joule Thermalstore 1.0 Installation Manual

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Thermalstore 1.0 & 2.0

Installation Manual

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Page 1 Thermalstore 1.0 & 2.0 Installation Manual...
Page 2 Pump and Cylinder Badge Underﬂ oor Heating Project Ref. on Supplied Schematic Direct Gas Fire Located on Cylinder Cylinder Badge Installer Address Contact Tel. Contact Email Joule Advance Installer I accept the terms and conditions avilable to view on jouleuk’s website...
Page 3: Table Of Contents
Introduction General Requirements Spare Parts ErP Product Information Thermalstore 1.0 Technical Speciﬁ cations - No Solar Thermalstore 1.0 Technical Speciﬁ cations - Solar Thermalstore 2.0 Technical Speciﬁ cations - No Solar Thermalstore 2.0 Technical Speciﬁ cations - Solar Mechanical & Electrical Diagrams...
Page 4: Introduction
These instructions consist of details for instal- lation, servicing, fault ﬁ 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.
Page 5 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...
Page 6 Consideration should be given to upgrading existing ½” (15mm) cold mains pipe- work to a larger size if the recommended minimum pressure/ﬂ ow rate is not being achieved. JOULE recommend that primary pipework used has a minimum diameter of 22mm to ensure low pressure loss.
Page 7 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 eﬀ...
Page 8 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.
Page 9: General Requirements
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 diﬀ 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.
Page 10 Thermalstore FITTING THE INLET CONTROL GROUP Excess pressure can lead to the DHW coil bursting. Make sure that there is suﬃ 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. HOT WATER PIPEWORK Run the ﬁrst part of the hot water distribution pipework in 22mm.
Page 11 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 eﬃ cient 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.
Page 12 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 ﬁ rst time, or if time controls have been ﬁ...
Page 13: Spare Parts
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...
Page 14 500L Dimensions (mm) (1490x530) (1400x600) (1815x530) (1600x600) 1570x710) (1900x710) Hot Water Storage Tank Volume Standing Loss Thermalstore 1.0 - No Solar Energy Eﬃ ciency Class Hot Water Storage Tank Volume Standing Loss Thermalstore 1.0 - Solar Energy Eﬃ ciency Class...
Page 15 Thermalstore 2.0 200L 250L 250L 300L 400L 500L Dimensions (mm) (1490x530) (1400x600) (1815x530) (1600x600) 1570x710) (1900x710) Hot Water Storage Tank Volume Standing Loss Thermalstore 2.0 - No Solar Energy Eﬃ ciency Class Hot Water Storage Tank Volume Standing Loss Thermalstore 2.0 - Solar Energy Eﬃ...
Page 16 Thermalstore 1.0 - No Solar Thermalstore...
Page 17 Technical Information 200L 250L 250L 300L 400L 500L Ø A (mm) B (mm) 1490 1815 1400 1600 1570 1900 C (mm) 1206 1526 1128 1328 1285 1635 D (mm) 1138 1013 1020 1254 E (mm) 1038 1154 F (mm) G (mm) H (mm) I (mm) J (mm)
Page 18 Thermalstore 1.0 - Solar Thermalstore...
Page 19 Technical Information 200L 250L 250L 300L 400L 500L Ø A (mm) B (mm) 1490 1815 1400 1600 1570 1900 C (mm) 1206 1526 1128 1328 1285 1635 D (mm) 1138 1013 1020 1254 E (mm) 1038 1154 F (mm) G (mm) H (mm) I (mm) J (mm)
Page 20 Thermalstore 2.0 - No Solar Thermalstore...
Page 21 Technical Information 200L 200L 250L 250L 300L 300L 400L 400L 500L 500L Ø A (mm) Ø A (mm) B (mm) B (mm) 1490 1490 1400 1400 1600 1600 1570 1570 1900 1900 C (mm) C (mm) 1206 1206 1128 1128 1323 1323 1275...
Page 22 Thermalstore 2.0 - Solar Thermalstore...
Page 23 Technical Information 200L 250L 300L 400L 500L Ø A (mm) B (mm) 1490 1400 1600 1570 1900 C (mm) 1206 1128 1323 1275 1635 D (mm) 1008 1020 1254 E (mm) 1154 F (mm) G (mm) H (mm) I (mm) J (mm) K (mm)
Page 24 Open Vented Boiler, Solid Fuel Boiler, 2 Radiator Zones & Heat Exchanger...
Page 25 Electrical Diagram...
Page 26 Thermalstore, Sealed Boiler, Solid Fuel Boiler, 2 Radiator Zones & Heat Exchanger...
Page 27 Electrical Diagram...
Page 28 Thermalstore, Sealed Boiler, 1 Underﬂ oor Heating Zone & Radiator Zone...
Page 29 Electrical Diagram...
Page 30 Thermalstore, Sealed Boiler, 2 Radiator Zones & Solar...
Page 31 Electrical Diagram...
Page 32 Thermalstore, Open Vent Boiler & 1 Radiator Zones...
Page 33 Electrical Diagram...
Page 34 Thermalstore, Open Vent Boiler & 2 Radiator Zones...
Page 35 Electrical Diagram...
Page 36 Thermalstore, Solid Fuel Boiler & 2 Radiator Zones...
Page 37 Electrical Diagram...
Page 38 Mechanical Diagram Thermalstore Thermalstore, Solid Fuel Boiler & 2 Radiator Zones...
Page 39 Electrical Diagram...
Page 40 hermalstore, Solid Fuel Boiler, 2 Radiator Zones, Heat Exchanger & Sealed Heating System...
Page 41 Electrical Diagram Electrical Diagram...
Page 42 Thermalstore, Sealed Boiler, Solid Fuel Boiler, 2 Radiator Zones, Heat Exchanger, Sealed Heating System & Solar Thermal...
Page 43 Electrical Diagram...
Page 44 Thermalstore, Open Vent Boiler, Solid Fuel Boiler, 1 Underﬂ oor Heating Zone, 1 Radiator Zone & Heat Exchanger...
Page 45 Electrical Diagram...
Page 46 Thermalstore, Solid Fuel Boiler, 2 Radiator Zone, Heat Exchanger & Solar Thermal...
Page 47 Electrical Diagram...
Page 48: Setting The Freshwater Module
Setting The Freshwater Module Thermalstore To set the ﬂ ow rate on the Freshwater Module on the Thermalstore 2.0, complete the following steps; • With the Thermalstore 2.0 hot, set the pump speed of the circulation pump (02) to speed 3. •...
Page 49: Installation
30°C and 60°C and is supplied by in the unvented kit. The Joule Thermalstore 1.0 is capable of delivering up to 22L/min at a pressure of 2 bar mains pressure. Calculations of water demand should be made based on this ﬂ...
Page 50 Thermalstore When installing an open vent heating system, it is recommended to use copper pipe with a minimum diameter of 22mm on standard boilers and a minimum of 28mm copper pipe on solid fuel boilers. Temperatures in the vent pipe from the open vent systems can exceed 90°C so ensure that the pipework used is suitable for high temperature applications.
Page 51: When Installing An Immersion Heater
When Installing An Immersion Heater Where an immersion heater is ﬁ tted, always check the immersion for signs of leak- age 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 ﬁ...
Page 52 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 recommended 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.
Page 53: Commissioning
Commissioning FILLING First you must ensure that the pressure in the dhw expansion vessel is the same as the setting of the pressure reducing valve i.e. 3 bar (45PSI). The valve is of the Schrader car tyre type. Check all the connections for water tightness including any factory made connections such as the immersion heater and the temperature and pressure relief valve.
Page 54: Maintenance
Maintenance Thermalstore 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 operational. DRAINING Switch the electrical power oﬀ (important to avoid damage to element). Isolate boiler from the unit.
Page 55 Check the pressure in the expansion vessel is charged to 3 bar. Turn oﬀ the water supply to the unit and open a hot tap ﬁrst. The air valve on expansion vessel is a Schrader (car tyre) type. Air or CO2 may be used to charge the expansion vessel. Unscrew the head on the inlet control set and clean the mesh ﬁ...
Page 56: Taking The Cylinder Out Of Use
Taking The Cylinder Out Of Use Thermalstore SHUTTING DOWN Ensure the cold water supply is isolated and at least two hot water draw oﬀ points are open prior to draining the cylinder. One of the hot water draw oﬀ points should be as close as possible to the height of cylinder in draw oﬀ...
Page 57 LOG BOOK The installer must comply with all of the installation instructions contained within this installation manual. On completion of the initial installation and after each sub- sequent annual service the Benchmark Log Book must be completed and signed by the competent person who has worked the unit.
Page 58: Troubleshooting
The discharge may also stop. 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.
Page 59 Fault Possible Cause Solution Water escaping from the case Compression ﬁ tting on hot - Check / remake joint sealing unit. draw oﬀ not sealing. paste. Cold water at hot tops. Immersion heater not switched Check / reset. on or cutout has triggered. Indirect - Boiler not working.
Page 60: Guarantee
• It has not been modiﬁ ed in any way, other than by JOULE • It has not been misused, tampered with or subjected to neglect.
Page 61 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 serviced annually. Joule fully endorse the Benchmark scheme and the code of practice can be obtained from www.centralheating.co.uk info@jouleuk.co.uk Tel: 02523552094 Registration can be made by logging online to www.jouleuk.co.uk...
Page 62: Notes
Thermalstore Notes _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________...
Page 63 Notes _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________...
Page 64 Mains Pressure Hot Thermalstore...
Page 65 Water Storage System Commisioning Checklist...
Page 66 Thermalstore...
Page 67 Service Record...
Page 68 Thermalstore JOULE IE mail Kylemore Park West, Ballyfermot, Dublin 10 +353 (1) 623 7080 +353 (1) 626 9337 info@joule.ie www.joule.ie JOULE UK mail Unit 17C&D Power Road, Plantation Bus. Pk. Bromborough, Wirral, CH62 3RN +44 (0) 1513 551 094 +44 (0) 1513 568 336 info@jouleuk.co.uk...

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