installed too? Sheet too Joule™ Cyclone Air Installer I accept the terms and conditions in the installation manual Cyclone Direct / Indirect Installation Guide...
  • Page 4 JOULE™ Product Warranty Terms & Conditions JOULE™ Cylinders Warning To The User The JOULE™ Cyclone Air stainless steel ves- sel carries a fully transferable 25-year guarantee • Do not remove or adjust any part of this against faulty materials or manufacture provided unvented water heater.

  • Page 5: Table Of Contents

    Table Of Contents Introduction General Requirements Unvented Kit Components Unvented Kit Checklist ErP Product Fiche Technical Data Indirect Technical Specification Direct Technical Specification Solar Technical Specification High Gain Specification High Gain Solar Specification Plumbing G3 Unvented Kit Testing Smart Control Immersion Setup Un-Plumbed Cylinder Schematic •...

  • Page 6: Introduction

    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.
  • Page 7 Visit www.centralheating.co.uk HWA Charter Member JOULE™ are proud to be a charter member of the the Hot Water Association (HWA), who has been formed through the union of the two UK industry trade bodies, WMA (Water Heater Manu- facturers Association) and MODUS (Manufacturers Of Domestic Unvented Systems).
  • Page 8 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 reticulat- ed 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.
  • Page 9 TDS content of the water. TDS, in mg/L, is approximately 70% of the conductivity in μS/ 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.

  • Page 10: General Requirements

    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. www.jouleuk.co.uk | www.joule.ie...
  • Page 11 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.
  • Page 12 Thermostatic Mixer When installing a solar system with an unvented JOULE™ Cyclone twin coil cylinder, a ther- mostatic 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...
  • Page 13 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. 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.

  • Page 14: Unvented Kit Components

    Unvented Kit Components TZM-I-00022MM TZ9-010-0000.5 TZC-D-000000Z TZG-3.0-A0.75I TI-I-L-14-3-1 TZU-000015X22 TI-S-L-14-3-1 www.jouleuk.co.uk | www.joule.ie...

  • Page 15: Unvented Kit Checklist

    Unvented Kit Checklist Capacity (ltr) Inlet Group TZG-3.0-A0.75I T&P Valve TZ9-010-0000.5 Tundish TZU-000015X22 Dual Stat TZC-D-000000Z Prim. Coil 2-P Z.Valve TZM-I-00022MM Direct Indirect Inlet Control Group Inlet Control Group Tundish Tundish T&P Valve (fitted) T&P Valve (fitted) 2 x 3kW Immersion (fitted) 3kW Immersion (fitted) Dual Cylinder Stat 2-port Zone Valve...

  • Page 16: Erp Product Fiche

    Storage Volume V (ltr) Standing Loss (kW) ErP Rating Nominal Capacity (ltr) High Gain Storage Volume V (ltr) Standing Loss (kW) ErP Rating Nominal Capacity (ltr) High Gain Solar Storage Volume V (ltr) Standing Loss (kW) ErP Rating www.jouleuk.co.uk | www.joule.ie...

  • Page 17: Technical Data

    ErP Product Fiche Information According to EN 12897:2016 Nominal Capacity (ltr) Direct STANDARD IMMERSION Storage volume V (ltr) Mixed water at 40°C (ltr) The declared load profile ErP Rating Energy Efficiency (%) Ann. el. consumption (kWh) 2740 2773 2785 2797 2801 2892 2900...

  • Page 18: Indirect Technical Specification

    Indirect Technical Specifi cation Legend Boiler Return Drain Aquastat Pocket Boiler Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Cold Water Inlet www.jouleuk.co.uk | www.joule.ie...
  • Page 19 Connection Sizes & Safety Hot & Cold Conn. Ø(mm) Coil Connection Ø (mm) Secondary Return Ø BSP (“) T&P Connection Ø BSP (“) T&P Press. Sett. (bar) 3 bar Exp. Relief Set. (bar) Dimensions Cylinder Height A (mm) 1030 1190 1310 1370 1490...

  • Page 20: Direct Technical Specification

    Direct Technical Specifi cation 30º 30º Legend Drain Aquastat Pocket Boiler Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Cold Water Inlet www.jouleuk.co.uk | www.joule.ie...

  • Page 21: T&P Press. Sett. (Bar)

    Connection Sizes & Safety Hot & Cold Conn. Ø (mm) Coil Connection Ø (mm) Secondary Return Ø BSP (“) T&P Connection Ø BSP (“) T&P Press. Sett. (bar) 3 bar Exp. Relief Set. (bar) Dimensions Cylinder Height A (mm) 1030 1190 1310 1370...

  • Page 22: Solar Technical Specification

    Boiler Return Drain Aquastat Pocket Boiler Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Cold Water Inlet 16 Solar/Boiler Flow 17 Solar/Boiler Return 18 Solar Stat Pocket www.jouleuk.co.uk | www.joule.ie...

  • Page 23: 1St Re-Heat Time (70% Dr. Off) 15L/M

    Connection Sizes & Safety Hot & Cold Conn. Ø (mm) Primary Coil Connection Ø (mm) Solar Coil Connection Ø (mm) Secondary Return Ø BSP (“) T&P Connection Ø BSP (“) T&P Press. Sett. (bar) 3 bar Exp. Relief Set. (bar) Dimesions Cylinder Height A (mm) 1310...
  • Page 24 High Gain Technical Specifi cation 15º 30º 30º Legend High Gain Return Drain Aquastat Pocket High Gain Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Cold Water Inlet www.jouleuk.co.uk | www.joule.ie...

  • Page 25: Prim. Coil Rat. @15L/M (Kw, 80±2°C)

    Connection Sizes & Safety Hot & Cold Conn. Ø (mm) Coil Connection Ø (mm) Secondary Return Ø BSP F (“) T&P Connection Ø BSP F (“) T&P Press. Set. (bar) 3 bar Exp. Relief Set. (bar) Dimensions Cylinder Height A (mm) 1310 1360 1490...
  • Page 26 High Gain Return Drain Aquastat Pocket High Gain Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Cold Water Inlet 16 Solar/Boiler Flow 17 Solar/Boiler Return 18 Solar Stat Pocket www.jouleuk.co.uk | www.joule.ie...
  • Page 27 Connection Sizes & Safety Hot & Cold Conn. (mm) Primary Coil Connection (mm) Solar Coil Connection (mm) Secondary Return BSP F (“) T&P Connection BSP F (“) T&P Press. Set. (bar) 3 bar Exp. Relief Set. (bar) Dimesions Cylinder Height A (mm) 1490 1510 1815...

  • Page 28: Plumbing G3 Unvented Kit

    T&P and P relief as shown in this diagram and also refer- ence to page 43-45 Discharge Arrangement Failure to install unvented kit correctly invalidate warranty and does not comply with Building Regulations. www.jouleuk.co.uk | www.joule.ie...

  • Page 29: Testing

    Testing Do not connect a 6kW Immersion without using a relay switch. 20 Amp Fused 2-pole Isolating Switch 230V AC ~50Hz Standard Immersion 20 Amp Fused 2-pole Isolating Switch 230V AC ~50Hz Smart Immersion 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.
  • Page 30 65°C 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. www.jouleuk.co.uk | www.joule.ie...
  • Page 31 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.

  • Page 32: Un-Plumbed Cylinder Schematic

    Isolation Valve (not supplied, must be accessible beside the cylinder) 2-port Zone Valve 3-prt Valve (not supplied) Drain Valve (not supplied) 10 Tundish 11 Heating Circ. Pump (required where boiler has no internal pump) Isolation Valve (not supplied) must be accessible beside the cylinder www.jouleuk.co.uk | www.joule.ie...

  • Page 33: Electrical Diagram S-Plan

    Un-Plumbed Cylinder Schematic Un-Plumbed Cylinder Schematic Electrical Diagram S-Plan Electrical Diagram S-Plan Cyclone Direct / Indirect Installation Guide...

  • Page 34: Mechanical Diagram Y-Plan

    Isolation Valve (not supplied, must be accessible beside the cylinder) 2-port Zone Valve 3-port Valve (not supplied) Drain Valve (not supplied) 10 Tundish 11 Heating Circ. Pump (required where boiler has no internal pump) Isolation Valve (not supplied) must be accessible beside the cylinder www.jouleuk.co.uk | www.joule.ie...

  • Page 35: Electrical Diagram Y-Plan

    Un-Plumbed Cylinder Schematic Un-Plumbed Cylinder Schematic Electrical Diagram Y-Plan Electrical Diagram Y-Plan Cyclone Direct / Indirect Installation Guide...

  • Page 36: Electronic Controls

    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. Before resetting the safety cut-out or altering the thermostat setting, isolate elec- trical supply to the unit before removal of the cover.

  • Page 37: Discharge Arrangement

    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 When operating normally water will not be discharged.
  • Page 38 0.8m 1.0m 1.4m 1.0m 1.4m 1.7m 1.4m 1.7m 2.3m or elbow in the discharge pipe Sizing of copper discharge pipe (D2) for a temp. relief valve with a G1/2 outlet size (as supplied) www.jouleuk.co.uk | www.joule.ie...
  • Page 39 Safety Device (temperature relief valve) Metal discharge pipe (D2) from temperature relief valve to tundish Tundish Minimum 300mm Discharge below fixed grating (Building Regulation G3 section 3.61 gives alternative points to of Metal discharge pipe (D2) from tundish, with continuous fall. (See Building Regulation G3 section 3.56, Table 1 and Fixed Grating...

  • Page 40: Commissioning

    Slowly manually open, for a few seconds, the Temperature and Pressure Relief Valve situated on the Cyclone Air unit. Check water discharged runs freely away through the tundish and discharge pipework. Close valve, ensure water flow stops and valve reseats correctly.
  • Page 41 Fill the indirect (primary) circuit following the boiler manufacturer’s commissioning instructions. To ensure the primary heating coil in the Cyclone Air is filled the 2-port motorised valve (sup- plied) should be manually opened by moving the lever on the motor housing to the MAN OPEN setting.

  • Page 42: User Instructions

    Do not turn off the water supply. Contact a competent installer for unvented water heaters to check the system. Do not tamper with any of the safety valves fitted to the Cyclone Air system, if a fault is suspected contact a competent installer.
  • Page 43 To recharge the air volume: Turn off the heat source to the cylinder via programmers/immersion isolation switch(es). Turn off the water supply to the Cyclone Air unit by turning off the isolating valve located before the Cold Water Combination Valve.

  • Page 44: Maintenance

    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 opera- tional Draining Switch the electrical power off (important to avoid damage to element). Isolate boiler from the unit.
  • Page 45 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.

  • Page 46: Taking The Cylinder Out Of Use

    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. www.jouleuk.co.uk | www.joule.ie...
  • Page 47 Cyclone Direct / Indirect Installation Guide...

  • Page 48: Troubleshooting

    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. www.jouleuk.co.uk | www.joule.ie...
  • Page 49 Fault Possible Cause Solution Water escaping from the Compression tting on hot - draw Check / remake joint sealing paste. case unit. off not sealing. Cold water at hot tops. Immersion heater not switched Check / reset. on or cutout has triggered. Indirect - Boiler not working.

  • Page 50: Benchmark Checklist

    Benchmark Checklist www.jouleuk.co.uk | www.joule.ie...
  • Page 51 Cyclone Direct / Indirect Installation Guide...

  • Page 52: Service Record

    Service 1 Date ......Date ......Engineer Name ............... Engineer Name ............... Company Name ............... Company Name ............... Telephone No ............... Telephone No ............... Comments ............... Comments ............................................................................................................................. Signature ............... Signature ............... www.jouleuk.co.uk | www.joule.ie...

  • Page 53: Notes

    Notes Cyclone Direct / Indirect Installation Guide...
  • Page 54 Notes www.jouleuk.co.uk | www.joule.ie...
  • Page 55 Cyclone Direct / Indirect Installation Guide...
  • Page 56 +353 (1) 623 7080 +44 (0) 1513 551 094 +353 (1) 626 9337 +44 (0) 1513 568 336 info@joule.ie info@jouleuk.co.uk www.joule.ie www.jouleuk.co.uk JOULE PL mail 23-200 Kraśnik, ul. Towarowa 34. +48 (0) 128811171 +48 (0) 814709046 biuro@joule-pl.pl www.joule-pl.pl JL-AIR-INS-008-09-2018 www.jouleuk.co.uk | www.joule.ie...

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