joule Cyclone Instruction Manual

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Unvented Cylinder
Installation & Maintenance
Manual

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

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INTRODUCTION
The instructions are an integral part of the appliance and must be given to the end
user on completion of the installation in order to comply with the current regulation.
It is important to carefully read the manual to understand all the information to ena-
ble safe installation, use and servicing. These instructions consist of details for instal-
lation, servicing, fault nding and replacement of parts for the cylinder purchased.
JOULE will not accept any liability in the event of damage for not complying with the
guidance in this instruction manual.
The instructions for this installation manual apply to the range of JOULE Cyclone
Indirect Unvented Cylinders.
Safety is paramount when installing unvented hot water systems and the following
instructions must be adhered to:
Only certied competant installers can install, commission and service the equipment
supplied.
The cylinder must be used for potable hot water only. Any other applications will be
considered incorrect use and JOULE will not be held liable for any losses resulting
from such use.
All installation and maintenance instructions must be observed to ensure the correct
operation of the equipment.
The electric immersion must not be switched on unless the cylinder is completely full
of water.
Domestic hot water may be stored at temperatures exceeding 60°C. Preventative
measures should be put in place to negate the possibility of scalding.
A maintenance schedule should be put in place with a competent person to service
the equipment annually to comply with the warranty conditions.
When servicing the system the mains supply to the cylinder should be isolated.
Only genuine spare parts should be used. A full list of items with relevant codes can
be found on page 23 .
The installation must be carried out by a person competent to install unvented hot
water systems. The installation must be carried out in accordance with the following
recommendations:

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All current Building Regulations issued by the Department of the Environment, i.e.
Approved Document L1 Building Standards (Scotland) (Consolidation) Regulations
issued by the Scottish Development Department UK Water Regulations/Byelaws
(Scotland)
Health & Safety Document No. 635 (The Electricity At Work Regulations 1989) The
installation should also be in accordance with the following British Standard Codes of
Practice:
BS 5449:1990 Forced circulation hot water systems
BS 5546:2000 Installation of hot water supplies for domestic purposes
BS 5918:1989 Solar heating systems for domestic hot water
BS 6700:2006 Design, installation, testing and maintenance of services supplying
water.
Failure to install this appliance correctly could lead to prosecution and will invalidate
the guarantee. It is in your own interest and that of safety to ensure that the law is
complied with.
HANDLING
Care must be taken when transporting, storing and installing the equipment:
At least two people should lift the cylinder to prevent injuries.
The cylinder must be stored in a dry area and must never be set the cylinder down
hard during handling.
Packaging should only be removed at the installation location.
The cylinder must be installed on a level oor with the required load bearing capabil-
ity.
Installation, servicing, maintenance and repair must be carried out by a competent
person.
All electrical wiring must be carried out by a qualied electrician and be installed in
accordance with current I.E.E Wiring Regulations.
A lack of safety devices can lead to potentially fatal injuries, all necessary safety devic-
es must be installed correctly in the system. The use of an electric immersion may lead
to the build up of electrical potential in the water. This can in turn cause corrosion of
the immersion. To prevent this, ensure the immersion heater, and the hot and cold
pipework are correctly bonded and connected to the earth line.
If plastic pipes are used they must be approved temperature resistant to 95°C at a
pressure of 10 Bar.

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WHAT IS BENCHMARK?
Benchmark places responsibilities on both manufacturers and installers. The purpose
is to ensure that customers are provided with the correct equipment for their needs,
that it is installed, commissioned and serviced in accordance with the manufacturer’s
instructions by competent persons and that it meets the requirements of the appro-
priate Building Regulations.
The Benchmark Checklist can be used to demonstrate compliance with Building Reg-
ulations 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 Hotwa-
ter Industry Council who manage and promote the scheme. Visit www.centralheating.
co.uk
WATER SUPPLY
The performance of any unvented system is only as good as the mains water supply
available. To this eect the maximum possible water demand should be assessed,
with the knowledge that the mains supplies both hot and cold services simultaneous-
ly.
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 con-
trol set has been designed to make the most of the ow rates available.
The water supply should be checked to ensure it can meet these requirements. If
necessary, consult the local water authority regarding the likely pressure and ow rate
availability.
Consideration should be given to upgrading existing ½” (15mm) cold mains pipe-
work to a larger size if the recommended minimum pressure/ow rate is not being
achieved. JOULE recommend that primary pipework used has a minimum diameter of
22mm to ensure low pressure loss.
Note: A high static (no ow) mains pressure is no guarantee of good ow availability.
In a domestic installation 1.5 bar and 25 l/min. should be regarded as the minimum.
The maximum mains pressure that the inlet control set can cope with is 10 bar.

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CHANGE OF WATER SUPPLY
The changing or alternating from one water supply to another can have a detrimental
eect on the operation and / or life expectation of the water heater storage cylinder,
pressure temperature relief valve and heating unit.
Where there is a changeover from one water supply to another, e.g. a rainwater tank
supply, bore water supply, desalinated water supply, public reticulated water supply
or water brought in from another supply, then water chemistry information should be
sought from the supplier or it should be tested to ensure the water supply meets the
requirements given in these guidelines for the Joule warranty to apply.
WATER CHEMISTRY
This water heater must be installed in accordance with this advice to be covered by
the Joule warranty. This water heater is manufactured to suit the water conditions of
most public reticulated water supplies. However, there are some known water chem-
istries which can have detrimental eects on the water heater and its operation and /
or life expectancy. If you are unsure of your water chemistry, you may be able to ob-
tain information from your local water supply authority. This water heater should only
be connected to a water supply which complies with these guidelines for the JOULE
warranty to apply.
WATER CHEMISTRY LEVELS AFFECTING WARRANTY
The JOULE warranty of this water heater will not cover resultant faults on components
including the storage cylinder where water stored in the storage cylinder exceeds at
any time any of the following levels:
Components Maximum Permitted Levels
Total Dissolved Solids 600 mg/Litre
Total Hardness 200 mg/Litre
Chloride 300 mg/Litre
Magnesium 10 mg/Litre
Calcium 20 mg/Litre
Sodium 150 mg/Litre
Iron 1 mg/Litre
Maximum pH 9.5
Minimum pH 6.5

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TOTAL DISSOLVED SOLIDS (TDS)
Some water analysis reports may state the conductivity of the water rather than the
level of total dissolved solids. Conductivity, measured in microsiemens per centime-
tre (µS / cm), is directly proportional to the TDS content of the water. TDS, in mg/L, is
approximately 70% of the conductivity in µS / cm.
The JOULE warranty will not cover resultant faults to the storage cylinder if this water
heater is connected at anytime to a water supply where the TDS content of the water
exceeds 600 mg/L. 16 In locations where TDS approaches 600 mg/L, e.g. due to sed-
iment, we strongly recommend tting an appropriate lter to ensure water entering
or in the water heater does not exceed this level at any time i.e. due to sediment build
up.
FEATURES OF THE UNVENTED CYLINDER
- Made from Duplex Stainless Steel for excellent corrosion resistance.
- Strong rust-proofed steel case.
- Insulation is by means of an approved CFC/HCFC free polyurethane foam with
an ozone depletion factor of zero.
- Available in a variety of sizes to suit - 125L, 150L, 170L, 200L, 250L, 300, 400 and
500 litres.
- All models including Solar models are available in Twin or Triple versions
Supplied complete with all the necessary safety and control devices needed to
connect to cold water mains
- All safety and control devices are pre-set.
- High quality controls selected that combine high ow rate performance with
min imum pressure drop which gives fantastic performance in all areas, with great
improvements in areas with poor water pressure.
WELLMASTER CYLINDERS
Only JOULE Wellmaster cylinders may be installed on a well, private water scheme or
any water source that does not come from the public mains.
Water that has been softened using salts or any other treatment may not be supplied
to any Joule cylinder. Un-softened water only must be supplied to the cylinder. Sof-
tened 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.

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GENERAL REQUIREMENTS
SITING THE UNIT
This unit can supply outlets above it or at some distance from it but any outlets above
the unit will reduce the available outlet pressure by 0.1 bar for every 1m of height
dierence. The maximum length of the “dead leg”should be as stated in the Water
Supply (Water Fittings) Regulations 1999 G18.7, in particular to the area of most fre-
quent use.
Particular attention is needed if sitting in a garage or outbuilding as the unit should
be protected from frost. All exposed pipework must be insulated. The unit must be
installed UPRIGHT on a at base capable of supporting its weight when full (please
see the technical specification section for weights).
Sucient access to allow maintenance of the valves should be considered. In addition
the immersion heaters are 400mm in length and this distance should be considered
to allow withdrawal for servicing if required. The discharge pipework from the safety
valves should fall continuously and terminate safely.
Negative pressure may form in cylinders installed very high in a building. To counter-
act this, an anti-vacuum valve can be installed to prevent damage to the cylinder. The
anti-vacuum valve ensures that pressure compensation as a result of air owing into
the cylinder.
CONNECTING TO THE CYLINDER
All of the pipework connections on the cylinder are female threaded. Upon filling /
commissioning, ensure all connections are completely watertight.
Note: No control or isolation valve should be fitted between the expansion relief valve
and the storage cylinder. The relief valve connections should not be used for any
other purpose.
COLD MAINS PIPEWORK
Run the cold main through the building to the place where is to be installed. Take care
not to run the cold pipe near hot water or heating pipe work so that the heat pick-up
is minimized. Identify the cold water supply pipe and t an isolating valve (not sup-
plied). A 22mm BS1010 stopcock can typically be used but a 22mm quarter turn full
bore valve would be better as it does not restrict the ow as much. Do not use “screw-
driver slot” or similar valves.

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Make the connection to the cold feed of the cylinder and incorporate a drain valve.
Position the inlet control just ABOVE the Temperature & Pressure Relief Valve (TPRV)
mounted on the side of the cylinder. This ensures that the cylinder does not have to
be drained down in order to service the inlet control set. Ensure that the arrow points
in the direction of the water ow. Select a suitable position for the expansion vessel.
Mount it to the wall using the bracket provided. Use the exible hose provided to
connect to the inlet control group.
BALANCED COLD CONNECTION
If there are to be showers, bidets or monobloc taps in the installation then a balanced
cold supply is necessary. There is a 22mm balanced connection on the inlet control
set.
FITTING THE INLET CONTROL GROUP
Excess pressure can lead to the cylinder bursting. The inlet control set supplied has
an expansion relief valve with a 15mm connection to allow it to be connected to the
tundish. Make sure that there is sucient space for future maintenance and also for
connection of the discharge pipe for the expansion relief valve.
It is essential that this connection is not covered or closed. The hot water expansion
vessel can be tted to the inlet control group using the supplied expansion vessel
exible hose.
HOT WATER PIPEWORK
Run the first part of the hot water distribution pipework in 22mm. This can be re-
duced to 15mm and 10mm as appropriate for the type of tap etc. Your aim should be
to reduce the volume of the hot draw-o pipework to a practical minimum so that the
time taken for the hot water is as quick as possible.
Do not use monobloc mixer tap or showers if the balanced cold connection is not
provided. Outlets of this type can back pressurise the unit and result in discharge.
EXPANSION VESSEL
The expansion vessel receives the increased water volume when expansion takes
place as the system heats up and it maintains a positive pressure in the system. The
expansion vessel contains a exible diaphragm, which is initially charged on one side
with nitrogen, but can be topped up with air when required.

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Select a suitable position for the expansion vessel. Mount it to the wall using the
bracket provided and connect to the inlet control set with the exible hose provided.
Ensure that the top of the vessel is accessible for servicing. The pipe connecting the
expansion vessel to the system should have a diameter of not less than 15mm and
must not contain any restrictions.
Prior to connecting the expansion vessel to the system the pipework should be
ushed and tested. When the vessel is connected the system should be pressurised
when cold. If the initial system water pressure is too high, the diaphragm will be dis-
placed 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 positive-
ly pumped. Either primary connection may be used as the primary ow. Reheat times
are identical either way. The primary circuit can be open vented or sealed, with up to
a maximum pressure of 3.5 bar. If you seal the primary circuit an additional expansion
vessel and safety valve is required.
The boiler may be Gas, Electric or Oil but must be under eective thermostatic con-
trol. Uncontrolled heat sources such as some AGA’s, back boilers, solid fuel stoves, etc.
are NOT SUITABLE. Please contact our Technical department for guidance. Connect
the two port zone valve (indirect only) into the primary ow pipework. The direction
of ow arrow should be towards the primary ow connection.
INSTALLING THE TWO PORT MOTORISED VALVE
The function of the Two Port Motorised Valve prevents the cylinder from overheating.
It can be installed on either horizontal or vertical pipework.
If it is mounted onto horizontal pipework the valve head must face upwards. The
direction of ow is marked on the body of the valve with arrows.
THERMOSTATIC MIXER
When installing a solar system with an unvented JOULE Cyclone twin coil cylinder,
a thermostatic mixing valve should be installed. Its function is to act as an anti scald
protection. The thermostatic mixer is to be set to a temperature of between 300C and
600C and is supplied by the installer.

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UNVENTED KIT COMPONENTS
Direct Indirect
Inlet Control Group Inlet Control Group
Tundish Tundish
T & P Valve (tted) T & P Valve (tted)
3kW Immersion (tted) 3kW Immersion (tted)
Expansion Vessel Expansion Vessel
Expansion Vessel Hose Expansion Vessel Hose
Dual Cylinder Stat
2 Port Zone Valve
SECONDARY CIRCULATION
On larger installations long pipe runs to draw-o points can cause signicant volumes
of water to be drawn o before an acceptable temperature can be reached. Second-
ary pumped circulation using a stainless steel or a bronze pump, and combined with
eective time and temperature controls can overcome this problem. Where second-
ary return circulation is required the pipework should be run in 15mm pipe. A suitable
WRAS approved stainless steel or bronze circulation pump must be used. A check
valve must also be installed to prevent backow.
On large secondary circulation systems it may be necessary to incorporate an extra
expansion vessel into the circuit to accommodate the increased system water volume.
Secondary circulation should be avoided on Direct electrically heated units being
used on o-peak electricity taris. It should be noted that the use of a secondary
circulation circuit can increase running costs as there will be circulation pipe losses.
High levels of insulation on secondary pipework are required to keep energy losses to
a minimum.
DEAD LEGS
The length of hot water draw o to taps and other outlets should be kept to a mini-
mum to reduce the amount of cold water drawn o before the hot water arrives. The
maximum recommended dead leg lengths are shown in gure 2.b. Where there is
more than one size of pipe on a dead leg, the equivalent length and size should be
estimated.
Where the dead leg length exceeds the recommended maximum, secondary circu-
lation should be installed. It should be controlled by a time switch and incorporate a
motorized valve that can prevent gravity circulation in the circuit.

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Pipe Size (mm) Maximum Length (m)
10, 12 20
15, 22 12
28 8
35 and above 3
SYSTEM NOISE
Noise in pipework may occur as a result of expansion of pipework over joists or where
the pipe has been left touching other pipes or a part of the building structure. Care
must be taken to ensure that the pipework is correctly bracketed, is not in tension
or compression, and does not carry the weight of components such as a circulation
pump.
SETTING THE HOT WATER TEMPERATURE
The hot water temperature is set on the dual thermostat by the competent person
during the installation. The dual thermostat should be set to 60°C. If you are heating
water in the cylinder for the rst time, or the time controls for the DHW zone have
been o for a prolonged period of time, the cylinder may take additional time to heat
up.
WARNINGS
Inappropriate adjustments can lead to the damages in the system. If any changes are
made to the cylinder, the controls, the water and power supply lines or the expansion
relief components there is a risk of steam escaping or rupture to the system.

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Technical Specication Direct
B GC ED F
A
15°
30°

15
Mechanical Diagram Direct Installation
Balanced Cold
Connection
01 02 09
04
10
06
03
Secondary Flow
05
Secondary
Return
Cold
Main
LEGEND
01 Bronze Pump
02 Non Return Valve (Not Supplied)
03 Inlet Control Group
04 Temperature & Pressure Relief Valve
05 Isolation Valve (Not Supplied)
06 Expansion Vessel With Wall Bracket
07 Two Port Zone Valve
08 Three Port Zone Valve (Not Supplied)
09 Drain Valve (Not Supplied)
10 Tundish
11 Heating Circulation Pump (Required where boiler has no internal pump)

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FITTING THE IMMERSION HEATER
Always check the immersion for signs of leakage before wiring commences.
The immersion heater must be completely submerged in water with a minimum of
200mm of water above the top of the immersion.
WARNING: DO NOT OPERATE THE IMMERSION HEATERS UNTIL THE CYLINDER HAS
BEEN FILLED WITH WATER
Wire the immersion through a double pole fused
spur. The contact separation must be no less than 3mm with a minimum breaking
capacity of 16A.
L
L
N
N
L
L
N
N
20 Amp Fused Double
Pole Isolating Switch
20 Amp Fused Double
Pole Isolating Switch
230 V AC - 50Hz
230 V AC - 50Hz

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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 connec-
tions.
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 con-
nection 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 immer-
sions should be tted.
The thermostat should be set so that the water is heated to a temperature between
600C and 650C. Water stored at temperatures below 600C can result in bacteria
growth and temperatures above 650C can cause scalding.
The immersion stat has an integrated high limit stat which If the primary thermostat
fails the limit thermostat takes over and shuts the element o before the water can
boil in the cylinder.
TESTING
If there is no hot water you can carry out several tests with your multimeter to decide
which component is faulty.
First remove the cover for the wiring and then check for voltage across the live and
neutral terminals on the element. If you get a reading the element is faulty (power
going through thermostat so stat is working).
Next, check whether the thermostat is working by connecting your multimeter to the
live out of the thermostat, if there is no reading the thermostat is faulty.
NOTE: IF THE WATER IS GETTING EXTREMELY HOT THEN THE THERMOSTAT IS STUCK IN
THE “ON”POSITION AND WILL NEED TO BE REPLACED.

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SAFETY
Disconnect the immersion from the mains electrical supply before removing any
covers.
Do not attempt to replace the immersion heater(s) with alternatives to those recom-
mended by JOULE.
Do not bypass the Thermal Cut-Out(s) in any circumstances.
REPLACING THE IMMERSION
First task is to isolate the power. Immersion heaters are rated at 3Kw and require their
own 20amp double pole isolation switch. Turn o the power from the isolation switch
and remove the fuse. Next turn o the water to the tank.
Drain the water from the tank via the drain cock using a hose. Remove the immersion
using an immersion spanner. Thread in the replacement immersion heater creating
the seal using a rubber o-ring or bre washer. Slot the immersion heater into the hole
with the washer and make sure the threads are lined up correctly. Tighten with which-
ever spanner you are using, taking care not to over tighten and risk damaging the
cylinder.
Open the taps up and turn the cold water supply back on. When water starts to come
out of the taps shut them o and check for leaks. If all is good wire up the immersion
heater, checking that your connections are good. Fit the cap on the immersion and
turn the power back on.
If the immersion is connected to a booster switch turn it on and check that it heats
up. Economy 7 immersion heaters will only turn on at set times during the night and
cannot be altered so check the following morning to see if the water has heated up
properly.

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Technical Specication Indirect
A
B C D E F G H I J
15°
30° 30°

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Mechanical Diagram
2 x Two Port Zone Valves (S-Plan) Variant Dual Thermostat
01 02 09
07
07
11
Dual
Stat
06
10
High
Limit
Stat
Secondary Flow
Boiler
Secondary
Return
Balanced Cold
Connection
05
03
Cold
Main
04
01 Bronze Pump
02 Non Return Valve (Not Supplied)
03 Inlet Control Group
04 Temperature & Pressure Relief Valve
05 Isolation Valve (Not Supplied)
06 Expansion Vessel With Wall Bracket
07 Two Port Zone Valve
08 Three Port Zone Valve (Not Supplied)
09 Drain Valve (Not Supplied)
10 Tundish
11 Heating Circulation Pump (Required where boiler has no internal pump)
LEGEND