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joule HHH-AEHP-00001, Installation & Maintenance Manual

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77

Modul-AIR Exhaust Air Heat Pump Installation Guide

Setting the Heat Pump airflow rate

After setting up the Modul-AIR and any external parts connected to it the heat pump air flow rate must be 
entered.

The procedure to input the HP rate is as follows:

To access the heat pump flow rate function of the Modul-AIR 
unit, navigate to the spanner icon on the home screen.

Enter the login code to access the installer functions. The 
installer code is issued during the Modul-AIR Joule installer 
training program.

Press the right arrow and press Yes to save the setting.

Navigate to the Modul-AIR settings menu and press the icon.

Summary of Contents for HHH-AEHP-00001

Page 1: ...ENG 0026 01 Joule Modul AIR All E Modul AIR All E with Green Comfort Module Modul AIR Aqua Installation Maintenance Manual...

Page 2: ...sphere The pressure relief device is to be operated regularly to remove lime deposits and to verify that it is not blocked Drain valves are located on the hot water tank to allow draining of the water...

Page 3: ...tion with the Joule Modul AIR The warranty terms are 2 years parts and labour on the Modul AIR heat pump Green Comfort module and allheatpumpsystemaccessoriessuppliedbyJoule with25yearswarrantyontheMo...

Page 4: ...handover document for client Is the system safe to operate Istheoverallsupplyairflowrategreaterthanbutnogreaterthan15 ofoverallextractairflowrate Incl type of ventilation system Is there adequate acce...

Page 5: ...ow High Rate l s Design Air Flow Low Rate l s Measured Air Flow Low Rate l s Installer Third Party Installer Third Party Kitchen Bathroom En suite Utility Room Reference Design Air Flow High Rate l s...

Page 6: ...een set up in accordance with manufacturer s instructions Have all distribution grilles been locked to prevent unauthorised adjustment Have Ductwork joints been properly made in accordance with the su...

Page 7: ...cable been used for exhaust air heat pump See Page 52 for cable requirements Is primary flow return insulated Has an electrical isolation switch been installed Has the correct size electrical circuit...

Page 8: ...nstalled equivalent ventilator area meet the requirements given in Section 1 2 of TGD F Have the correct number and location of extract fans terminals been installed that satisfy relevant Table of Tab...

Page 9: ...pework 49 Modul AIR Electrical Connections 56 Modul AIR Electrical Schematic 58 Modul AIR Main PCB Board 60 Modul AIR Electrical Overview 61 Green Comfort Electrical Schematic 63 Green Comfort Main PC...

Page 10: ...does not need to be in possession of a STEK or F gas certification The purpose of the manual is to support you in installing the Modul AIR with or without the Green Comfort unit safely and correctly T...

Page 11: ...11 Modul AIR Exhaust Air Heat Pump Installation Guide Modul AIR Type Plate Green Comfort Type Plate...

Page 12: ...ly sent to Joule and the installer CE MARKING This is the CE logo with which Joule indicates that the product meets the legal requirements FOR INDOOR USE ONLY This symbol indicates that the Modul AIR...

Page 13: ...orage tank This variant contains both an integrated electric flow heater and a three way valve The Modul AIR Aqua is variant for domestic hot water generation in applications where central heating is...

Page 14: ...14 www jouleuk co uk www joule ie Modul AIR Dimensions The dimensions covering the full range of Modul AIR configurations are shown below...

Page 15: ...15 Modul AIR Exhaust Air Heat Pump Installation Guide Green Comfort Dimensions The dimensions covering the full range of Modul AIR configurations are shown below...

Page 16: ...N A 2300 N A Average electrical consumption power heat pump W 300 300 300 N A IP Class X2 X2 X2 X2 Max working pressure kPa 300 300 300 300 Cord type 3 core cable flex 1m 3 core cable flex 1m 3 core c...

Page 17: ...Chlorine mg I 0 2 0 2 0 2 0 2 Fluorides not allowed not allowed not allowed not allowed INSTALLATION ROOM Max permissible air humidity installation room rH 85 85 85 85 Max allowed temperature o C 35...

Page 18: ...EHP 00002 Joule Modul AIR Aqua Solo HHH AEHP 00001 Joule Modul AIR All E All necessary parts for installing the Modul AIR A Modul AIR Unit x1 D Support fix assembly HZQ V S1051095 1x B Condensate hose...

Page 19: ...ensure all are present before installation Green Comfort Box Contents Item number Name HHH GCPH 00001 Green Comfort Module All necessary parts for installing the Green Comfort A Support fix assembly H...

Page 20: ...ways stop the unit disable the protection switch andcontactJoule stechnicalsupportiftheunitproducessmoke ifthepowercableishotordamaged or if the unit is very noisy Handle electrical appliances with ca...

Page 21: ...ment In case of a refrigerant leakage try to avoid contact with the refrigerant as this could result in serious injury It is only permitted to install the Modul AIR in a room that is free of frost Onl...

Page 22: ...o be Joule approved low voltage OpenTherm controllers only Item No Heat Pump Unitw Max Circuit Amps Rec RCBO Size HHH AEHP 00002 Joule Modul AIR Aqua Solo 16 16 Amp HHH AEHP 00001 Joule Modul AIR All...

Page 23: ...recommended Air is the most prevalent cause of restricted flow in the system Make sure that all pipework can easily be purged of air and that all air is removed from the system prior to starting the...

Page 24: ...rotect the Heat Pump from damage For transport e g via a stairs the Heat Pump may be tilted for a maximum of 15 minutes up to a maximum angle of 45 degrees The Heat Pump can weigh up to 60kg At least...

Page 25: ...prior to citing an area for installing the unit Clearance is required to provide sufficient space for installation and maintenance Minimum Required space around the Modul AIR Unit a min 300mm b min 50...

Page 26: ...t Water Tank Tank Heights x TUMA 00150 LFC 1102mm TUMA 00180 LFC 1293mm TUMA 00210 LFC 1478mm x mm 700mm 545mm 500mm Min 100mm Min 100mm Min 100mm 500mm Door Height 2100 mm Void Width 900mm 500mm 400m...

Page 27: ...ound the Modul AIR Unit a min 300mm d maximum 2 5m b min 500mm e min 350mm c min 300mm f min 10mm when using the top connection for incoming ventilation air min 500mm when using the side connection fo...

Page 28: ...Hot Water Tank x mm 700mm 500mm 545mm Min 100mm Min 100mm 500mm Door Height 2100 mm Tank Heights x TUMA 00150 LFC 1102mm TUMA 00180 LFC 1293mm TUMA 00210 LFC 1478mm Void Width 1200mm 500mm 400mm 285m...

Page 29: ...of 200kg m2 If the wall mass is lower than this ensure the recommended wall build up is adhered to The Modul AIR should always be hung level however there is a permitted tolerance of 2 If there are a...

Page 30: ...ible attempt to do so would void Joules statutory responsibilities Wall Mounting Increase weight for the wall to be capable of holding to 225kg m2 for Modul AIR and GC If the wall mass is lower than t...

Page 31: ...R Wall Bracket 1 7 Metal Stud Wall 1 8 Heavy Hex Flange Screw M8 X 80 2 EX Modul AIR 220 90 BEND H 90 Solid External Party Wall Internal Wall Adjoining Hallway Internal Wall Adjoining Utility Internal...

Page 32: ...32 www jouleuk co uk www joule ie Modul AIR Concrete Block Wall Build up 1 3 4 6 8 5 2 7...

Page 33: ...oining Utility Internal Wall Adjoining Bedroom The exploded view on the following page details the required wall build up to adequately support the Modul AIR and Green Comfort if the dwelling has Conc...

Page 34: ...34 www jouleuk co uk www joule ie Modul AIR and Green Comfort Concrete Block Wall Build up 1 4 10 5 6 9 2 3 7 8...

Page 35: ...s used as the standard wall finish Item Description Qty 1 Modul AIR 1 2 Modul AIR Wall Bracket 1 3 Timber Noggin 7 4 Concrete Floor Slab 1 5 Plywood Sheet 1 6 Standard Wall Finish 1 7 Heavy Hex Flange...

Page 36: ...36 www jouleuk co uk www joule ie Modul AIR Timber Stud Build up 1 4 8 7 2 5 6 3...

Page 37: ...e stud before the plasterboard is used as the standard wall finish Item Description Qty 1 Modul AIR 1 2 Green Comfort 1 3 Modul AIR Wall Bracket 1 4 Green Comfort Wall Bracket 1 5 Heavy Hex Flange Scr...

Page 38: ...38 www jouleuk co uk www joule ie Modul AIR and Green Comfort Timber Stud Build up 8 7 6 5 4 3 1 2 10 9...

Page 39: ...R Exhaust Air Heat Pump Installation Guide Connecting the Modul AIR Modul AIR Aqua Pipe Connections Modul AIR ALL E Pipe Connections Drain Return Flow Drain Common System Return DHW Tank Flow Space He...

Page 40: ...tract Air or Air In to the Heat Pump is the heat source to the Exhaust Air Heat Pump system The extract air is fed via the ductwork to the Heat Pump from all wet rooms within the dwelling TheExhaustAi...

Page 41: ...tchen extractor fan to the kitchen ceiling valve of the extract ductwork When cooking always use the kitchen extractor fan Before connecting the Insulated flexible ducts to the top of the Heat Pump ta...

Page 42: ...s The Heat Pump does not have a pressure relief valve incorporated The installer MUST ensure the system is protected from over pressurisation The valve prevents abnormal water pressure from damaging t...

Page 43: ...lush Valve H I Filterball J Hot Outlet K Balanced Cold Outlet L M Mains Boosted Cold Inlet Pressure Relief Valve G B E C D I D J M L K A MEV Ventilation Modul AIR ALL E F Inlet Control Group Descripti...

Page 44: ...Outlet K Balanced Cold Outlet L Mains Boosted Cold Inlet Pressure Relief Valve F B E C D H D I L K J A MEV Ventilation Modul AIR AQUA Inlet Control Group Description B Modul AIR Hot Water Tank A Tundi...

Page 45: ...ul AIR All E Green Comfort Righthand side Modul AIR All E Green Comfort Lefthand side Green Comfort Flow Green Comfort Return Drain DHW Tank Flow Space Heating Flow Common System Return Space Heating...

Page 46: ...unit UTP data lead connection to be used to link with the Modul AIR unit Mains electrical connection through supplied fly lead The flow and return connections on the underside of the unit are 15mm com...

Page 47: ...ly Air or Fresh Air to the dwelling from the Green Comfort is the conditioned air that s has passed through the filters and heat exchanger within the Green Comfort unit The Supply air is fed via the d...

Page 48: ...separated by a minimum distance of 3 meters M Modul AIR ALL E Green Comfort Module MVHR Ventilation Descriptio n A Modul AIR Hot Water Tank B Modul AIR Heat Pump C Tundish D Green Comfort Module E1 Po...

Page 49: ...d or adjusted by a competent installer The adjusting of the pressure should be done before the expansion vessel is installed i e the pipe connection must be open to atmosphere The vessel must be sized...

Page 50: ...itres A 8L expansion vessel pre charged to 0 5 bar is sufficient A 10L expansion vessel pre charged to 1 0 bar is sufficient NOTE if any of the system data values change a different vessel would be re...

Page 51: ...e correct order 1 Connect the fill flush pump to the fill flush valve as shown It is important to connect the feed hose from the fill flush pump to Valve A and the drain hose to Valve B This ensures t...

Page 52: ...he recommended pre charge pressure is between 1 5 and 2 0 bar 6 When the pre charge pressure has been reached Valve A should be closed If the pre charge pressure has exceeded 1 5 bar Valve B can be op...

Page 53: ...rator The condensation water must be drained from the unit to allow the unit to function normally That is why the Heat Pump must be connected to a drain pipe To connect the Modul AIR to the drainpipe...

Page 54: ...he system in the correct order 1 Connect the fill flush pump to the fill flush valve as shown It is important to connect the feed hose from the fill flush pump to Valve A and the drain hose to Valve B...

Page 55: ...is between 1 5 and 2 0 bar 6 When the pre charge pressure has been reached Valve A should be closed If the pre charge pressure has exceeded 1 5 bar Valve B can be opened to allow system pressure to b...

Page 56: ...ied UTP Comms cable UTP Data cable 3 meter x1 Supplied The Heat Pump MUST be connected to the mains through a suitably sized RCBO The power cable is pre wired to the Exhaust Air Heat Pump This Equipme...

Page 57: ...the Heat Pump The Heat Pump is to be wired to the mains through use of a suitably sized RCBO Check all connections and the mains voltage is correct before powering On the Heat Pump to prevent damage t...

Page 58: ...ermostat E RF Receiver optional F Suitably Sized RCBO Terminals 6 5 4 3 of connector P6 and 4 3 of P12 are polarity insensitive I mmersion Heater 0 10V Ventilation Contro l B A TopS ensor Bottom Senso...

Page 59: ...Receiver optional E Suitably Sized RCBO Terminals 6 5 4 3 of connector P6 and 4 3 of P12 are polarity insensitive HZMA SENS 0001 I mmersion Heater 0 10V Ventilation Contro l B A TopS ensor Bottom Sens...

Page 60: ...60 www jouleuk co uk www joule ie The internal electrical connection layout of the Modul AIR is shown above Modul AIR Main PCB Board...

Page 61: ...ck P16 on the Modul AIR PCB board The immersion must be grounded using the provided earthing connections on the Modul AIR casing Two Domestic Hot Water Tank Sensors are provided with the unit The sens...

Page 62: ...ing the location of any room sensor Room thermostats sensors need a free flow of air to operate correctly so they must not be covered by curtains or blocked by furniture Nearby electric fires televisi...

Page 63: ...Receiver optional F Green Comfort Module G Suitably Sized RCBO Terminals 6 5 4 3 of connector P6 and 4 3 of P12 are polarity insensitive 1 Ph 220 240Vac 50Hz 32 Amps Power Supply G B Immersion Heater...

Page 64: ...Green Comfort is shown above P SENSOR AIRFLOW EXT BUS RJ45 USB COM PORT T AIR IN M 230 Vac L N GND Tach PWM T AIR OUT FAN M MODULATING VALVE ACTUATOR N 230 Vac L CLOSE 230 Vac L OPEN L N 1L N PE 16 A...

Page 65: ...cable is directly plugged into the data port on the bottom side of the Green Comfort Unit The other end of the UTP cable is to be fed into the Modul AIR unit using the entry grommets and plugged into...

Page 66: ...ed with a CO2 sensor and or a humidity sensor The CO2 sensor is connected to the mains and the humidity sensor is powered by two AA batteries Place the CO2 sensor in the living room for optimum air qu...

Page 67: ...f 3 Bar Heat up time is based on the EN12897 standard and the Heat Pump reheat time may differ Heat loss is based on the EN12897 standard Modul AIR Indirect Tank Specs Item No TUMA 00150 LFC TUMA 0018...

Page 68: ...consult the Direct Indirect Slimline Modul AIR Un Plumbed Unvented Cylinder Installation Maintenance Manual INS JUKCYL 020 Reference Description Connection Size A Hot water Outlet 22mm compression con...

Page 69: ...duremustbeentirelycomplete Beforeyoustartthecommissioningproceduremake sure you have received and read all the provided information sheets The data in the info sheets is necessary to know in order to...

Page 70: ...ler menubyenteringapassword Thispasswordisenteredbyperforminganumberoftasksinafixedsequence on the display In order to receive this drawing pattern you first must have successfully completed the Joule...

Page 71: ...71 Modul AIR Exhaust Air Heat Pump Installation Guide Modul AIR Unit Menu Overview...

Page 72: ...72 www jouleuk co uk www joule ie...

Page 73: ...up will vary there is a fan calibration feature on the Modul AIR It is essential to run the fan calibration feature before setting the Low and High airflow rates as the fan calibration feature sets th...

Page 74: ...Adjust air valves screen and press start On the Calibrate airflow screen the total airflow can be adjusted In this mode the fan will increase and or decrease its speed to keep the airflow constant The...

Page 75: ...nce and therefore needs the least adjustment this is most often the furthest valve from the unit 5 Nextworkbacktowardstheunitandadjusteachceilingvalveuntilthedesiredairflowrateisachieved 6 When all va...

Page 76: ...er the value of the high in the same way Press the right arrow and press Yes to save the setting Set the value of the low setting using the minus and plus buttons Press the right arrow The confirmatio...

Page 77: ...ocedure to input the HP rate is as follows To access the heat pump flow rate function of the Modul AIR unit navigate to the spanner icon on the home screen Enter the login code to access the installer...

Page 78: ...lings volume This value will be provided to you by joule at commissioning stage of your system Use the minus and plus buttons to input the value given Press the arrow at the top left to exit the scree...

Page 79: ...de is recommended to be used at all times For systems without sensors the unit should be left to Home during normal operation conditions This is the standard trickle flow setting for the Heat Pump The...

Page 80: ...edure to input the time and date is as follows Navigate to the Modul AIR settings menu and press the icon Navigate to Time and press the icon Press Yes to save the setting Set the hours and minutes on...

Page 81: ...n this manual The procedure to set the external controls is as follows First access the installer functions of the Modul AIR unit Navigate to the spanner icon on the home screen Press the OT thermosta...

Page 82: ...system requirements The procedure to setup the backup heater is as follows ToaccesstheinstallerfunctionsoftheModul AIRunit navigate to the spanner icon on the home screen Enter the login code to acces...

Page 83: ...ettings icon The confirmation screen will appear Press Yes to save the settings Set the additional power of the backup heater Set the maximum temperature of the flow heater Use the minus and plus butt...

Page 84: ...t water for taps and showers The procedure to setup the tank is as follows ToaccesstheinstallerfunctionsoftheModul AIRunit navigate to the spanner icon on the home screen Enter the login code to acces...

Page 85: ...ty or CH Space Heating Priority If the tank has an element enable to 2kW option Otherwise select N A Select the volume of the tank installed Press the right arrow Select the desired setpoint temperatu...

Page 86: ...air supply The procedure to setup the Green Comfort Module as follows ToaccesstheinstallerfunctionsoftheModul AIRunit navigate to the spanner icon on the home screen Next scroll to the right to the Se...

Page 87: ...oing air temperature of the Green Comfort module in relation to the desired room temperature room thermostat Press the arrow in the top left to exit the screen leave The confirmation screen will appea...

Page 88: ...ing instructions detailed in the previous Filling Venting section of this manual 2 Turn on the Modul AIR 3 On the display the procedure is as follows Tap the Settings icon in the main menu Navigate to...

Page 89: ...aerator the system is properly vented If air also comes out of the vent the central heating system must be vented again 2 Disconnect the power supply to the Modul AIR 3 lf present disconnect the power...

Page 90: ...Modul AIR Status tab Tap the Settings icon in the main menu Navigate to Modul AIR Status and press the icon The temperatures sensor values are displayed here On the next page the unit s airflow rate a...

Page 91: ...here Checking the backup heater Status Information about the status of the Backup heater can be found in the installer menu under the Backup heater Status tab Tap the Settings icon in the main menu N...

Page 92: ...about the status of the Tank can be found in the installer menu under the Tank Status tab Tap the Settings icon in the main menu Navigate to Tank Status and press the icon The tank temperature sensor...

Page 93: ...Code Error Meaning Possible Solution 10 Water Pressure low 0 8 bar Increase water pressure 20 Filter reached end of lifespan Replace the Air Filter 80 No temperature difference across the condenser Ch...

Page 94: ...emperature sensor error Check sensor Replace if necessary 32 Back up heater water heater temperature sensor error Check sensor Replace if necessary 33 Air In sensor error Green Comfort Module Check se...

Page 95: ...ck sensor Replace if necessary 70 Water pressure sensor error Check sensor Replace if necessary 71 Back up heater protection active Check sensor Replace if necessary 90 Compressor locked repeated erro...

Page 96: ...ard Disregarding of these points may have a negative effect on the Modul AIR warranty and void Joules statutory responsibilities Spare parts list The design and operation of an exhaust air heat pump s...

Page 97: ...ZQ V S1013240 3 way valve actuator head 18 HZQ V S1051260 Electric backup heater assembly 19 HZQ V S1029010 Condensate hose 20 HZQ V S1012811 Pipe socket 150 mm 21 HZQ V S1051095 Support fix assembly...

Page 98: ...andard frequency of 12 months Check the filter menu on the display to see when the filter needs to be replaced Inspection and cleaning if necessary of the heat exchangers fans Inspection of condensati...

Page 99: ...t or damp hands or when barefoot Do not store inflammable products in the neighbourhood of the unit The unit is only suitable for 230 VAC 50Hz electric mains Never modify the fan or electronics by you...

Page 100: ...its internals This also allows the perfect opportunity to inspect and clean the other parts of the unit that may require it Opening of Modul AIR procedure Remove the front plate The plate is held on w...

Page 101: ...drip tray should be checked from time to time and cleaned when necessary How to clean the drip tray Cleaning the drip tray Unscrew the single top screw and remove the cover plate Remove the drain hos...

Page 102: ...102 www jouleuk co uk www joule ie Cleaning the drip tray Carefully pull the drip tray out of the Modul AIR Clean the drip tray Reassemble the Modul AIR by reversing the previous steps...

Page 103: ...nstaller menu under the Green Comfort status tab Tap the Settings icon in the main menu Navigate to Green Comfort Status and press the icon The temperatures sensor values are displayed here On the nex...

Page 104: ...ilter menu on the Modul AIR display to see when the filter needs to be replaced How to replace a filter Replacing the GreenComfort filter Switch off the Green Comfort Remove the front plate The plate...

Page 105: ...the vent Check that the water pressure has remained between 1 5 and 2 0 bar If not repeat steps 4 7 Remove the filling hose and close the filling valve properly Navigate to the Modu AIR Settings scree...

Page 106: ...Joule b damages to the product caused by workers visitors on the job site or post installation work c damages caused by accident natural disaster such as fire foods lightning etc force majeure sabotag...

Page 107: ...d 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...

Page 108: ...nded to reduce noise transmitted inside ventilation ductwork With the Modul AIR depending on the frequency the in duct sound power level can reduce by up to 25 as seen in graph through the use of the...

Page 109: ...5 47 9 63 5 Flow Rate 200m3 h Compressor Off Hz 63 125 250 500 1k 2k 4k 8k WEIGHTED Breakout dB Modul AIR 52 45 4 50 1 47 2 42 9 40 1 36 2 35 1 49 Induct Modul AIR Extract 59 9 69 9 64 54 41 4 36 5 33...

Page 110: ...ul AIR 52 45 4 50 1 47 2 42 9 40 1 36 2 35 1 49 GreenComfort 49 6 54 5 53 2 39 3 35 3 31 3 24 4 25 46 5 Induct Modul AIR Extract 59 9 69 9 64 54 41 4 36 5 33 9 32 3 57 5 GreenComfort Supply 57 8 62 1...

Page 111: ...ry exit grilles should be separated by a minimum distance of 3 meters M N Descriptio n A Modul AIR Hot Water Tank B Modul AIR Heat Pump C Tundish D Green Comfort Module E1 Potable Expansion Vessel E2...

Page 112: ...AIR PCB B Modul AIR Heat Pump C Hot Water Tank D Opentherm Thermostat E Suitably Sized RCBO Terminals 6 5 4 3 of connector P6 and 4 3 of P12 are polarity insensitive I mmersion Heater B A TopS ensor...

Page 113: ...C Hot Water Tank D Opentherm Thermostat E Green Comfort Module F Suitably Sized RCBO Terminals 6 5 4 3 of connector P6 and 4 3 of P12 are polarity insensitive 1 Ph 220 240Vac 50H z 32 Amps Power Suppl...

Page 114: ...IR PCB B Modul AIR Heat Pump C Hot Water Tank D Suitably Sized RCBO Terminals 6 5 4 3 of connector P6 and 4 3 of P12 are polarity insensitive Immersion Heater B A TopS ensor Bottom Sensor C Tank Senso...

Page 115: ...115 Modul AIR Exhaust Air Heat Pump Installation Guide...

Page 116: ...Pontefract West Yorkshire WF8 4PS UK e info jouleuk co uk t 0330 808 8488 f 0 1513 568 336 Unit 407 NW Business Park Cappagh Road Ballycoolin Blanchardstown Dublin e info joule ie t 353 1 6237080 f 3...

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