joule Thermalstore 1.0 User manual

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Thermalstore 1.0 & 2.0
Installation Manual

Thermalstore
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Table of Contents
4 Introduction
9 General Requirements
13 Spare Parts
14 ErP Product Information
16 Thermalstore 1.0 Technical Specifications - No Solar
18 Thermalstore 1.0 Technical Specifications - Solar
20 Thermalstore 2.0 Technical Specifications - No Solar
22 Thermalstore 2.0 Technical Specifications - Solar
24 Mechanical & Electrical Diagrams
48 Setting The Freshwater Module
49 Installation
51 When Installing An Immersion Heater
53 Commissioning
54 Maintenance
56 Taking The Cylinder Out Of Use
58 Troubleshooting
60 Guarantee
62 Notes
64 Benchmark Log Book
66 System Record

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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 finding and replacement of parts for the cylinder purchased.
JOULE will not accept any liability in the event of damage for not complying with the
guidance in this instruction manual.
The instructions for this installation manual apply to the range of JOULE Cyclone
Indirect Unvented Cylinders.
Safety is paramount when installing unvented hot water systems and the following
instructions must be adhered to:
Only certified competant installers can install, commission and service the equipment
supplied.
The cylinder must be used for potable hot water only. Any other applications will be
considered incorrect use and JOULE will not be held liable for any losses resulting
from such use.
All installation and maintenance instructions must be observed to ensure the correct
operation of the equipment.
The electric immersion must not be switched on unless the cylinder is completely full
of water.
Domestic hot water may be stored at temperatures exceeding 60°C. Preventative
measures should be put in place to negate the possibility of scalding.
A maintenance schedule should be put in place with a competent person to service
the equipment annually to comply with the warranty conditions.
When servicing the system the mains supply to the cylinder should be isolated.
Only genuine spare parts should be used. A full list of items with relevant codes can
be found on page 13 .
The installation must be carried out by a person competent to install unvented hot
water systems. The installation must be carried out in accordance with the following
recommendations:
Introduction

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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
capability.
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
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.

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A thermostatic mixer should be installed in the system to prevent the risk of scalding.
If there are leaks found in the system, shut o 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 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
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 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.
Code Description
KCZMVI-0200LFC 200L Thermal Store 2.0
KCZMVS-0200LFC 200L Thermal Store 2.0 Solar
KCZMVI-0250LFC 250L Thermal Store 2.0
KCZMVS-0250LFC 250L Thermal Store 2.0 Solar
KCZMVI-0300LFC 300L Thermal Store 2.0
KCZMVIS-0300LFC 300L Thermal Store 2.0 Solar
KCZMVI-0400LFC 400L Thermal Store 2.0
KCZMVS-0400LFC 400L Thermal Store 2.0 Solar
KCZMVI-0500LFC 500L Thermal Store 2.0
KCZMVS-0500LFC 500L Thermal Store 2.0 Solar

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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 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 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.
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 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 ow as much. Do not
use “screwdriver slot” or similar valves.
Make the connection to the cold feed of the DHW coil cylinder and incorporate a
drain valve. 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 bal-
anced cold supply is necessary. There is a 22mm balanced connection on the inlet
control set.
General Requirements

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FITTING THE INLET CONTROL GROUP
Excess pressure can lead to the DHW coil bursting. Make sure that there is sufficient
space for future maintenance and also for connection of the discharge pipe for the
expansion relief valve.
It is essential that this connection is not covered or closed.
HOT WATER PIPEWORK
Run the first part of the hot water distribution pipework in 22mm. This can be
reduced to 15mm and 10mm as appropriate for the type of tap etc. Your aim should
be to reduce the volume of the hot draw-off pipework to a practical minimum so
that the time taken for the hot water is as quick as possible.
Do not use monobloc mixer tap or showers if the balanced cold connection is not
provided. Outlets of this type can back pressurise the unit and result in discharge.
EXPANSION VESSEL
The expansion vessel receives the increased water volume when expansion takes
place as the system heats up and it maintains a positive pressure in the system. The
expansion vessel contains a flexible diaphragm, which is initially charged on one
side with nitrogen, but can be topped up with air when required.
The pipe connecting the expansion vessel to the system should have a diameter of
not less than 15mm and must not contain any restrictions.
Prior to connecting the expansion vessel to the system the pipework should be
flushed and tested. When the vessel is connected the system should be pressurised
when cold. If the initial system water pressure is too high, the diaphragm will be
displaced too far into the vessel. This will leave the vessel unable to accommodate
the volume of expansion water. The result of this is an increase in system pressure
and the safety valve will lift.

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PRIMARY CONNECTIONS
The JOULE Thermalstore has 9 direct tappings for the integration of the heating
system with the DHW, allowing for numerous heat sources to combine in an
extremely efficient manner to generate DHW and space heating.
The boiler or boilers may be Gas, Electric, Oil, Solid Fuel, Biomass, Solar, or a
combination of a number of these.
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. Secondary pumped circulation using a stainless steel or a bronze pump,
and combined with e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 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. 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 insula-
tion 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 min-
imum 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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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 STORE TEMPERATURE
The JOULE Thermalstore temperature is set on the dual thermostat by the
competent person during the installation. The dual thermostat should be set to 70
° C. If you are heating water in the cylinder for the rst time, or if time controls have
been tted on the Thermalstore, the cylinder may take additional time to heat up.
Pipe Size (mm) Maximum Length (m)
10, 12 20
15, 22 12
28 8
35 and above 3
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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Spare Parts
Thermalstore 1.0
Expansion Vessel TV-P-000001L
Dual Stat TZC-D-000000Z
T&P Relief Valve TZG-3.0-0.75L
Immersion TZ9-7.0-000.5
Mixing Valve OZM-0000.75HP
Pressure Reducing Valve TZH-3.0-0022M

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200L 250L 250L 300L 400L 500L
Dimensions (mm) (1490x530) (1400x600) (1815x530) (1600x600) 1570x710) (1900x710)
Thermalstore 1.0 - No Solar
Hot Water Storage Tank Volume
(L)
196 247 247 290 390 494
Standing Loss 81 87 89 92 102 115
Energy Efficiency Class C C C C C C
Thermalstore 1.0 - Solar
Hot Water Storage Tank Volume 193 244 244 287 387 492
Standing Loss 83 89 91 96 102 115
Energy Efficiency Class C C C C C C
ErP Product Information
Thermalstore 1.0

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Thermalstore 2.0
200L 250L 250L 300L 400L 500L
Dimensions (mm) (1490x530) (1400x600) (1815x530) (1600x600) 1570x710) (1900x710)
Thermalstore 2.0 - No Solar
Hot Water Storage Tank Volume
(L)
196 247 247 290 390 494
Standing Loss 81 87 89 92 102 115
Energy Efficiency Class C C C C C C
Thermalstore 2.0 - Solar
Hot Water Storage Tank Volume 193 244 244 287 387 492
Standing Loss 83 89 91 96 102 115
Energy Efficiency Class C C C C C C

Thermalstore
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Thermalstore 1.0 - No Solar

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Technical Information
200L 250L 250L 300L 400L 500L
Thermalstore 1.0
Ø A (mm) 530 530 600 600 710 710
B (mm) 1490 1815 1400 1600 1570 1900
C (mm) 1206 1526 1128 1328 1285 1635
D (mm) 921 1138 889 1013 1020 1254
E (mm) 821 1038 789 913 920 1154
F (mm) 576 656 588 648 655 765
G (mm) 396 396 418 418 425 425
H (mm) 296 296 318 318 325 325
I (mm) 196 196 218 218 225 225
J (mm) 636 721 633 708 730 815

Thermalstore
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Thermalstore 1.0 - Solar

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Technical Information
200L 250L 250L 300L 400L 500L
Thermalstore 1.0 - Solar
Ø A (mm) 530 530 600 600 710 710
B (mm) 1490 1815 1400 1600 1570 1900
C (mm) 1206 1526 1128 1328 1285 1635
D (mm) 921 1138 889 1013 1020 1254
E (mm) 821 1038 789 913 920 1154
F (mm) 576 656 588 648 655 765
G (mm) 586 685 568 618 630 730
H (mm) 486 584 468 518 530 630
I (mm) 196 196 218 213 225 225
J (mm) 526 606 548 563 575 675
K (mm) 636 721 633 703 730 815

Thermalstore
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Thermalstore 2.0 - No Solar