joule Cyclone Instruction Manual

Cyclone Direct / Indirect Installation Guide 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

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2
• This appliance can be used by children aged from
8 years and above and persons with reduced phys-
ical, sensory or mental capabilities or lack of ex-
perience and knowledge if they have been given
supervision or instruction concern-ing use of the
appliance in a safe way and understand the hazards
involved. Children shall not play with the appliance.
Cleaning and user maintenance shall not be made
by chil-dren without supervision
• Water may drip from the discharge pipe of the
pressure-re-lief device and that this pipe must be
left open to the atmosphere
• The pressure-relief device is to be operated regu-
larly to remove lime deposits and to verify that it is
not blocked
• For an appliance intended to be permanently con-
nected to the water mains and not connected by a
hose-set, this is stated
• A discharge pipe connected to the pressure-relief
device is to be installed in a continuously downward
direction and in a frost-free environment
• 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)

Cyclone Direct / Indirect Installation Guide 3
Warranty Card
Please register your product online
Homeowner
Name
Address
Contact Tel.
Contact Email
Installer
Name
Address
Contact Tel.
Contact Email
Product Product
Installed
Serial Number Installation
Date
Cylinder Located on
cylinder badge
Solar Thermal Take from
solar controller
Solar PV Ser. No. from
String / Micro Inverter
Air Source Heat Pump Located on external
heat pump badge
Integrated Heat Pump
and Cylinder
Located on
cylinder badge
Underfloor Heating Project ref. on
supplied schematic
Direct Gas Fire Cylinder Located on
cylinder badge
Was a Pre-Plumbed
cylinder installed too?
If installed, please fill out the Heat Pump Commissioning
Sheet too
Joule™ Cyclone Air Installer
I accept the terms and conditions in the installation manual
MUST BE COMPLETED AND
THEN REGISTERED ONLINE
TO COMPLETE WARRANTY

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4
JOULE™ Product Warranty Terms & Conditions
JOULE™ Cylinders
The JOULE™ Cyclone Air stainless steel ves-
sel carries a fully transferable 25-year guarantee
against faulty materials or manufacture provided
that:
• It has been installed in the United King-
dom or the Republic of Ireland as per the
instructions provided in the installation
manual provided with the cylinder and in
accord- ance with all of the relevant stand-
ards, regulations and codes of practice in
force at the time.
• It has not been modified in any way, other
than by JOULE™
• It has not been misused, tampered with or
subjected to neglect.
• The system is fed from the public mains
water supply.
• It has only been used for the storage of po-
table water.
• It has not been subjected to frost damage.
• The unit has been serviced annually.
• The Service Log Book has been completed
after each annual service.
• The warranty card is filled in and a copy is
sent by email to [email protected]
Exclusions
The guarantee does not cover cylinders affect-
ed by the following;
• The effects of scale build up on the cylin-
der.
• Any labour charges associated with replac-
ing 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 ser-
viced annually.
Unvented Kit & Other Components
The cold water controls supplied with JOULE
models carry a 2-years guarantee. All other com-
ponents that are fitted to, or supplied, with the
unit carry a 2-years guarantee.
Warning To The User
• Do not remove or adjust any part of this
unvented water heater.
• If the unvented water heater develops
fault, such as a flow of water from the dis-
charge pipe switch the heater off.
• In all cases contact a competent installer.
• The Benchmark Log Book at the end of the
manual must be filled in at annual service.
Warning To The Installer
• Read the installation instructions before
commencing.
• Unvented water heaters are a controlled
service as defined in the latest edition of
the Building Regulations and should only
be fitted by a competent installer.
• The installation is subject to building reg-
ulation approval.
• You must notify the local authority of in-
tention to install.
• After installation the instructions manual
must be completed and left with the house-
holder.
• Use only manufacturer’s recommended re-
placement parts.
Installed by
Installer
Name
Address
Contact Tel.
Completion
Date

Cyclone Direct / Indirect Installation Guide 5
Table Of Contents
6 Introduction
10 General Requirements
14 Unvented Kit Components
15 Unvented Kit Checklist
16 ErP Product Fiche
17 Technical Data
18 Indirect Technical Specification
20 Direct Technical Specification
22 Solar Technical Specification
24 High Gain Specification
26 High Gain Solar Specification
28 Plumbing G3 Unvented Kit
29 Testing
30 Smart Control Immersion Setup
Un-Plumbed Cylinder Schematic
32 • Mechanical Diagram S-Plan
33 • Electrical Diagram S-Plan
Un-Plumbed Cylinder Schematic
34 • Mechanical Diagram Y-Plan
35 • Electrical Diagram Y-Plan
36 Electronic Controls
37 Discharge Arrangement
40 Commissioning
42 User Instructions
44 Maintenance
46 Taking The Cylinder Out Of Use
48 Troubleshooting
50 Benchmark Checklist
52 Service Record
53 Notes
NEW

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6
Introduction
The instructions are an integral part of the appliance and must be given to the end user on com-
pletion 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 in-
stallation, use and servicing. These instructions consist of details for installation, servicing, fault
finding and replacement of parts for the cylinder purchased.
JOULE™ will not accept any liability in the event of damage for not complying with the guidance
in this instruction manual.
The instructions for this installation manual apply to the range of JOULE™ Cyclone Air Unvented
Cylinders.
Safety is paramount when installing unvented hot water systems and the following instructions
must be adhered to:
•Only certified competant installers can install, commission and service the equipment sup-
plied.
•The cylinder must be used for potable hot water only. Any other applications will be consid-
ered 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 opera-
tion of the equipment.
•The electric immersion must not be switched on unless the cylinder is completely full of wa-
ter.
• 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 equip-
ment 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 14.
The installation must be carried out by a person competent to install unvented hot water systems.
The installation must be carried out in accordance with the following recommendations:
All current Building Regulations issued by the Department of the Environment, i.e. Building
Regulation G3 (England and Wales), Technical Standard P3 (Scotland) or Building Regulation
P5 (Northern
Ireland) and the Water Fitting Regulations (England and Wales) or Water Byelaws (Scotland).
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 guaran-
tee. It is in your own interest and that of safety to ensure that the law is complied with.

Cyclone Direct / Indirect Installation Guide 7
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 down hard during handling.
• Packaging should only be removed at the installation location.
• The cylinder must be installed on a level or with the required load bearing capability. Instal-
lation, servicing, maintenance and repair must be carried out by a competent person.
• All electrical wiring must be carried out by a qualified electrician and be installed in accord-
ance 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
10bar.
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, com-
missioned 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 in-
stallation, commissioning and servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hot Water Industry Council who manage and promote
the scheme. 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).
The objectives of the HWA are “To be recognised as the leading body in domestic hot water
storage and, through cooperation and partnerships, to support, drive and promote the sustained
growth and improvement of standards within the entire domestic hot water industry”.
The HWA operate a Charter that all members of the association observe.
The HWA Charter Statement requires that all members adhere to the following:
• To supply fit for purpose products clearly and honestly described
• To supply products that meet or exceed appropriate standards and building and water regula-
tions
• To provide pre and post technical support
• To provide clear and concise warranty details to customers

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8
Water Supply
The performance of any unvented system is only as good as the mains water supply available. To
this extent 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 3bar, controlled by the inlet control set, and is capable of delivering over 50 litres per min-
ute. The high quality inlet control set has been designed to make the most of the low rates available.
The water supply should be checked to ensure it can meet these requirements. If necessary, con-
sult the local water authority regarding the likely pressure and flow rate availability.
Consideration should be given to upgrading existing 1/2” (15mm) cold mains pipework to a larger
size if the recommended minimum pressure / flow rate is not being achieved. JOULE™ recom-
mend that primary pipework used has a minimum diameter of 22mm to ensure low pressure loss.
A high static (no flow) mains pressure is no guarantee of good flow availability. In
a domestic installation 1.5bar and 25ltr/min should be regarded as the minimum.
The maximum mains pressure that the inlet control set can cope with is 10bar.
Change Of Water Supply
The changing or alternating from one water supply to another can have a detrimental effect on
the operation and/or life expectation of the water heater storage cylinder, pressure temperature
relief valve and heating unit.
Where there is a changeover from one water supply to another, e.g. a rainwater tank supply, bore
water supply, desalinated water supply, public reticulated water supply or water brought in from
another supply, then water chemistry information should be sought from the supplier or it should
be tested to ensure the water supply meets the requirements given in these guidelines for the
JOULE™ warranty to apply.
Water Chemistry
This water heater must be installed in accordance with this advice to be covered by the JOULE™
warranty. This water heater is manufactured to suit the water conditions of most public 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. If you are unsure of your
water chemistry, you may be able to obtain information from your local water supply authority.
We recommend not to use water softener, however if it is used the water is required to be kept at
potable standards. This water heater should only be connected to a water supply which complies
with these guidelines for the JOULE™ warranty to apply.
Introduction

Cyclone Direct / Indirect Installation Guide 9
Water Chemistry Levels Affecting Warranty
The JOULE™ warranty of this water heater will not cover resultant faults on components includ-
ing 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
Soldium 150 mg/litre
Iron 1 mg/litre
Maximum pH 9.5
Minimum pH 6.5
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 propor-
tional to the TDS content of the water. TDS, in mg/L, is approximately 70% of the conductivity in μS/
cm.
The JOULE™ warranty will not cover resultant faults to the storage cylinder if this water heater
is connected at anytime to a water supply where the TDS content of the water exceeds 600 mg/L.
16 In locations where TDS approaches 600 mg/L, e.g. due to sediment, we strongly recommend
fitting an appropriate filter to ensure water entering or in the water heater does not exceed this
level at any time i.e. due to sediment build up.
Features Of The Unvented Cylinder
• Made from Duplex Stainless Steel for excellent corrosion resistance.
• Strong rust-proofed steel case.
• Insulation is by means of an approved CFC/HCFC free polyurethane foam with an ozone
depletion factor of zero.
• Available in a variety of sizes to suit - 100L, 125L, 150L, 170L, 180L, 200L, 210L, 250L and 300L litres.
• All safety and control devices are pre-set.
• High quality controls selected that combine high ow rate performance with minimum pres-
sure drop which gives fantastic performance in all areas, with great improvements in areas
with poor water pressure.

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10
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 dfference. 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 protect-
ed from frost. All exposed pipework must be insulated. The unit must be installed upright on a
flat base capable of supporting its weight when full (please see the technical speci cation section for
weights).
Sufficient access to allow maintenance of the valves should be considered. In addition the immer-
sion heaters are 400mm in length and this distance should be considered to allow withdrawal for
servicing if required. The discharge pipework from the safety valves should fall continuously and
terminate safely.
Negative pressure may form in cylinders installed very high in a building. To counteract this,
an anti-vacuum valve can be installed to prevent damage to the cylinder. The anti-vacuum valve
ensures that pressure compensation as a result of air flowing into the cylinder.
Connecting To The Cylinder
All of the pipework connections on the cylinder are female threaded. Upon filling / commission-
ing, ensure all connections are completely watertight.
No control or isolation valve should be fitted between the expansion relief valve and
the storage cylinder. The relief valve connections should not be used for any other
purpose.
Cold Mains Pipework
Run the cold main through the building to the place where is to be installed. Take care not to run
the cold pipe near hot water or heating pipe work so that the heat pick-up is minimized. Identify
the cold water supply pipe and fit an isolating valve (not supplied). A 22mm BS1010 stopcock can
typically be used but a 22mm quarter turn full bore valve would be better as it does not restrict
the flow as much. Do not use “screwdriver slot” or similar valves.
Make the connection to the cold feed of the cylinder and incorporate a drain valve. Position the
inlet control just above the Temperature & Pressure Relief Valve (TPRV) mounted on the side of
the cylinder. This ensures that the cylinder does not have to be drained down in order to service
the inlet control set. Ensure that the arrow points in the direction of the water flow.