joule Cyclone Instruction Manual

Cyclone Direct / Indirect Installation Guide 1
Direct, Indirect & Solar
Unvented Cylinder
Installation & Maintenance Manual
JL-CYDID-INS-008
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COMMISSIONING
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2
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
Project ref. on
supplied schematic
Direct Gas Fire Cylinder Located on
cylinder badge
Was a Pre-Plumbed
cylinder installed too? Sheet too
Joule™ Advance Installer
I accept the terms and conditions in the installation manual
MUST BE COMPLETED AND
THEN REGISTERED ONLINE
TO COMPLETE WARRANTY

Cyclone Direct / Indirect Installation Guide 3
Joule™ Product Warranty Terms & Conditions
Unvented Kit & Other Components
The Joule™ 25-yearwarranty covers Joule™ cylin -
ders installed in domestic propertiesagainst corrosion
foraperiod of 25 years from the date of purchase.
All other components, including valves, expansion
are covered by atwo yearwarranty from the date
of purchase of the Joule™ product which in -
cludesone year’s parts and labourand one year
parts only.
Joule™ Wellmaster
The Joule™ Wellmasterstainless steel vessel car-
riesafullytransferable 10-yearguarantee against
faulty materialsor manufacture provided that:
-
dom or the Republic of Ireland as per the
instruc- tions 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.
than by Joule™.
subjected to neglect.
table water.
-
tion within 3 months of the cylinder instal -
lation. Ifthere are signs of corrosion on the
anode it must be replaced.
be put in place based on the ndings of the
initial 3 month inspection.
tions is 12 months.
sent by email to [email protected]
Joule™ Cyclone
The Joule™ Cyclonestainless steel vessel car -
ries afullytransferable 25-yearguarantee against
faulty materialsor manufacture provided that:
or the Republic of Ireland as per the instruc -
tions provided in the installation manual
provided with the cylinder and in accord-
ance with all of the relevant standards,
regulations and codes of practice in force
at the time.
than by Joule™
subjected to neglect.
water supply.
table water.
after each annual service.
sent by email to [email protected]
Exclusions
by the following;
ing the unit or its parts.
-
failure or malfunction of the unit.
Please note that invoices for servicing may be
viced annually.

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4
Exclusions
by the following;
not been routinely maintained.
ing the unit or its parts.
failure or malfunction of the unit.
Please note that invoices for servicing may be
viced annually.
and the code of practice can be obtained from
www.centralheating.co.uk
Warning To The User
-
vented water heater.
Warning To The Installer
commencing.
-
tion to install.
must be completed and left with the house -
holder.
-
placement parts.
Installed by
Installer
Name
Address
Contact Tel.
Completion
Date

Cyclone Direct / Indirect Installation Guide 5
Table Of Contents
6 Introduction
16 ErP Product Fiche
27 Testing
28 Smart Control Immersion Setup
29 Immersion Testing
49 Maintenance
52 Troubleshooting
56 Service Record
57 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 comple -
tion of the installation in order to comply with the current regulation.
Itis important to carefully read the manual to understand all the information to enable safe installa -
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 thisinstallationmanual applyto the range of Joule™ Cyclone Unvented Cylinders.
Safety is paramount when installing unvented hot water systems and the following instructions must
be adhered to:
incorrect use and Joule™ will not be held liable for any losses resulting from such use.
should be put in place to negate the possibility of scalding.
-
ment annually to comply with the warranty conditions.
on page 14.
The installation must be carried out by aperson competent to install unvented hot water systems.
The installation must be carried out in accordance with the following recommendations:
-
Failure to install this appliance correctly could lead to prosecution and will invalidate the guarantee.
Itis in your own interest and that of safety to ensure that the law is complied with.

Cyclone Direct / Indirect Installation Guide 7
Handling
-
tion, servicing, maintenance and repair must be carried out by acompetent person.
with current I.E.E Wiring Regulations.
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. Toprevent
this, ensure the immersion heater, and the hot and cold pipework are correctly bonded and
connected to the earth line.
10bar.
A thermostatic mixer should be installed in the system to prevent the risk of scalding. Ifthere are
the cylinder
What Is Benchmark?
-
sioned and serviced in accordance with the manufacturer’s instructions by competent persons and
-
Visit www.centralheating.co.uk
HWA Charter Member
Joule™ are proud to be acharter member of the the Hot Water Association (HWA), that has been
The objectives of the HWA are “Tobe 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”.

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8
Water Supply
The performance of any unvented system is only as good as the mains water supply available. To
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 minute.
that primary pipework used has aminimum diameter of 22mm to ensure low pressure loss.
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
operation and/or life expectation of the water heater storage cylinder, pressure temperature relief
valve and heating unit.
Where there is achangeover from one water supply to another, e.g. arainwater 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
warranty to apply.
Water Chemistry
This water heater must be installed in accordance with this advice to be covered by the Joule™ war -
ranty. This water heater is manufactured to suit the water conditions of most public reticulated water
the water heater and its operation and/or life expectancy. Ifyou are unsure of your water chemistry,
you may be able to obtain information from your local water supply authority.
Introduction

Cyclone Direct / Indirect Installation Guide 9
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:
Maximum Permitted Levels
600 mg/litre
Total Hardness 200 mg/litre
300 mg/litre
Magnesium 10 mg/litre
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 dis -
The Joule™ warranty will not cover resultant faults to the storage cylinder if this water heater is
any time i.e. due to sediment build up.
Features Of The Unvented Cylinder
-
tion factor of zero.
with all the necessary safety and control devices needed to connect to cold water mains
drop which gives fantastic performance in all areas, with great improvements in areas with poor
water pressure.

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10
General Requirements
Wellmaster Cylinders
source that does not come from the public mains.
Water supplied to the cylinder must conform to the water chemistry table on the previous page. A
Ifany of the water parameters are higher than set out in the table including total
hardness regardless of wheter or not it is fed from amain water connection aJoule™
Wellmaster cylinder must be used.
Ifany of the water parameters are higher than set out in the table including Total Hardness regardless
of whether or not it is fed from amainwaterconnectionaJoule™ Wellmastercylinder must be used.
Siting The Unit
This unit can supply outlets above it or at some distance from it but any outlets above the unit will
length of the “dead leg” should be as stated in the Water Supply (Water Fittings) Regulations 1999
Particular attention is needed if siting in agarage or outbuilding as the unit should be protected from
frost. All exposed pipework must be insulated. The unit must be installed upright on abase capable
-
sion heaters are 400mm in length and this distance should be considered to allow withdrawal for
terminate safely.
Negative pressure may form in cylinders installed very high in abuilding. Tocounteract this, an an -
ti-vacuum valve can be installed to prevent damage to the cylinder. The anti-vacuum valve ensures
Connecting To The Cylinder
and commissioning, ensure all connections are completely watertight.
storage cylinder. The relief valve connections should not be used forany other purpose.

Cyclone Direct / Indirect Installation Guide 11
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
Make the connection to the cold feed of the cylinder and incorporate adrain 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
for the expansion vessel. Mount it to the wall using the bracket provided.
Balanced Cold Connection
Ifthere are to be showers, bidets or monobloc taps in the installation then abalanced cold supply
is necessary. There is a22mm 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 a15mm connection to allow it to be connected to the tundish. Make sure that there
expansion relief valve.
Itis essential that this connection is not covered or closed. The hot water expansion vessel should
Hot Water Pipework
as possible.
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 apositive pressure in the system. The expansion vessel contains
Select asuitable position for the expansion vessel. Mount it to the wall using the bracket provided
the top of the vessel is accessible for servicing. The pipe connecting the expansion vessel to the
system should have adiameter of not less than 15mm and must not contain any restrictions.

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12
General Requirements
When the vessel is connected the system should be pressurised when cold. Ifthe 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
The primary circuit can be open vented or sealed, with up to amaximum pressure of 3.5 bar. Ifyou
heat sources such as some AGA’s, back boilers, solid fuel stoves, etc. are not suitable.Please con -
Installing The Two Port Motorised Valve
The function of the Two Port Motorised Valve prevents the cylinder from overheating. Itcan be in -
stalled on either horizontal or vertical pipework.
marked on the body of the valve with arrows.
Thermostatic Mixer
mixing valve should be installed. Its function is to act as an anti scald protection. The thermostatic
Secondary Circulation
in 15mm pipe. A suitable WRAS approved stainless steel or bronze circulation pump must be used.
vessel into the circuit to accommodate the increased system water volume. Secondary circulation
should be noted that the use of asecondary circulation circuit can increase running costs as there
energy losses to aminimum.

Cyclone Direct / Indirect Installation Guide 13
Dead Legs
leg lengths are shown in the table below. Where there is more than one size of pipe on adead leg,
-
ommended maximum, secondary circulation should be installed. Itshould be controlled by atime
switch and incorporate amotorized valve that can prevent gravity circulation in the circuit.
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 aresult of expansion of pipework over joists or where the pipe has
the pipework is correctly bracketed, is not in tension or compression, and does not carry the weight
of components such as acirculation pump.
Setting The Hot Water Temperature
The hot water temperature is set on the dual thermostat by the competent person during the instal -
cylinder may take additional time to heat up.
Inappropriate adjustments can lead to the damages in the system. Ifany changes are
made to the cylinder, the controls, the water and power supply lines or the expansion
relief components there is arisk of steam escaping or rupture to the system.

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14
TZ9-4.0-0000.5
TZ9-4.0-000.75
TZM-I-00022MM
TV-P-000012L
TV-P-000019L
TV-P-000024L
TZG-3.0-0.75L
TZG-3.0-0001L
TI-I-L-14-3-1
Unvented Kit Components
TV-P-000035L
TV-P-000050L TI-S-L-14-3-1
Smart

Cyclone Direct / Indirect Installation Guide 15
100 125 150 170 200 250 300 400 500
Inlet Group TZG-3.0-0.75L TZG-3.0-
0001L
Expansion Vessel TV-P-000019L TV-P-
000024L
TV-P-
000035L
TV-P-
000050L
T&P Valve TZ9-4.0-0000.5 TZ9-4.0-000.75
Tundish
TZM-I-00022MM
Unvented Kit Checklist
Indirect
Tundish Tundish
Expansion Vessel Expansion Vessel
2-port Zone Valve

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16
100 125 150 170 200 250 300 400 500
Direct Vertical
Storage volume V (ltr) 99 127 150 169 200 250 294 - -
149 191 225 254 300 377 441 - -
LLLLLL - -
ErP Rating - -
39 39 38 38 38 37 37 - -
Ann. el. consumption(kWh)
2650 2654 2715 2719 2723 2764 4508 - -
16 16 16 16 16 16 16 - -
60 60 60 60 60 60 60 - -
(kWh/24h) 12.189 12.213 12.577 12.601 12.625 12.868 20.962 - -
100 125 150 170 200 250 300 400 500
Indirect & Solar Vertical
Storage Volume V (ltr) 96 124 147 168 194 247 290 390 495
Standing Loss (kW)44 52 55 58 78 87 92 102 115
ErP Rating
ErP Product Fiche Information

Cyclone Direct / Indirect Installation Guide 17
Maximum mains water supply pressure 2.5MPa(25 bar)
0.3MPa(3 bar)
Expansion vessel pressure 1.0MPa(10 bar max)
Expansion relief valve setting 0.6MPa(6 bar)
Maximum design pressure 0.4MPa(4 bar)
T&P relief valve setting
Primary coil operating pressure (max) 0.6MPa(6 bar)
Immersion heater rating (a.c. supply only) single phase 3kW 50/60Hz~
Storage weights (empty and full)
Indirect coil ratings
Pressure drop across the indirect coils
Technical Data
Indirect models in conformance with BS EN 12897:2016

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18
10 Secondary Return
13 T&P Relief Valve
F
CC
D
A
B
13
10
9
8
7
3
2
E
G
H
14
15º
30º
93
30º

Cyclone Direct / Indirect Installation Guide 19
100 125 150 170 200 250 300 400 500
950 1030 1190 1310 1490 1815 1600 1570 1900
500 540 540 540 540 540 600 710 710
188 196 196 196 196 196 218 225 225
333 211 341 341 341 361 383 405 455
478 511 486 486 516 586 608 675 745
543 651 651 651 581 651 673 740 810
628 751 786 881 981 1271 1153 1180 1440
743 800 911 1031 1211 1531 1333 1280 1640
Performance 100 125 150 170 200 250 300 400 500
22 23 26 27 31 37 42 52 54
12 14 17 18 21 25 29 37 38
Weight Empty (kg) 27 30 34 37 41 49 56 62 89
Weight Full (kg) 152 155 184 207 241 299 356 462 589
2)0.58 0.58 0.58 0.58 0.67 0.77 0.77 1.16 1.25
20 20 20 20 21 23 23 25 26
45 45 45 45 65 76 76 88 90
382 382 382 382 401 440 440 478 497
100 125 150 170 200 250 300 400 500
22 22 22 22 22 22 22 28 28
22 22 22 22 22 22 22 22 22
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.75
3bar
T&P Press. Set. (bar)777777777
Exp. Relief Set. (bar) 666666666

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20
10 Secondary Return
13 T&P Relief Valve
DC
A
B
13
10
9
3
F
G
14
15
E
30º30º
10 3