“Streamline Closed Circuit”
GAS BOOSTED
SOLAR WATER HEATER
OWNER’S MANUAL
AND
WARRANTY / INSTALLATION INFORMATION
WARNING: Plumber – Be Aware
Use copper pipe ONLY. Plastic pipe MUST NOT be used.
It is a requirement of a solar water heater installation that all
pipe work be in copper and not plastic, due to the effects of
high water temperatures.
Solahart Industries Pty Ltd
ABN 45 064 945 848
This water heater must be installed and serviced by an authorised person.
Please leave this guide with the householder.
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CONTENTS
HOUSEHOLDER – We recommend you read pages 5 to 16.
The other pages are intended for the installer but may be of interest.
About Your Water Heater............................................................................................. 5
How Your Water Heater Works.................................................................................. 10
Regular Care ............................................................................................................... 12
Save A Service Call .................................................................................................... 13
Installation – Solar Storage Tank.............................................................................. 17
Installation – Solar Collectors ................................................................................... 26
Connections – Plumbing............................................................................................ 29
Connections – Electrical............................................................................................ 33
Commissioning........................................................................................................... 35
Draining The Water Heater......................................................................................... 51
Water Supplies............................................................................................................ 52
Warranty ...................................................................................................................... 53
Solahart Offices .......................................................................................................... 56
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INTRODUCTION
Congratulations on choosing a “STREAMLINE CLOSED CIRCUIT GAS BOOSTED” solar water heater.
We are confident that your purchase will provide you many years of trouble free hot water.
All over the world, the Solahart name is synonymous with quality in water heating. From humble
beginnings in the pioneering days of Western Australia, a reputation has been built up over nearly a
century.
In 1905, two enterprising plumbers formed the company known as S. W. Hart, a name that was
retained for over 70 years. Even in its early stages, S. W. Hart was involved in the manufacture of metal
products for water storage and water heating. Since 1953, S. W. Hart, now Solahart Industries Pty Ltd,
has been producing thermosyphon solar hot water systems, which is well over 40 years of hot water
experience.
Solahart is the market leader in Australia and a dominant brand throughout the world. Our network of
distributors covers over 70 countries in Europe, North America, Africa and Asia. In our home market of
Australia, we offer the widest range of thermosyphon solar water heater products, and we are now
releasing the “STREAMLINE CLOSED CIRCUIT GAS BOOSTED” active solar hot water system. Our
product is positioned within the hot water market as a reliable, durable product with state of the art
manufacturing technology.
It is with the above in mind that we at Solahart Industries Pty Ltd are confident that your purchase of the
“STREAMLINE CLOSED CIRCUIT GAS BOOSTED” solar water heater will provide you reliable hot
water with quality after sales service back up.
Thankyou
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ABOUT YOUR WATER HEATER
MODEL TYPE
Congratulations for choosing a Solahart® water heater. Your Solahart Streamline closed circuit solar
water heater is designed for the solar collectors to be roof mounted and the solar storage tank to be
installed at ground or floor level. The solar storage tank is suitable for outdoor installation only and with
either Solahart ‘J’ or ‘KF’ solar collectors. The system is suitable for installation in areas subject to frost
or freeze conditions. Freeze conditions occur below 6°C.
HOW HOT SHOULD THE WATER BE?
The solar control unit will circulate the closed circuit fluid through
typical maximum
temperature from solar
the solar collectors until a temperature of approximately 75°C is
reached in the solar storage tank. During periods of low solar
gain
energy gain, the gas booster will boost the water temperature
automatically to a minimum 60°C when required.
booster setting and
minimum recommended
Note: The preset outlet booster temperature setting of the gas
stored water temperature
booster cannot be adjusted by the householder. The setting can
only be adjusted by your nearest Solahart Dealer. The preset
outlet booster temperature setting of the gas booster is 60°C.
maximum recommended
supply temperature to
bathrooms and ensuites
To meet the requirements of the National Plumbing Standard the
temperature setting must not be below 60°C.
Warning: Temperature controllers must not be fitted to this
water heater as part of a solar water heater system because
water at a temperature much higher than the controller setting
can be delivered.
HOTTER WATER INCREASES THE RISK OF SCALD INJURY
This water heater can deliver water at temperatures which can cause scalding. Check the water
temperature before use, such as when entering a shower or filling a bath or basin, to ensure it is
suitable for the application and will not cause scald injury.
We recommend and it may also be required by regulations that an approved temperature limiting
device be fitted into the hot water pipe work to the bathroom and ensuite when this water heater is
installed. This will keep the water temperature below 50°C at the bathroom and ensuite. The risk of
scald injury will be reduced and still allow hotter water to the kitchen and laundry.
This water heater has two outlets. One is a hot water outlet and the other is a tempered water outlet.
The purpose of the hot water outlet is to deliver hot water at between 60°C and 75°C, usually for
kitchen and laundry use. The purpose of the tempered water outlet is to deliver water up to 50°C,
usually for bathroom or ensuite use.
WARNING
This water heater is not intended to be operated, adjusted or tampered with by young children or infirm
persons. Young children should be supervised to ensure they do not interfere with the water heater.
The water heater uses 240 V AC electrical power for operation of the control systems and the
electrically operated components. The removal of the front covers will expose 240 V wiring. They must
only be removed by an authorised or qualified person.
The power lead from the water heater must be plugged into a weatherproof electrical outlet. Take care
not to touch the power plug with wet hands.
Care should be taken not to touch the pipe work connecting the solar storage tank and the solar
collectors. Very high temperature closed circuit fluid can be generated by the solar collectors under
certain conditions and flow through the pipe work from the solar collectors to the solar storage tank.
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ABOUT YOUR WATER HEATER
SAFETY
This water heater is supplied with temperature sensors, a FlameSafe™ protection system, pressure
relief valves and a combination temperature pressure relief valve. These devices must not be tampered
with or removed. The water heater must not be operated unless each of these devices is fitted and is in
working order.
If the power supply cord or plug to the solar storage tank is damaged, it must be replaced by an
authorised person in order to avoid a hazard. The power supply cord and plug must be replaced with a
genuine replacement part available from Solahart. Phone your nearest Solahart Dealer to arrange for
an inspection.
The warranty can become void if relief valves or other safety devices are tampered with or if the
installation is not in accordance with these instructions.
•
Do not store flammable or combustible materials near the
water heater. Flammable liquids (such as petrol),
newspapers and similar articles must be kept well away
from the water heater and the flue terminal.
•
Do not use aerosols, stain removers and household
chemicals near the water heater whilst it is working. Gases
from some aerosol sprays, stain removers and household
chemicals become corrosive when drawn into a flame.
•
•
Do not store swimming pool chemicals, household
cleaners, etc., near the water heater.
Do not place anything on top of the water heater or in
contact with the flue terminal. Ensure the flue terminal is not
obstructed in any way at any time.
•
Do not use Propane / Butane gas mixtures in a Propane model. A Propane model is designed to
operate on Propane only. The use of Propane / Butane mixture, such as automotive LPG fuel, in a
Propane model is unsafe and can cause damage to the water heater.
TO TURN OFF THE WATER HEATER
If you plan to be away from home for a few nights, we suggest you leave the water heater switched on.
If it is necessary to turn off the water heater:
•
Switch off the electrical supply at the power outlet to the solar storage tank if there is no risk of
freezing conditions occurring (refer to note below).
•
•
Close the gas isolation valve at the inlet to the water heater.
Close the cold water isolation valve at the inlet to the water heater.
Note: If there is a risk of freezing conditions, the electrical supply to the water heater should not be
switched off unless the gas booster is drained, otherwise damage could result (refer to “Freeze
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ABOUT YOUR WATER HEATER
TO TURN ON THE WATER HEATER
•
Screw in the drain plugs at the cold water inlet and hot water outlet of the gas booster if the gas
booster has been drained.
•
•
Open the cold water isolation valve fully at the inlet to the water heater.
Open all of the hot water taps in the house (don’t forget the shower).
Air will be forced out of the taps.
•
•
•
Close each tap as water flows freely from it.
Open the gas isolation valve fully at the inlet to the water heater.
Plug in the water heater at the power outlet and switch on the electrical supply.
The power outlet must be switched on for the solar controls to operate and solar gain to be
achieved and for the gas booster to operate.
The gas booster will operate automatically when you open a hot tap, if boosting is required.
HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY?
person and the installation must comply with National Standards AS/NZS 3500.4, AS 5601,
AS/NZS 3000 and all local codes and regulatory authority requirements. In New Zealand, the
installation must conform with the New Zealand Building Code.
on page 5).
PIPE WORK AND INSULATION
The solar hot and solar cold pipe work between the solar storage tank and the solar collectors
MUST BE of copper and fully insulated with closed cell polymer insulation or similar (minimum
thickness 13 mm). The insulation must be weatherproof and UV resistant if exposed. The insulation will
offer corrosion protection to a metal roof against water runoff over the copper pipe, assist in avoiding
accidental contact with the solar pipe work and also reduce pipe heat losses.
The insulation must be fitted up to the connections on both the solar collectors and the solar storage
tank, as very high temperature closed circuit fluid can flow from the solar collectors to the solar storage
tank under certain conditions.
There must be a continuous fall in the pipe work from the solar collectors to the solar storage tank. The
continuous fall is essential to assist in the drain back function of the solar system.
Plastic pipe MUST NOT be used, as it will not withstand the temperature of the closed circuit fluid
RAIN WATER TANK
If the solar collectors and solar pipe work are installed on a section of roof which is part of a rain water
runoff collection system, then it is recommended this section of roof and its gutter be isolated from the
rain water collection system. The gutter should be isolated to a width greater than the solar collectors
and pipe work and must have suitable drainage. This is to ensure in the event of a leak from the solar
collectors or pipe work, a rainwater tank cannot be contaminated with closed circuit fluid.
The closed circuit fluid contains food grade additives (rust inhibitor and anti-freeze agent), is non-toxic
and is harmless to the environment. However, if it enters a rain water tank, it can kill off microscopic
algae which are typically present in the water causing an unpleasant odour to develop and resulting in
the rain water tank having to be drained and cleaned.
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ABOUT YOUR WATER HEATER
DOES THE WATER QUALITY AFFECT THE WATER HEATER?
The water heater is suitable for most public water supplies, however some water qualities may have
detrimental effects on the cylinder, gas booster heat exchanger and fittings. If you are in a known
HOW LONG WILL THE WATER HEATER LAST?
There are a number of factors that will affect the length of service the water heater will provide. These
include the water quality, the water pressure, temperature (inlet and outlet) and the water usage
pattern. However, your Solahart water heater is supported by a comprehensive warranty (refer to
ANODE PROTECTION
The anode(s) installed in your water heater will slowly dissipate whilst protecting the cylinder. The life of
the water heater cylinder may be extended by arranging for an authorised person to inspect the
anode(s) and replace if required.
The suggested time after installation when the anode(s) should be inspected is 8 years.
For softened water supplies or in areas of poor water quality, it is recommended the anode(s) be
FREEZE PROTECTION
Solar Circuit
The solar circuit must be installed with a continuous fall in the pipe work from the solar collectors to the
solar storage tank, the solar hot and solar cold pipes must be fully insulated with closed cell polymer
insulation (minimum thickness 13 mm) and the system charged with correctly mixed closed circuit fluid
to offer protection against freeze damage. The system has NO WARRANTY for freeze damage if there
is not a continuous fall in the solar hot and solar cold pipes, or they are uninsulated, or the closed circuit
The anti freeze control of the solar circuit is designed so there is no closed circuit fluid in the solar
collectors or solar cold and solar hot pipes when the pump is off.
Gas Booster Water Heater
The gas booster has a frost protection system. The frost protection system will protect the gas booster
from damage, by preventing ice forming in the waterways of the gas booster, in the event of freezing
conditions occurring.
Notes:
•
The gas booster frost protection system will be rendered inoperable if electrical power is not
available at the water heater. Damage caused by freezing due to the unavailability of power at the
water heater is not covered by warranty (refer to “Warranty Exclusions” on page 53).
•
If it is necessary to switch the power off to the water heater and there is a risk of freezing, then it is
necessary to drain the gas booster (refer to “Draining the Gas Booster Water Heater” on page 9).
•
•
Pipe work to and from the water heater must be adequately insulated to prevent freezing.
The water heater is not suitable for installation in areas where the ambient temperature falls below -
20ºC (including wind chill factor).
•
Refer to “Warranty Exclusions” on page 53.
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ABOUT YOUR WATER HEATER
DRAINING THE GAS BOOSTER WATER HEATER
•
•
•
Open a hot tap (preferably the shower outlet).
Unscrew the two drain plugs, one each at the cold water inlet and hot water outlet, on the
underside of the water heater.
Water will drain from the water heater.
•
When water stops flowing from the water heater, close the hot tap.
Note: It is recommended not to screw the drain plugs back in, until the water heater is to be turned on
again.
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HOW YOUR WATER HEATER WORKS
SOLAR OPERATION
The Solahart Streamline closed circuit solar water heater has its vitreous enamel lined solar storage
tank installed at ground or floor level, remotely from the solar collectors. This water heater is an indirect
solar hot water system with a heat exchanger in the solar storage tank. The heat exchanger is filled with
closed circuit fluid and is connected to the solar collectors forming a closed circuit.
As the sun heats the solar collectors, the increase in temperature activates the pump. The pump
switches on whenever the solar collectors are hotter than the water in the tank. The pump moves the
closed circuit fluid from the solar storage tank heat exchanger through an insulated copper pipe to the
solar collectors to be heated by the sun’s energy and then back to the heat exchanger. Heat transfers
from the closed circuit fluid in the heat exchanger to the water stored in the solar storage tank.
This process continues while solar energy is available and until the water in the solar storage tank
reaches a temperature of approximately 75°C. The pump is then deactivated and the closed circuit fluid
in the solar collectors and solar pipe work drains back into the heat exchanger in the solar storage tank.
The closed circuit provides protection to the solar collectors and solar circuit in harsh water areas. The
drain back principle provides protection to the system in freezing conditions.
Automatic safety controls are fitted to the water heater to provide safe and efficient operation.
GAS BOOSTING OPERATION
Water stored in the solar storage tank passes through the gas
booster when a hot tap is opened. The gas booster is for heating
the water at times of low solar energy gain, such as during cloudy
or rainy weather, or during winter months.
Solar heated water can reach temperatures up to 75°C in the solar
storage tank. When the solar heated water temperature is above
58°C, the gas booster will not boost the water temperature.
The gas booster operates automatically if heating of the water is
required. When the solar heated water temperature is below 58°C,
the gas burners ignite to provide immediate heating of the water to
a minimum temperature of 60°C. The heat produced by the burner
is transferred to the water through the heat exchanger. The water is
heated to a constant temperature by the automatic adjustment of
the gas supply to the burner to suit the water flow rate. The gas
burners extinguish when the hot tap is closed.
Automatic safety controls are fitted to the water heater to provide safe and efficient operation.
WATER OUTLET TEMPERATURE
This water heater has two outlets. One is a hot water outlet and the other is a tempered water outlet.
The purpose of the hot water outlet is to deliver hot water at between 60°C and 75°C, usually for
kitchen and laundry use. The purpose of the tempered water outlet is to deliver water up to 50°C,
usually for bathroom or ensuite use.
The tempered water outlet is from the tempering valve, located under the pipe cover at the front of the
water heater immediately below the gas booster. The tempering valve is the brass valve with a green
plastic cap. The tempering valve mixes hot water from the solar storage tank and gas booster with cold
water from the mains supply and delivers tempered water from its outlet.
The hot water outlet is located above the tempering valve. Depending upon how the water heater was
installed, either both or only one of these outlets may have been plumbed to the hot water pipe work in
the premises.
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HOW YOUR WATER HEATER WORKS
MAINS PRESSURE
The water heater is designed to operate at mains pressure by connecting directly to the mains water
supply. If the mains supply pressure in your area exceeds that shown on page 19, a pressure limiting
valve must be fitted. The supply pressure should be greater than 350 kPa for true mains pressure
operation to be achieved. The supply pressure should be greater than 140 kPa for the rated flow and
performance of the gas booster to be achieved.
GOING ON HOLIDAYS
It is not necessary to switch off the electrical supply at the power outlet to the water heater if you are
going away. However, if it is necessary to switch off the power to the water heater, refer to “To Turn Off
The Water Heater” on page 6. If the power to the water heater is switched off and there is a risk of
freezing, then it is necessary to drain the gas booster (refer to “Draining the Gas Booster Water Heater”
on page 9)
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REGULAR CARE
TEMPERATURE PRESSURE RELIEF VALVE
This valve is near the top of the water heater and is essential for its safe operation. It is possible for the
valve to release a little water through the drain line during each heating period. This occurs as the water
is heated and expands by approximately 1/50 of its volume.
Continuous leakage of water from the valve and its drain line may indicate a problem with the water
WARNING: Never block the outlet of this valve or its drain line for any reason.
Operate the easing lever on the temperature pressure relief
valve once every six months. It is very important you raise
and lower the lever gently.
WARNING: Failure to do this may result in the water heater
cylinder failing.
If water does not flow freely from the drain line when the lever is
lifted, then the water heater should be checked by your nearest
Solahart Dealer.
The temperature pressure relief valve should be checked for
performance or replaced at intervals not exceeding 5 years, or
more frequently in areas where there is a high incidence of water
EXPANSION CONTROL VALVE
In many areas, including South Australia, Western Australia and
scaling water areas, an expansion control valve is fitted to the
cold water line to the water heater. Water will flow from its drain
line during the heating period.
water
heater
Operate the easing lever on the expansion control valve once
every six months. It is very important you raise and lower the
lever gently. The expansion control valve should be checked for
performance or replaced at intervals not exceeding 5 years, or
more frequently in areas where there is a high incidence of water
deposits.
lift until water
flows from the
drain line –
drain
line
lower gently
COLLECTOR GLASS
Ensure the glass on your solar collectors is free of dust, salt spray or any other matter, which may
reduce the effectiveness of the solar collectors. If the collector glass becomes dirty, hose down or if the
solar collectors are accessible, wash the collector glass with water and a soft brush when the solar
collectors are cool. Have any trees trimmed which may shade the solar collectors.
GENERAL MAINTENANCE
The jacket of the water heater can be cleaned with a soft cloth and warm mild soapy water. Under no
circumstances should abrasive materials or powders be used.
SERVICING
For safe and efficient operation, the water heater should be serviced annually by your nearest Solahart
Dealer. Only genuine replacement parts should be used on this water heater.
Warning: Servicing of the water heater should only be carried out by authorised personnel.
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SAVE A SERVICE CALL
Check the items below before making a service call. You will be charged for attending to any condition
or fault that is not related to manufacture or failure of a part.
COLD WATER FROM THE HOT TAP
•
•
Close the hot tap, wait 10 seconds and open the hot tap again.
Is the hot tap open enough? The gas booster burners will not light if the flow rate is less than
3.0 L / min.
•
•
Solar control unit and gas booster not operating
ƒ
Check the power supply cord is plugged in and the
power outlet switched on.
ƒ
Is power available in the house? Try using another
electrical appliance.
Gas supply
ƒ
ƒ
Is the isolation valve in the gas line open?
Is there a gas supply to the rest of the house? Try
lighting another gas appliance.
ƒ
Has the gas line been purged of air after installation?
Refer to your plumber.
NO WATER FROM THE HOT TAP
No flow of water from the hot tap may indicate a restriction in or failure of the cold water supply to the
water heater. Check for water flow at other taps and that the cold water isolation valve (refer to
GAS BOOSTER OPERATING TOO FREQUENTLY
You may find that the gas booster operates more frequently than expected. This will occur when the
solar preheat water temperature is lower than 58°C, which may be experienced during periods of low
solar energy gain or if there has been heavy hot water usage. Factors to consider are:
•
Insufficient sunlight
Insufficient sunlight due to cloudy weather during summer months or low solar energy contribution
in winter months may mean the gas booster operates more often.
•
Collectors shaded
If trees or other objects shade the solar collectors or if the glass is dirty, the effectiveness of the
solar collectors will be greatly reduced. Have the trees trimmed or the solar collectors relocated if
•
Collector area is too small
For most installations, the number of solar collectors recommended in Solahart literature has been
proven to provide the required solar energy to meet the average family needs. However, in some
circumstances, it may be necessary to install an additional solar collector.
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SAVE A SERVICE CALL
•
Are you using more hot water than you think?
Is one outlet (especially the shower) using more hot water than you think?
Very often it is not realised the amount of hot water used, particularly when showering. Carefully
review the family’s hot water usage. As you have installed an energy saving appliance, energy
saving should also be practised in the home. Adjust your water usage pattern to take advantage of
maximum solar gains.
Have your plumber install a flow control valve to each shower outlet, basin and sink to reduce water
usage.
•
•
Temperature pressure relief valve running
Is the relief valve discharging too much water? (Refer to “Temperature Pressure Relief Valve
Water heater size
Do you have the correct size water heater for your requirements? The sizing guide in the sales
needed.
WATER FLOW FLUCTUATES
More than one or two hot taps in use at the same time may cause a decrease in the hot water flow from
the taps.
•
•
Is there more than one or two hot taps open, or are appliances such as a dishwasher or washing
machine, in use at the same time?
Ensure only one or two hot taps (or appliance) are on at the one time.
Check the flow of the water from one tap, eg, the shower.
The shower should be adjusted so the hot tap is fully open.
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SAVE A SERVICE CALL
TEMPERATURE PRESSURE RELIEF VALVE RUNNING
•
•
•
Normal Operation
It is normal and desirable this valve allows a small quantity
of water to escape during the heating cycle. However, if it
discharges more than a bucket full of water in 24 hours,
there may be another problem.
Continuous dribble
Try gently raising the easing lever on the relief valve for a
few seconds (refer to “Temperature Pressure Relief Valve”
matter and clear the fault. Release the lever gently.
Steady flows for long period (often at night)
This may indicate the mains water pressure sometimes rises
above the designed pressure of the water heater. Ask your
installing plumber to fit a pressure limiting valve.
NEVER replace the relief valve with one of a higher pressure rating.
•
Heavy flows of hot water until the water heater is cold - then stops until water reheats
The water heater must be switched off at the isolating switch or switchboard. Phone your nearest
Solahart Dealer to arrange for an inspection.
EXPANSION CONTROL VALVE RUNNING
If an expansion control valve is fitted in the cold water line to the water heater (refer to page 29) it may
discharge a small quantity of water instead of the temperature pressure relief valve on the water heater.
The benefit is that energy is conserved as the discharged water is cooler.
PRESSURE RELIEF VALVE DISCHARGING
A pressure relief valve is incorporated into the gas booster controls. This valve protects the gas
booster, by allowing water to escape, in the event of excessive pressure build up in the waterways.
•
•
Normal operation
A small volume of water may discharge from the bottom of the gas booster when a hot tap is
suddenly closed.
Continuous dribble
A continuous dribble may indicate the water supply pressure is above the design pressure for the
gas booster. If so, a pressure limiting valve must be installed on the cold water supply pipe to the
FAN CONTINUES TO RUN AFTER WATER HEATER OPERATION STOPS
It is the normal operation of the gas booster for the fan to continue running after heating of the water is
finished. The fan may run for up to six minutes after the burners extinguish, to prepare for the next
ignition.
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SAVE A SERVICE CALL
CLOUDS OF WHITE ‘VAPOUR’ FROM THE FLUE TERMINAL
During the heating cycle, it is not unusual to see water vapour
clouds steaming from the flue terminal, particularly on cold days.
This is normal operation of the gas booster.
ERROR CODE
The water heater provides a diagnostic error code in the event of
an interruption to its operation. The error code is displayed on
the front of the water heater on the OK MONITOR. If an error
code appears:
•
Close the hot tap and switch off the electrical supply to the
water heater.
•
Wait 5 minutes, then switch on the electrical supply to the
water heater and open a hot tap.
If the error code persists, take note of the code and turn off the
hot tap. Phone your nearest Solahart Dealer to arrange for
inspection.
HIGH GAS BILLS
With the installation of your new solar hot water system, maximum gas energy savings can be achieved
with careful planning of hot water usage. Should you at any time, feel your gas account is too high, we
suggest you check the following points:
•
page 15).
•
Is one outlet (especially the shower) using more hot water
than you think? (Refer to “Gas Booster Operating Too
Frequently” on page 13).
•
Is there a leaking hot water pipe, dripping hot water tap, etc?
Even a small leak will waste a surprising quantity of hot
water and energy. Replace faulty tap washers, and have
your plumber rectify any leaking pipe work.
•
•
Is the gas booster operating too frequently? (Refer to “Gas
Booster Operating Too Frequently” on page 13).
Consider recent changes to your hot water usage pattern
and check if there has been any increase in tariffs since
your previous account.
COLLECTOR GLASS
Warranty DOES NOT cover breakage of solar collector glass. Check your household insurance policy
covers collector glass breakage.
Warning: Collector glass must not be replaced whilst the solar collector is on the roof.
The collector glass is not offered as a replacement part and no attempt should be made to remove it.
Should the solar collector require replacement, contact your nearest Solahart Dealer.
IF YOU HAVE CHECKED ALL THE FOREGOING AND STILL BELIEVE YOU NEED ASSISTANCE,
CALL YOUR NEAREST SOLAHART DEALER.
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INSTALLATION – SOLAR STORAGE TANK
THIS WATER HEATER IS FOR OUTDOOR INSTALLATION ONLY.
THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING.
Check the water heater is suitable for the gas type available.
(refer to the rating label on the water heater)
The system is suitable for installation with Solahart ‘J’ or ‘KF’ solar collectors.
The solar circuit must be installed with a continuous fall of a minimum 5° in the pipe work from the solar
collectors to the solar storage tank, the solar hot and solar cold pipes must be fully insulated with closed
cell polymer insulation (minimum thickness 13 mm) and the system charged with correctly mixed closed
circuit fluid to offer protection against freeze damage. The system has NO WARRANTY for freeze
damage if there is not a continuous fall in the solar hot and solar cold pipes or they are uninsulated or
SOLAR WATER HEATER STORAGE TANK LOCATION
The solar storage tank is suitable for outdoor installation only. The solar storage tank should be
installed close to the most frequently used outlet and its position chosen with safety and service in
mind. Make sure people (particularly children) will not touch the flue terminal. The flue terminal and air
inlet must be clear of obstructions and shrubbery.
Consideration must also be given to the position of the solar storage tank in relation to the solar
collectors. There are limitations on both the maximum length of the solar hot and solar cold pipes and
the maximum height between the solar storage tank and the solar collectors. Refer to “Solar Collector
Clearance must be allowed for servicing of the solar
storage tank and gas booster. The solar storage tank
must be accessible without the use of a ladder or
scaffold. Make sure the temperature pressure relief
valve lever is accessible and the front panel and front
covers can be removed for service.
You must be able to read the information on the rating
plate. If possible leave headroom of one water heater
length so the anode can be inspected or replaced.
Remember you may have to remove the entire solar
storage tank later for servicing.
The installation must comply with these installation
instructions
and
with
the
requirements
of
AS/NZS 3500.4, AS 5601, AS/NZS 3000 and all local
codes and regulatory authority requirements. In New
Zealand, the installation must conform with the New
Zealand Building Code.
The water heater must not be installed in an area with a corrosive atmosphere where chemicals are
stored or where aerosol propellants are released. Remember the air may be safe to breathe, but when
it goes through a flame, chemical changes take place which may attack the water heater.
It is recommended the solar storage tank be installed at ground or floor level and must stand vertically
upright.
Note: It is important for the solar storage tank to be orientated vertically upright in order for the falling
film of closed circuit fluid to operate efficiently.
A secondary flue is not required. The water heater must not be installed indoors or in a confined space.
17
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INSTALLATION – SOLAR STORAGE TANK
The top of the solar storage tank must be a minimum of 500 mm below the bottom of the solar
collectors for the system to operate correctly.
As a guide the following requirements extracted from the Australian Gas Installations Standard
AS 5601, must be observed.
•
At least 300 mm between the top of the gas booster and the
eaves.
•
At least 300 mm between the gas booster and the edge of
any opening into the building, measured horizontally along
the wall.
•
At least 300 mm between the gas booster and a return wall
or external corner, measured horizontally along the wall.
•
•
At least 1500 mm below any openable window.
At least 1500 mm between the gas booster and any opening
into a building, in the direction of the flue discharge.
•
At least 500 mm between the gas booster and a fence, wall or other obstruction, in the direction of
the flue discharge.
The water heater can be turned through 90°, either to the left or to the right, with the discharge from the
flue terminal discharging parallel to the wall. It is important the distance requirements from the
Australian Gas Installations Standard AS 5601 are observed.
FROST PROTECTION
The water heater has a frost protection system. The frost protection system will protect the water heater
from damage, by preventing ice forming in the waterways of the water heater, in the event of freezing
conditions occurring.
The solar collectors and solar cold and solar hot pipes only contain closed circuit fluid when the pump is
operating during periods of solar gain when heating is required. When the solar pump stops operating,
the closed circuit fluid drains back into the storage tank heat exchanger. The closed circuit fluid is an
anti-freeze agent which, when mixed to the correct specification, can withstand temperatures of -17°C
before it may freeze.
The frost protection system to the gas booster will be rendered inoperable if electrical power is not
available at the water heater. Damage to the water heater caused by freezing of the pipe work to or
from the water heater is not covered under warranty. Refer to AS/NZS 3500.4 for precautions to be
taken for installations in frost prone areas. The water heater is not suitable for installation in areas
where the ambient temperature falls below -20ºC (including wind chill factor).
18
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INSTALLATION – SOLAR STORAGE TANK
MAINS WATER SUPPLY
Where the mains water supply pressure exceeds that shown in the table below, an approved pressure
limiting valve is required and should be fitted as shown in the installation diagram (refer to diagram on
Model
270
Relief valve setting
1000 kPa
850 kPa
Expansion control valve setting *
Max. mains supply pressure
With expansion control valve
Without expansion control valve
Min. mains supply pressure
680 kPa
800 kPa
140 kPa
* Expansion control valve not supplied with the water heater.
TANK WATER SUPPLY
If the water heater is supplied with water from a tank supply, then a pressure pump system is
recommended to ensure a minimum water pressure of 140 kPa is achieved to allow the gas booster to
operate. Take care to avoid air locks.
Notes:
•
•
It is not recommended to install this water heater with a low pressure water supply.
This water heater is not suitable for connection to bore water or spring water unless a water
treatment device is fitted.
•
•
If sludge or foreign matter is present in the water supply, it is recommended a suitable filter be
incorporated in the cold water line to the water heater.
Refer to “Water Supplies” on page 52.
19
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INSTALLATION – SOLAR STORAGE TANK
RAIN WATER TANK
If the solar collectors and solar pipe work are to be installed on a section of roof which is part of a rain
water runoff collection system, then it is recommended this section of roof and its gutter be isolated
from the rain water collection system. The gutter should be isolated to a width greater than the solar
collectors and pipe work and must have suitable drainage. The installer should ensure in the event of a
leak from the solar collectors or pipe work, a rainwater tank cannot be contaminated with closed circuit
fluid.
The section of roof and gutter should be isolated from the rainwater collection system before the
commissioning of the solar water heater, so that any leak or spillage during commissioning does not
make its way into the rainwater tank.
This section of roof and guttering can be isolated by either:
•
blocking this section of gutter from the remaining gutter and fitting two separate down pipes, one to
take any run-off water from that section of roof away to waste and the other to the rainwater
collection side of the gutter to take the rain water run off to the rain water tank.
•
blocking this section of gutter from the remaining gutter and fitting a tube or pipe of a material
compatible with the gutter material in this section of the gutter and penetrating the separation
pieces at either end to allow rainwater runoff to pass from one part of the rainwater collection
system to the other. It may be necessary to fit a down pipe to the section of blocked gutter to take
any run-off water from that section of roof away to drain.
•
•
installing a false gutter inside of the existing gutter, with a down pipe penetrating the existing gutter
to take any run-off water from that section of roof away to waste. The false gutter should be no
deeper than half of the depth of the existing gutter, so as to enable rain water run off to flow under
the false gutter.
installing a flashing from the underside of the roofing material, with a continuous fall, to over the
outside lip of the gutter. The flashing should extend wider than the collectors and pipe work and
turned up at the ends so if there is leakage of closed circuit fluid, it cannot enter the gutter.
If any of these solutions are not practical, then the installer should discuss alternative options to suit the
installation with the house holder.
Any alterations to the roof drainage system must comply with the relevant building regulations, codes
and standards.
20
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INSTALLATION – SOLAR STORAGE TANK
HOT WATER DELIVERY
This water heater can deliver water at temperatures which can cause scalding. This water heater has
both a hot water outlet connection and a tempered water outlet connection. The temperature of the
water from the hot water outlet can be up to 75°C and the water from the tempered water outlet can be
up to 50°C.
The delivery water temperature requirements of AS/NZS 3500.4 allow water in excess of 50°C to be
delivered to fixtures not used primarily for ablution purposes, such as in a kitchen or laundry. These
types of fixtures can be supplied from the hot water outlet of this water heater.
It is necessary and we recommend that a tempered water line, from the outlet connection of the
temperature limiting device, be fitted between the water heater and the hot water outlets in any ablution
area such as a bathroom or ensuite, to reduce the risk of scalding. The installing plumber may have a
legal obligation to ensure the installation of this water heater meets the delivery water temperature
requirements of AS/NZS 3500.4 so that scalding water temperatures are not delivered to a bathroom,
ensuite or other ablution area.
The tempered water outlet from this water heater will not deliver temperatures exceeding 50°C, in
accordance with AS 4032.2 There is no statutory requirement to fit a supplementary temperature
limiting device if this water heater is installed in other than an early childhood centre, school, nursing
home or a facility for young, aged, sick or disabled people.
Where another temperature limiting device is installed adjacent to the water heater, the cold water line
to the temperature limiting device can be branched off the cold water line either before or after the
isolation valve, pressure limiting valve and non return valve to the water heater. If an expansion control
valve is required, it must always be installed after the non return valve and be the last valve prior to the
water heater. The hot water line to this temperature limiting device must be taken from the hot water
outlet connection of the water heater and not from the tempered water outlet connection of the water
heater.
If a pressure limiting valve is installed on the cold water line to the water heater and the cold water line
to another temperature limiting device branches off before this valve or from another cold water line in
the premises, then a pressure limiting valve of an equal pressure setting may be required prior to the
temperature limiting device.
Two Temperature Zones
Using Temperature Limiting Device Integrated with Water Heater
21
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INSTALLATION – SOLAR STORAGE TANK
CIRCULATED HOT WATER FLOW AND RETURN SYSTEM
A solar water heater should not be installed as part of a circulated hot water flow and return system in a
building. The benefits of solar gain will be significantly reduced and energy gained from the sun lost
through the pipe work.
If a circulated flow and return system is required, it is necessary to bypass the solar water heater and
install a secondary water heater connected to the hot water flow and return line and supplied from the
solar water heater. The secondary water heater must be a storage water heater able to provide a hot
water outlet temperature of at least 60°C. Note: The thermostat must always be set to at least 60°C.
Temperature Limiting Device
A temperature limiting device cannot be installed in circulated hot water flow and return pipe work. The
tempered water supplied from the tempered hot water outlet on this water heater or from another
temperature limiting device cannot be circulated.
Where a circulated hot water flow and return system is required in a building, a temperature limiting
device can only be installed on a dead leg, branching off the circulated hot water flow and return pipe or
a dead leg installed from the tempered water outlet of this water heater.
If circulated tempered water were to be returned back to the water heater, depending on the location of
the return line connection on the water supply line to the water heater, then either:
•
water will be supplied to the cold water inlet of the temperature limiting device at a temperature
exceeding the maximum recommended water supply temperature, or
•
when the hot taps are closed no water will be supplied to the cold water inlet of the temperature
limiting device whilst hot water will continue to be supplied to the hot water inlet of the temperature
limiting device.
These conditions may result in either water at a temperature exceeding the requirements of
AS/NZS 3500.4 being delivered to the hot water outlets in the ablution areas, or the device closing
completely and not delivering water at all, or the device failing. Under either condition, the operation
and performance of the device cannot be guaranteed.
Circulated Hot Water Flow and Return System – Solar Water Heater
22
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INSTALLATION – SOLAR STORAGE TANK
REDUCING HEAT LOSSES
The cold water line to and the tempered water and hot water lines from the water heater must be
insulated in accordance with the requirements of AS/NZS 3500.4. The insulation must be weatherproof
and UV resistant if exposed.
The pipe work between the solar storage tank and the solar collectors must be insulated in accordance
with the requirements of AS/NZS 3500.4. The insulation must be weatherproof and UV resistant if
exposed. The insulation must be fitted up to the connections on both the solar storage tank and the
solar collectors.
ANODE TYPES
The correct anode type for the water supply being used must be fitted in the water heater (refer to
Total Dissolved Solids in water supply to the water heater
Anode colour code
0 – 40 mg/L
40 – 600 mg/L
600 – 2500 mg/L
Green
Black
Blue
SADDLING - PIPE WORK
To prevent damage to the cylinder when attaching pipe clips or saddles to the water heater jacket, we
recommend the use of self-drilling screws with a maximum length of 12 mm. Should pre drilling be
required, extreme caution must be observed when penetrating the jacket of the water heater.
Note: Damage to the cylinder as a result of saddling to the jacket will void the warranty.
23
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INSTALLATION – SOLAR STORAGE TANK
DIMENSIONS AND TECHNICAL DATA
Model
DBV 270
Capacity
Delivery
270 litres
Mass
165 kg (empty)
435 kg (full)
Test Point
Gas Pressure (kPa)
Hourly Gas
Min. Gas
Max. Gas
Pressure
(kPa)
Gas Booster
Details
Gas Booster
Model
25°C rise Consumption Pressure
(litres / min)
(MJ)
(kPa)
minimum
0.17
maximum
0.91
Natural
271 026 NF
271 026 PF
26
26
199
199
1.13
2.75
3.50
3.50
Propane
0.22
1.20
Model numbers: N = Natural, P = Propane. Letter N or P is included in the model number, eg DBV 270 N5, to
denote gas type.
Specifications are subject to change with ongoing product improvements.
24
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INSTALLATION – SOLAR COLLECTORS
SOLAR COLLECTOR LOCATION
Consideration must be given to the position of the solar collectors in relation to the solar storage tank.
There are limitations on both the maximum length of the solar hot and solar cold pipes and the
maximum height between the solar storage tank and the solar collectors. Refer to “Solar Storage Tank
•
•
The solar collectors must be installed in a shade free position.
The solar collectors are to be installed facing toward
the equator (i.e. north facing in the southern
hemisphere and south facing in the northern
hemisphere). Where this orientation is not practical, a
system facing up to 45° from the equator will have its
efficiency reduced by approximately 5%.
•
Inclination of the solar collectors should be
approximately equal to 90% of the local latitude angle.
The latitudes of some Australian cities are listed on
angle for simplicity of installation and appearance, but
must never be less than 10°. If the roof angle varies
by 15° from the correct angle, efficiency will be
reduced by 10%.
•
For an installation on a roof with a pitch less than 10°,
a Variable Pitch stand is required. Refer to your local
Solar Distributor for details.
•
•
•
For an installation at right angles to (across) the roof pitch, a Flat Roof stand and an Across Pitch
stand are both required. Refer to your local Solar Distributor for details.
For an installation opposite to (against) the roof pitch, a Flat Roof stand and an Against Pitch stand
are both required. Refer to your local Solar Distributor for details.
The collector kit is suitable for installations with an inclination of up to 45°. Where the solar
collectors are installed at inclinations greater than 45°, a With Pitch frame is necessary. Refer to
your local Solar Distributor for details.
•
•
•
The roof must be suitable to take the mass of the solar collectors. Each solar collector and its
fittings weighs approximately 45 kg when full of water.
The installation must comply with the requirements of AS/NZS 3500.4 and all local codes and
regulatory authority requirements.
Refer to the installation instructions supplied with the collector kit for details on the installation of
the solar collectors.
LATITUDE OF SOME AUSTRALIAN CITIES
Adelaide
Cairns
Hobart
Port Hedland
Rockhampton
Sydney
35°S
24°S
27°S
31°S
17°S
35°S
12°S
28°S
42°S
34°S
38°S
32°S
20°S
24°S
34°S
19°S
Alice Springs
Brisbane
Canberra
Darwin
Mildura
Melbourne
Perth
Broken Hill
Geraldton
Townsville
26
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INSTALLATION – SOLAR COLLECTORS
PIPE LENGTHS
The solar hot and solar cold pipes between the solar storage tank and the solar collectors shall:
•
•
be of DN15 hard drawn copper pipe.
have a continuous fall from the solar collectors to the solar storage tank of a minimum 5° (1 in
10 grade).
•
not exceed the maximum recommended lengths as specified in the table.
Maximum recommended total combined pipe length and number of 90° bends
1 or 2 Collectors
3 Collectors
Pipe Size
Pipe Length
40 metres
Pipe Length
30 metres
90° Bends
90° Bends
DN15
20
20
For each additional 90° bend, reduce the maximum total pipe length by 0.5 metres.
For each additional metre of pipe length, reduce the number of 90° bends by two.
Note: One 90° elbow is equal to two 90° bends.
Notes:
•
•
It is important not to cross connect the solar cold and solar hot pipes to the incorrect connections.
The solar cold pipe connects to the bottom of the solar collectors and the solar hot pipe connects to
the top of the solar collectors diagonally opposite to the solar cold pipe connection.
•
•
The hot sensor connection is at the top of the solar collector, directly above the solar cold inlet
connection.
Refer to “Warning: Plumber – Be Aware” on page 28.
It is essential for these requirements to be followed for the system to operate correctly and efficiently.
Solar pipe work which is oversized, or does not have the correct fall, or is too long can result in the
drain back system not operating effectively.
Maximum Height To Collectors
The solar collectors must be the highest point of the system. The maximum height of the solar
installation, from the base of the solar storage tank to the top of the solar collectors, is 9 m. The pump
will not circulate closed circuit fluid through heights greater than 9 m and solar gain will not be achieved.
27
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INSTALLATION – SOLAR COLLECTORS
WARNING: Plumber – Be Aware
•
The solar hot and solar cold pipes between the solar storage tank and the solar collectors
MUST BE of copper and fully insulated with closed cell polymer insulation or similar (minimum
thickness 13 mm). The insulation must be weatherproof and UV resistant if exposed. All
compression fittings must use brass or copper olives.
The insulation will offer corrosion protection to a metal roof against water runoff over the copper
pipe, assist in avoiding accidental contact with the solar pipe work and also reduce pipe heat
losses.
•
•
The insulation must be fitted up to the connections on both the solar collectors and the
solar storage tank, as very high temperature closed circuit fluid can flow from the solar
collectors to the solar storage tank under certain conditions.
Plastic pipe MUST NOT be used, as it will not withstand the temperature of the closed circuit
fluid generated by the solar collectors under stagnation conditions. The solar collectors can
generate extremely high closed circuit fluid temperatures up to 150°C. Plastic pipe cannot
withstand these temperatures and MUST NOT be used. Failure of plastic pipe can lead to the
release of high temperature closed circuit fluid and cause severe water damage and flooding.
•
There must be a continuous fall in the pipe work between the solar collectors and solar
storage tank for efficient and effective drain back to occur. The highest point of the solar cold
pipe and solar hot pipe must be where they connect to the solar collectors.
28
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CONNECTIONS – PLUMBING
CONNECTION SIZES
•
•
•
•
•
•
•
Hot water connection: RP¾/20.
Cold water connection: RP¾/20.
Tempered water connection: RP¾/20
Solar hot (from collector) connection: DN15 compression fitting.
Solar cold (to collector) connection: DN15 compression fitting.
Temperature Pressure Relief valve connection: RP½/15.
Gas connection: R¾/20.
All plumbing work must be carried out by a qualified person and in accordance with the National
Plumbing Standard AS/NZS 3500.4 and local authority requirements.
All gas work must be carried out by a qualified person and in accordance with the Australian Gas
Installations Standard AS 5601 and local authority requirements.
It is necessary to remove the pipe cover from underneath the gas booster, by undoing the retaining
screws, in order to make the water and gas connections to the water heater. Refit the pipe cover at the
completion of the installation.
WATER INLET AND OUTLETS
All pipe work must be cleared of foreign matter before
connection and purged before attempting to operate the
water heater. All olive compression fittings must use
brass or copper olives. Use thread sealing tape or
approved thread sealant on all fittings.
An isolation valve and non return valve must be
installed on the cold water line to the water heater. Use
the arrangement shown in the diagram. Refer also to
arrangements for the cold water inlet, tempered water
and hot water outlets are shown on page 29. The solar
hot and solar cold pipe connections are shown on
A disconnection union must always be provided at the
cold water inlet, tempered water and hot water outlets
on the water heater to allow for disconnection of the
water heater. It is necessary to remove the brass plug
from the hot water outlet fitting if a hot water line is to
be installed. This plug can be used to plug the
hot water
outlet
tempered water outlet if a tempered water line is not
being installed. Refer to the diagram for the connection
points to the water heater.
tempered
water outlet
cold water
Insulation used on the tempered water and hot water
lines must extend up to the outlets of the water heater.
The valve and fittings must also be insulated up to the
hot water outlet of the gas booster.
inlet
29
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CONNECTIONS – PLUMBING
This solar storage tank has either a plastic dip tube or
fitting liner in the inlet and outlet fittings (see diagram).
These must be in place for the water heater to function
properly. Do not remove or damage them by using heat
nearby. They will be pushed into the correct position as
the fitting is screwed in.
PIPE SIZES
To achieve true mains pressure operation, the cold water line to the water heater should be the same
size or bigger than the tempered water and hot water lines from the water heater. The minimum
recommended tempered pipe and hot pipe sizes are DN20.
The pipe sizing for hot water supply systems should be carried out by persons competent to do so,
choosing the most suitable pipe size for each individual application. Reference to the technical
specifications of the water heater and local regulatory authority requirements must be made.
RELIEF VALVE
The temperature pressure relief valve is shipped behind the lower front cover of the water heater. The
temperature pressure relief valve must be fitted before the water heater is operated. Before fitting the
relief valve, make sure the probe has not been bent. Seal the thread with Teflon tape - never hemp.
Make sure the tape does not hang over the end of the thread.
Screw the valve into the correct opening (refer to the installation diagram on page 25) leaving the valve
outlet pointing downwards. Do not use a wrench on the valve body - use the spanner flats provided.
RELIEF VALVE DRAIN
Temperature Pressure Relief Valve
A copper drain line must be fitted to the relief valve to carry the discharge clear of the water heater.
Connect the drain line to the relief valve using a disconnection union. The pipe work from the relief
valve to the drain should be as short as possible and fall all the way from the water heater with no
restrictions. It should have no more than three right angle bends in it. Use DN15 pipe.
The outlet of the drain line must be in such a position that flow out of the pipe can be easily seen (refer
to AS/NZS 3500.4) - but arranged so hot water discharge will not cause injury, damage or nuisance.
The drain line must discharge at an outlet or air break not more than 9 metres from the relief valve.
In locations where water pipes are prone to freezing, the drain line must be insulated and not exceed
300 mm in length. In this instance, the drain line is to discharge into a tundish through an air gap of
between 75 mm and 150 mm.
Warning: As the function of the temperature pressure relief valve on this water heater is to
discharge high temperature water under certain conditions, it is strongly recommended the pipe work
downstream of the relief valve be capable of carrying water exceeding 93°C. Failure to observe this
precaution may result in damage to pipe work and property.
Solar Circuit Relief Valve
Ensure the outlet of the solar circuit relief valve is facing toward the rear of the water heater installation.
A copper drain line must be fitted to the relief valve to carry the discharge clear of the water heater.
Connect the drain line to the relief valve using a disconnection union. The pipe work from the relief
valve to the drain should be as short as possible and fall all the way from the water heater with no
restrictions. It should have no more than three right angle bends in it. Use DN10 pipe.
The outlet of the drain line must be in such a position that flow out of the pipe can be easily seen (refer
to AS/NZS 3500.4) - but arranged so hot water discharge will not cause injury, damage or nuisance.
The drain line must discharge at an outlet or air break not more than 9 metres from the relief valve.
30
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CONNECTIONS – PLUMBING
In locations where water pipes are prone to freezing, the drain line must be insulated and not exceed
300 mm in length. In this instance, the drain line is to discharge into a tundish through an air gap of
between 75 mm and 150 mm.
EXPANSION CONTROL VALVE
Local regulations may make it mandatory to install an expansion control valve (ECV) in the cold water
line to the water heater. In other areas, an ECV is not required unless the saturation index is greater
water area where there are sufficient quantities of silica dissolved in the water.
The expansion control valve must always be installed after the non return valve and be the last valve
separately from the drain of the relief valve.
GAS INLET
The gas connection is made at the underside of the gas
booster. The pipe work must be cleared of foreign
matter before connection and purged before attempting
to operate the water heater. An isolation valve and
disconnection union must be installed to allow servicing
AS 5601 for the correct pipe sizing.
Note: The pipe size selection must take into account
the high gas input of the gas booster (refer to table on
the premises.
Warning: Always isolate the gas booster before
pressure testing the gas supply system. Disconnect the
gas booster after the isolating cock to prevent the risk
of serious damage to the gas control. Warranty does
gas inlet
not cover damage of any nature resulting from failure to
observe this precaution. Refer to rating label for gas
types and pressures.
SOLAR INLET AND OUTLET
All pipe work must be cleared of foreign matter before connection and purged before attempting to
operate the water heater. All olive compression fittings must use brass or copper olives. Use thread
sealing tape or approved thread sealant on all fittings.
The solar cold outlet and solar hot inlet connections are located at the top of the solar storage tank.
Notes:
•
It is important not to cross connect the solar cold and solar hot pipes to the incorrect connections.
ƒ
The solar cold pipe connects to the bottom of the solar collectors and the solar hot pipe
connects to the top of the solar collectors on the opposite side to both the solar cold pipe
connection and the hot sensor connection.
ƒ
ƒ
The solar hot inlet connection is located in the centre of the top of the solar storage tank (the
connection is marked by a label on top of the storage tank).
The solar cold outlet connection is located toward the outer edge of the top of the solar storage
tank (the connection is marked by a label on top of the storage tank).
•
Connect the solar pipes to the solar storage tank using only the fittings supplied.
31
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CONNECTIONS – PLUMBING
To connect the solar cold and solar hot pipes to the solar storage tank:
•
Remove the compression nut and olive from each
of the solar cold outlet and solar hot inlet fittings at
the top of the solar storage tank. Remove the
rubber washer from each of the unions and
discard.
compression nut & olive
•
•
Connect the solar cold pipe (flow to the collector) to
the nipple in the solar cold outlet using the
compression nut and olive supplied.
solar hot pipe
connection
solar cold pipe
connection
Connect the solar hot pipe (flow from the collector)
to the nipple in the solar hot inlet using the
compression nut and olive supplied.
AUXILIARY PUMP
The maximum height of the solar installation from the base of the solar storage tank to the top of the
solar collectors is 9 m. The pump supplied with the solar storage tank will not circulate closed circuit
fluid through heights greater than 9 m and solar gain will not be achieved. For heights greater than 9 m,
an auxiliary pump must be installed. This pump is the same model as contained within the solar storage
tank.
The auxiliary pump (kit PN 299914) is to be installed:
•
•
•
•
•
•
on the solar cold pipe from the solar storage tank to the solar collectors
within 1 m of the top of the solar storage tank
with the inlet and outlet in a vertical orientation
securely fixed to a structure, such as a wall, with suitable screws or anchors.
wired to the control board (refer to “Auxiliary Pump” on page 34).
within a suitable weatherproof enclosure to protect it from rain as the pump is not weatherproof.
The installation of an auxiliary pump will enable a maximum height of 18 m to be achieved.
32
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CONNECTIONS – ELECTRICAL
The power supply to the water heater must not be switched on until the water heater is filled
with water.
MEGGER READING
It is not mandatory to conduct a megger test on a plug in appliance, however if a megger test is
conducted on this water heater, then the following should be noted.
Warning: This water heater contains electronic equipment and 500 V insulation tests must only be
conducted between either active and earth or neutral and earth. An active to neutral test WILL damage
the electronics.
An insulation test result of approximately 660 KΩ for this water heater is normal.
Typically the insulation resistance between live and earthed parts of an electrical installation should not
be less than 1 MΩ. However AS/NZS 3000:2000 clause 6.3.3.3.2 ‘Results’ states:
“The value of 1 MΩ may be reduced to:
•
•
0.01 MΩ for sheathed heating elements or appliances; or
a value permitted in the Standard applicable to electrical equipment.”
This model water heater is categorised as a ‘stationary class 1 motor operated appliance’ and has been
tested to AS/NZS 3350.1:2002 clause 16 ‘Leakage current and electric strength’ and has passed the
requirements of this Standard. Therefore, this model water heater complies with the condition stated in
AS/NZS 3000:2000 clause 6.3.3.3.2 (b).
ELECTRICAL CONNECTION
All electrical work and permanent wiring must be carried out by a qualified person and in accordance
with the Wiring Rules AS/NZS 3000 and local authority requirements.
Warning: Temperature controllers must not be fitted to this water heater as part of a solar water
heater system because water at a temperature much higher than the controller setting can be delivered.
The water heater requires a 240 V AC, 50 Hz mains power supply for operation. The solar storage tank,
supplied with a 1.8 metre power cord to operate the solar control unit and gas booster, requires a
switched general purpose outlet (GPO) to be located within 1.2 metres of the installation. The GPO
must have a continuous power supply. The GPO is required to be weatherproof if installed outdoors.
The power consumption of the water heater is:
Power
consumption
Component
Solar controller
Solar pump
Comments
3 Watts
Constant load
Maximum load at solar heating cycle start up
(for approximately two (2) minutes)
165 Watts
50 Watts
Average load during the solar heating cycle
Anti frost device active
Gas booster
150 Watts
The water heater will only operate on a sine wave at 50 Hz. Devices generating a square wave cannot
be used to supply power to the water heater.
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CONNECTIONS – ELECTRICAL
HOT SENSOR LEAD
House the hot sensor lead at the water heater in the flexible conduit provided and secure the conduit in
the cut out on the tab located behind the upper front cover. Connect the hot sensor cable to the hot
sensor cable connector located on the tab behind the upper front cover. Secure the hot sensor lead to
the water heater jacket to prevent possible damage.
TEMPERATURE SETTING
The preset outlet booster temperature setting of the gas booster should not be adjusted. The setting
can only be adjusted by your nearest Solahart Dealer. The preset outlet booster temperature setting is
60°C.
AUXILIARY PUMP
The auxiliary pump, if installed, must be wired to the control board. The wiring must be housed in a
flexible conduit, which must be secured to the side of the solar storage tank. Connect the wiring to the
terminals on the auxiliary pump and to the terminals marked “2nd Pump” on the control board. Refer to
WIRING DIAGRAM
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COMMISSIONING
TO FILL AND TURN ON THE WATER HEATER
The power supply to the solar storage tank and solar control unit must not be switched on until
the water heater is filled with water.
•
•
Open all of the hot water taps in the house (don’t forget the shower).
Open the cold water isolation valve fully on the cold water line to the water heater.
Air will be forced out of the taps.
•
•
•
•
•
Close each tap as water flows freely from it.
Check the pipe work for leaks.
Open the gas isolation valve fully.
Check the gas pipe work for leaks.
Open the isolation valve in the pipe work between the outlet of the heat exchanger and the solar
pump, located behind the lower front cover of the solar storage tank.
•
•
•
Plug in the water heater at the power outlet.
Commission the solar circuit (refer to “Solar Circuit” on page 36).
Switch on the electrical supply at the power outlet to the water heater.
The power outlet must be switched on for the solar controls to operate and solar gain to be
achieved and for the gas booster to operate and have its frost protection activated.
•
•
Check the gas inlet and burner gas pressure of the gas booster (refer to “Gas Inlet Pressure” on
page 48 and “Burner Gas Pressure” on page 48).
Open a hot tap.
The gas booster will operate automatically.
•
Check to ensure the flow from each connected hot tap is sufficient to operate the gas booster.
The minimum operating flow rate for all models is 3.0 litres per minute.
Explain to the householder the functions and operation of the solar water heater.
Warning: Upon completion of the installation and commissioning of the water heater, leave this
guide with the householder or responsible officer. DO NOT leave this guide inside of the cover of the
water heater, as it may interfere with the safe operation of the water heater or ignite when the water
heater is turned on.
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COMMISSIONING
SOLAR CIRCUIT
It is necessary to commission and check the operation of the solar circuit. The commissioning
procedure includes:
•
•
•
•
checking the circulation of closed circuit fluid through the solar circuit.
checking the drain back function of the solar circuit.
pressure testing the solar circuit to ensure there are no leaks.
checking the level of the closed circuit fluid and adjusting if required.
The water heater is supplied charged with closed circuit fluid. The level of the closed circuit fluid only
needs to be checked if:
•
•
•
•
a third solar collector is installed.
there is a significant leak in the solar pipe work and closed circuit fluid has been discharged.
the maximum recommended solar pipe length is exceeded.
a second solar pump is installed if the maximum height from the base of the solar storage tank to
the top of the solar collectors exceeds 9 m (refer to “Pipe Lengths” on page 27).
Additional Equipment
Additional equipment will be required for the commissioning and checking of the solar circuit. This
includes checking the closed circuit fluid level and conducting a drain back test. The following
equipment is required:
•
•
•
•
•
a 1500 mm long x 12 mm (½”) diameter clear hose (closed circuit fluid level hose).
one (1) ½” hose clamp.
a suitable plug for one end of the hose.
suitable tape to affix the hose to the side of the solar storage tank.
a torch to illuminate the working area under the heat exchanger and storage tank cylinder.
Closed Circuit Fluid
The water heater is supplied charged with closed circuit fluid and it is not necessary to add further
closed circuit fluid to the system. If the closed circuit fluid has been completely drained or discharged
from the solar circuit and needs to be replaced, then the amount to be added is:
•
•
5 litres of Hartgard concentrate, mixed with
11 litres of water.
It is necessary to undertake the solar circuit commissioning procedure if the closed circuit fluid has
been replaced.
The closed circuit fluid contains food grade additives (rust inhibitor, anti-freeze agent, colour) and is
harmless to the environment. However, it is good practice to recover any excess closed circuit fluid and
remove from site.
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COMMISSIONING
Warning: Although non-toxic, the following first aid advice and procedures should be followed if the
closed circuit fluid concentrate comes into human contact or is spilt:
•
•
•
•
•
Swallowed - give milk or water and seek medical attention.
Eyes - wash with running water.
Skin - remove contaminated clothing and wash skin with water and soap.
Inhaled - seek fresh air, rest and keep warm.
Spilt - immediately remove contaminated clothing, stop leak source, absorb with a dry agent and
eliminate any ignition sources nearby.
PRE-COMMISSIONING WARNINGS
•
It is recommended to conduct the solar circuit commissioning procedure with the solar collectors
covered, otherwise during the commissioning and checking procedure of the solar circuit, the
closed circuit fluid may experience solar gain as it passes through the solar collectors. This will
increase both the temperature and pressure of the closed circuit fluid and air inside of the solar
circuit.
•
•
The electrical supply must be switched off before the solar circuit is opened either at the solar
circuit relief valve or at the compression nut on either of the solar hot or solar cold pipes at the top
of the solar storage tank.
If it is necessary to open the solar circuit at the solar circuit relief valve or at the compression nut on
either of the solar hot or solar cold pipes at the top of the solar storage tank, then care must be
taken so as not to be scalded by either the closed circuit fluid or the air escaping from the solar
circuit.
Pre-Commissioning Notes
•
Before commencing the solar circuit commissioning procedure, check the solar cold and solar hot
pipe work to ensure:
ƒ
there is a continuous fall from the solar collectors to the solar storage tank of a minimum 5°
(1 in 10 grade).
ƒ
ƒ
the maximum recommended pipe length is not exceeded.
the maximum height from the base of the solar storage tank to the solar collector is not
exceeded.
Rectify the solar pipe work if there is either insufficient fall or not a continuous fall of at least 5°
from the solar collectors to the solar storage tank or if either of the maximum pipe length or
maximum height of the system has been exceeded, before commencing the solar circuit
commissioning procedure. Refer to “Pipe Lengths” on page 27.
•
•
The solar collectors will gain a high level of heat during periods of solar radiation. If the solar pump
is activated during a period of high solar radiation and the solar collectors have not been covered,
the initial flow of closed circuit fluid will absorb this heat and a rumbling sound may be heard. This
is normal and the solar circuit will achieve a stable operating condition once full flow through the
solar circuit is established.
The solar pump is set on the speed setting 3. This speed setting must not be adjusted. The solar
control unit automatically controls and adjusts the speed of the pump to maximise solar
contribution. Manual adjustment of the speed dial setting may result in the system not operating
correctly or efficiently.
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COMMISSIONING
Commissioning the Solar Circuit
To commission and check the solar circuit:
1. Switch off the electrical supply at the power outlet to
the solar storage tank.
heat exchanger
isolation valve open
If the pump has been operating, wait five minutes to
allow the drain back of the closed circuit fluid in the
solar circuit.
2. Remove the pipe cover from below the gas booster
and the lower and upper front covers from the solar
storage tank.
3. Ensure the isolation valve in the pipe work between
the outlet of the heat exchanger and the solar pump,
located behind the lower front cover of the solar
storage tank, is fully open.
Attach Closed Circuit Fluid Level Hose
4. Attach the clear hose to the solar circuit.
To attach the hose:
heat
exchanger
drain valve
closed
ƒ
Ensure the heat exchanger drain valve is closed.
attach
hose
The heat exchanger drain valve is located
adjacent to the solar pump, behind the lower front
cover of the solar storage tank.
ƒ
Attach one end of the hose to the hose tail
connection.
It may be necessary to secure the hose with a
hose clamp.
ƒ
ƒ
Plug the free end of the hose.
Affix the hose securely in a vertical orientation to
the front of the solar storage tank using tape,
adjacent to the text, “MINIMUM FLUID LEVEL
WITH PUMP OPERATING”.
affix hose
to tank
5. Disconnect the drain line from the solar circuit relief
valve at the top of the solar storage tank. Remove the
spring clip from the solar circuit relief valve and
remove the valve.
Warning: The solar circuit may be under
pressure. Take care when removing the solar circuit
relief valve, as a sudden discharge of pressurised hot
air may be experienced. This discharge will create a
sharp sound of air being released.
disconnect
drain line
and remove
solar circuit
relief valve
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COMMISSIONING
6. Open the heat exchanger drain valve and remove the
heat
plug from the end of the hose.
exchanger
drain valve
open
The closed circuit fluid will flood the hose to the static
level of the closed circuit fluid inside of the heat
exchanger.
7. Mark the static level of the closed circuit fluid on the
side of the solar storage tank with a non permanent
marker.
Solar Circuit Circulation
8. Disconnect the hot sensor lead from the connecting
plug located on the tab in the upper front cover
opening.
It is important, at the end of this procedure when the
commissioning and checking of the solar circuit is
complete, to reconnect the hot sensor lead, otherwise
when the electrical supply is switched on, the solar
pump will deactivate after one hour and the solar
control unit will then enter a fault mode and no solar
gain will be achieved.
disconnect hot
sensor lead
9. Switch on the electrical supply at the power outlet to the solar storage tank.
Warning: Take care not to enter the area inside the solar storage tank behind the front cover
whilst the power is on as the electrical circuit will be live.
The pump will activate and commence pumping closed circuit fluid around the solar circuit.
The level of the closed circuit fluid in the clear hose will slowly drop to the dynamic operating level.
Allow the pump to operate for three (3) minutes (one and two collector systems) or for five (5)
minutes (3 collector system) to allow the solar circuit to fill with closed circuit fluid and stabilise.
Note: The solar pump will operate for one hour with the hot sensor lead disconnected, before
automatically turning itself off (refer to step 12).
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COMMISSIONING
10. Check the closed circuit fluid is circulating around the solar circuit.
To check circulation:
ƒ
Listen for the trickling sound of the closed circuit fluid returning into the heat exchanger by
placing your ear against the side toward the top of the solar storage tank.
If the fluid is circulating around the solar circuit, a trickling sound will be heard as the fluid
returns back into the heat exchanger.
If no trickling sound is heard, check:
¾
¾
the hot sensor lead is disconnected at the solar storage tank.
If connected, disconnect the hot sensor lead at the solar storage tank (refer to step 8).
the isolation valve in the pipe work between the outlet of the heat exchanger and the solar
pump, located behind the lower front cover of the solar storage tank, is fully open.
Warning: Switch off the electrical supply at the power outlet to the solar storage tank
before entering the area inside the solar storage tank behind the front cover.
If closed, open the isolation valve on the outlet of the heat exchanger (refer to step 3).
¾
there is no leakage from the solar circuit. It is important to check all of the solar circuit pipe
work, including in the roof space and on the roof.
If leaking, rectify any leaks in the solar circuit.
¾
¾
the height from the base of the storage tank to the top of the collectors has not exceeded
the maximum allowable height.
the length of solar cold and solar hot pipe has not exceeded the maximum recommended
pipe length.
If the maximum allowable height or the maximum recommended pipe length has been
exceeded, it may be necessary to relocate the solar collectors to either a lower level or
closer to the solar storage tank, or install a second solar pump, or relocate the solar
storage tank closer to the solar collectors. Refer to “Pipe Lengths” on page 27.
11. Mark the dynamic level of the closed circuit fluid in the
hose on the side of the solar storage tank with a non
permanent marker when satisfied the solar circuit
circulation is operating satisfactorily.
mark dynamic
level on tank
12. If the procedure to check the solar circuit circulation is
not complete before the pump has automatically
turned off, then:
ƒ
ƒ
switch off the electrical supply at the power outlet to the solar storage tank.
wait ten (10) minutes for the operating system to reset to its commissioning sequence,
otherwise the pump will not operate when the power supply is switched on.
ƒ
recommence this procedure from step 9.
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COMMISSIONING
Drain Back Function
13. Switch off the electrical supply at the power outlet to the solar storage tank.
The pump will deactivate.
The closed circuit fluid will drain back down to the heat exchanger and the level of the closed circuit
fluid in the clear hose will rise.
Wait five (5) minutes to allow the drain back of the closed circuit fluid in the solar circuit.
14. Note the level of the closed circuit fluid in the fluid level hose.
The closed circuit fluid should drain back to the original static level.
If the closed circuit fluid does not drain back completely to this level, then check:
ƒ
there is a continuous fall of at least 5° (1 in 10 grade) in the solar pipe work from the solar
collectors to the solar storage tank.
ƒ
the solar collectors have an inclination of not less than 10°.
(refer to “Solar Collector Location” on page 26)
ƒ
the connectors on the inlet and outlet of the collectors are orientated downwards to ensure
complete drain back of the closed circuit fluid from the solar collectors.
If necessary, rectify the:
ƒ
ƒ
ƒ
solar pipe work if there is either insufficient fall or not a continuous fall in the pipe work.
solar collector inclination if it is less than 10°.
orientation of the connectors downwards if they are not orientated correctly.
Recheck the drain back function of the solar circuit by repeating step 7 and recommencing this
procedure from step 9.
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COMMISSIONING
Closed Circuit Fluid Level
15. Measure the distance from the text marking “MINIMUM FLUID LEVEL WITH PUMP OPERATING”
to the closed circuit fluid dynamic level marked on the side of the solar storage tank during step 11.
The correct closed circuit fluid dynamic level for efficient operation of the system when the pump is
operating is between the “MINIMUM FLUID LEVEL WITH PUMP OPERATING” text marking on the
side of the solar storage tank and 150 mm above this mark.
ƒ
If the closed circuit fluid dynamic level marked on the side of the solar storage tank during
step 11 is greater than 150 mm above the text marking, it will be necessary to drain closed
circuit fluid from the heat exchanger.
ƒ
If the closed circuit fluid dynamic level is below the text marking, it will be necessary to add
water to the heat exchanger to top up the level of closed circuit fluid.
There is sufficient Hartgard concentrate in the solar circuit heat exchanger such that only water
needs to be added to the system if it is required to top up the level of closed circuit fluid.
Note: The operating dynamic level of the closed circuit fluid, upon the completion of
commissioning, must not be less than the “MINIMUM FLUID LEVEL WITH PUMP OPERATING”
text marking on the side of the solar storage tank or greater than 150 mm above this mark.
If the dynamic fluid level is greater
than 150 mm above the text marking, it
will be necessary to drain closed circuit
fluid from the heat exchanger
‘Y mm’
greater
than
150 mm
above text
marking
MINIMUM FLUID LEVEL WITH PUMP OPERATING
‘X mm’
below text
marking
If the dynamic fluid level is below
the text marking, it will be necessary
to add water to the heat exchanger
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COMMISSIONING
16. Determine the correct amount of water to be added to or closed circuit fluid to be drained from the
heat exchanger if the dynamic level is either below the text marking “MINIMUM FLUID LEVEL
WITH PUMP OPERATING” or more than 150 mm above this mark.
Each 100 mm of fluid level height is equivalent to three (3) litres of closed circuit fluid.
20 mm
40 mm
60 mm
0.6 litres
1.2 litres
1.8 litres
80 mm
100 mm
120 mm
2.4 litres
3.0 litres
3.6 litres
140 mm
160 mm
180 mm
4.2 litres
4.8 litres
5.4 litres
ƒ
Mark the required closed circuit fluid level to be obtained on the side of the solar storage tank
with a non permanent marker beside the clear hose, in relation to the static level marked on the
side of the solar storage tank during step 7.
Eg: If the dynamic level is 30 mm below the text marking, then place a mark 30 mm above the
static level marked on the side of the solar storage tank in step 7. It would be necessary to add
one litre of water to the heat exchanger.
Eg: If the dynamic level is 180 mm above the text marking, then place a mark at least 30 mm,
but no more than 180 mm, below the static level marked on the side of the solar storage tank.
It would be necessary to drain between one litre and five litres of closed circuit fluid from the
heat exchanger.
mark
‘X mm’
mark static level to achieve
above
static mark
mark between
‘Y mm’ and
‘Y + 150 mm’
below static
mark
static level marked on tank during step 7
mark static level to achieve
If the dynamic fluid level is greater than
150 mm above the text marking, then
place a mark below the static level marked
on the tank of between equal to this
distance and this distance plus 150 mm.
‘Y mm’
greater
than
150 mm
above text
marking
MINIMUM FLUID LEVEL WITH PUMP OPERATING
‘X mm’
below text
marking
If the dynamic fluid level is below the text
marking, then place a mark equal to this distance
above the static level marked on the tank
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COMMISSIONING
17. Add water to top up the level of the closed circuit fluid in the heat exchanger if required.
To add water to the closed circuit fluid:
ƒ
If not already removed, disconnect the drain line and remove the spring clip from the solar
circuit relief valve at the top of the solar storage tank and remove the valve (refer to step 5).
Warning: The solar circuit may be under pressure. Take care when removing the solar
circuit relief valve, as a sudden discharge of pressurised hot air may be experienced. This
discharge will create a sharp sound of air being released.
ƒ
ƒ
Place a funnel in the relief valve fitting.
Add water slowly through the funnel until the level of fluid in the hose is at the desired level as
marked on the solar storage tank.
Note: It may be necessary to undo the compression nut on the solar hot pipe at the top of the
solar storage tank and loosen the pipe work from the fitting to assist the flow of water into the
closed circuit through the funnel.
ƒ
ƒ
Remove the funnel from the relief valve fitting.
Position the solar hot pipe correctly in its fitting and tighten the compression nut if this has been
loosened.
18. Drain closed circuit fluid from the heat exchanger if required.
To drain closed circuit fluid:
ƒ
If not already removed, disconnect the drain line and remove the spring clip from the solar
circuit relief valve at the top of the solar storage tank and remove the valve (refer to step 5).
Warning: The solar circuit may be under pressure. Take care when removing the solar
circuit relief valve, as a sudden discharge of pressurised hot air may be experienced. This
discharge will create a sharp sound of air being released.
ƒ
Place the end of the solar fluid hose into a graduated volumetric container and drain closed
circuit fluid until the level of fluid in the hose is at the desired level as marked on the solar
storage tank.
It may be necessary to drain off the closed circuit fluid in small amounts, raising the hose back
to the top of the solar storage tank and noting the level of the closed circuit fluid in the clear
hose each time, so as not to drain below the desired level.
Note: The closed circuit fluid contains food grade additives (rust inhibitor, anti-freeze agent,
colour) and is harmless to the environment. However, it is good practice to recover any excess
fluid and remove from site.
ƒ
Re-affix the hose to the same location on the side of the solar storage tank.
19. If water has been added to or closed circuit fluid has been drained from the heat exchanger,
recommence this procedure from step 9.
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COMMISSIONING
Pressure Testing the Solar Circuit
20. Close the heat exchanger drain valve.
heat
exchanger
drain valve
closed
21. Refit the solar circuit relief valve, orientating the valve
outlet to the rear of the solar storage tank. Secure
with the spring clip. Reconnect the drain pipe to the
valve.
22. Switch on the electrical supply at the power outlet to
the solar storage tank.
The pump will activate and commence pumping fluid around the solar circuit.
Note: The level of the closed circuit fluid in the clear hose will not change, as the heat exchanger
drain valve has been closed.
Allow the pump to operate for three (3) minutes (one and two collector systems) or for five (5)
minutes (3 collector system) to allow the solar circuit to stabilise and fill with closed circuit fluid.
Note: The solar pump will operate for one hour with the hot sensor lead disconnected, before
automatically turning itself off. Refer to step 24.
23. Check the solar pipe work and collector unions for leaks whilst the pump is operating and the solar
circuit is at its working pressure. It is important to check all of the solar circuit pipe work, including in
the roof space and on the roof.
24. If the procedure to check the solar pipe work for leaks is not complete before the pump has
automatically turned off, then:
ƒ
ƒ
switch off the electrical supply at the power outlet to the solar storage tank.
wait ten (10) minutes for the operating system to reset to its commissioning sequence,
otherwise the pump will not operate when the power supply is switched on.
ƒ
recommence this procedure from step 22.
25. Switch off the electrical supply at the power outlet to the solar storage tank.
The pump will deactivate.
The closed circuit fluid will drain back down to the heat exchanger.
26. Rectify any leaks in the solar pipe work and collector unions.
If brazing is required to fix any leaks, then it is necessary to remove the solar circuit relief valve
(refer to step 5).
Warning: The solar circuit may be under pressure. Take care when removing the solar circuit
relief valve, as a sudden discharge of pressurised hot air may be experienced. This discharge will
create a sharp sound of air being released.
27. If minor leaks have been rectified, recommence this procedure from step 22. If a major leak has
been rectified, recommence this procedure from step 5.
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COMMISSIONING
Remove Closed Circuit Fluid Level Hose
28. Remove the clear hose from the solar storage tank when satisfied the commissioning procedure is
complete. To remove the hose:
ƒ
ƒ
Ensure the heat exchanger drain valve is closed.
heat
exchanger
drain valve
closed
Remove the hose from the side of the storage tank
and place the end into a container to collect the
closed circuit fluid remaining in the hose.
ƒ
ƒ
Replace the plug into the free end of the hose and lay
the hose flat on the ground.
remove hose
Loosen the hose clamp, if fitted, and carefully remove
the hose and hose clamp from the heat exchanger
drain valve fitting, ensuring there is no spillage of the
closed circuit fluid.
Clean up any spillage of closed circuit fluid.
ƒ
Place the open end of the hose into the container and recover the remainder of the closed
circuit fluid from the hose.
Note: The closed circuit fluid contains food grade additives (rust inhibitor, anti-freeze agent,
colour) and is harmless to the environment. However, it is good practice to recover any excess
closed circuit fluid and remove from site.
Completing the Commissioning of the Solar Circuit
29. Reconnect the hot sensor lead to the connecting plug
located on the tab in the upper front cover opening.
It is important to reconnect the hot sensor lead,
otherwise when the electrical supply is switched on, the
solar pump will deactivate after one hour and the solar
control unit will then enter a fault mode, will not operate
and no solar gain will be achieved.
reconnect
hot sensor
lead
30. Replace the lower and upper front covers of the solar
storage tank and the pipe cover to the underneath of
the gas booster.
31. Clean off the marks made on the side of the solar storage tank.
32. Remove the covers from the solar collectors.
33. Switch on the electrical supply at the power outlet to the solar storage tank.
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COMMISSIONING
DIAGNOSTIC FEATURES OF THE SOLAR CONTROLLER
The solar storage tank incorporates an electronic solar control module. This is located inside of the
lower front cover and houses both a green and a red LED. The LEDs emit either a constant glow or a
series of flashes with a 2 second interval between flashes. The green LED indicates the current
operational mode of the solar water heater and the red LED indicates a fault mode. To view the status
of the LEDs, it is necessary to remove the lower front cover.
Warning: The removal of the lower front cover will expose 240 V wiring. It must only be removed by
an authorised or service person.
The modes are:
Flashes
Operational Modes
Solid green
(remains on)
Standby mode
1 x green
2 x green
3 x green
4 x green
5 x green
Flooding solar circuit
Checking solar contribution
Pump flow control
Pump flow established
Tank at maximum temperature
Flashes
1 x red
2 x red
3 x red
4 x red
Fault Modes
Hot sensor in collector – open circuit
Hot sensor in collector – short circuit
Cold sensor – open or short circuit
Top three tank thermistors – open or short circuit
47
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COMMISSIONING
GAS INLET PRESSURE
IMPORTANT - CHECK the gas supply pressure at the inlet to the water heater with the water heater
and all other gas burning appliances in the premises operating (burners alight). The minimum gas
supply pressure is:
Natural Gas
1.13 kPa
Propane
2.75 kPa
If this minimum cannot be achieved, it may indicate the meter or the gas line to the water heater is
undersized. It is important to ensure that an adequate gas supply pressure is available to the water
heater when other gas burning appliances, on the same gas supply, are operating.
It is necessary to remove the pipe cover from underneath the gas booster, by undoing the retaining
screws, in order to test the gas pressure at the inlet of the gas booster. Refit the pipe cover at the
completion of the installation.
BURNER GAS PRESSURE
It is necessary to check the burner gas pressure at both the minimum and maximum operational
settings. It is necessary to have the electrical supply to the water heater switched on, the hot water
must be flowing and the burners on to check and if necessary adjust the operational gas pressures.
Warning: The removal of the front cover will expose 240 volt wiring. Take care not to touch wiring
terminals.
•
Ensure the burners are not operating. Close any hot taps and turn off the gas supply at the gas
isolation valve.
•
•
•
•
Remove the screws holding the front panel to the jacket.
Gently disengage the front panel and pull forward to remove from the water heater.
Locate the burner pressure test point on the main burner manifold and connect a manometer.
Turn on the gas supply at the gas isolation valve.
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COMMISSIONING
Minimum test point gas pressure
Refer to the rating label on the water heater for the minimum test point gas pressure.
1. Open a hot tap slowly until the burners ignite.
2. Press and hold down the MIN button (“1L” is shown
on the LED display), and observe the reading on
the manometer.
L.E.D.
display
3. Release the MIN button. If the manometer reading
observed in Step 2 agrees with the rating label, no
further adjustment is required.
test point
orifice
washer
4. To adjust, press and hold down the adjuster button
(“LH” is shown on the LED display).
adjuster button
max button
Note: The adjuster button must be held down
continuously through steps 4 to 6.
min button
manometer
test point
screw
5. Press the MIN button and observe the reading on
the manometer.
Note: While the MIN button is pressed, the gas
pressure will at first increase then decrease,
cycling between an upper gas pressure limit (39 on
LED display) and a lower gas pressure limit (01 on
LED display).
6. Release the MIN button when the reading on the manometer agrees with the rating label.
7. Release the adjuster button.
Notes:
•
If the burners extinguish and / or an error code starts to flash on the display, release the MIN and
adjuster buttons, close the hot tap, clear the error code, turn on the water heater and recommence
the procedure from Step 1.
•
•
If the adjuster button is released before Step 6, clear any error code (if displayed) and recommence
the procedure from Step 1.
To clear an error code, refer to “Error Codes” on page 16.
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COMMISSIONING
Maximum test point gas pressure
Refer to the rating label on the water heater for the maximum test point gas pressure.
Follow Steps 1 to 7 of the “Minimum test point gas pressure” procedure, but open the hot tap fully and
use the MAX button instead of the MIN button.
Note: In Step 2, “3H” or “4H” will be shown on the LED display, depending on the model of the water
heater.
After setting the minimum and maximum test point gas pressures:
•
•
•
•
•
•
Close the hot tap.
Remove the manometer and refit and tighten the test point screw.
Open a hot tap again so the burners ignite.
Test for gas leaks.
Refit the front panel and screws to the water heater.
Close the hot tap.
TO TURN OFF THE WATER HEATER
If it is necessary to turn off the water heater on completion of the installation, such as on a building site
or where the premises is vacant, then:
•
•
•
•
Switch off the electrical supply at the power outlet to the water heater (refer to note below).
Close the gas isolation valve at the inlet to the water heater.
Close the cold water isolation valve at the inlet to the water heater.
Drain the gas booster if there is a risk of freezing conditions occurring (refer to “Draining The Water
Heater” on page 51).
Note: The frost protection system of the gas booster will be rendered inoperable if electrical power is
not available at the water heater. Damage caused by freezing due to the unavailability of power at the
water heater is not covered by warranty (refer to “Warranty Exclusions” on page 53). If the power has
been switched off to the water heater and there is a risk of freezing, then it is necessary to drain the gas
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DRAINING THE WATER HEATER
To drain the water heater:
Gas Booster Water Heater
•
•
•
Open a hot tap (preferably the shower outlet).
Unscrew the two drain plugs, one each at the cold water inlet and hot water outlet, on the
underside of the gas booster.
Water will drain from the gas booster.
•
When water stops flowing from the gas booster, close the hot tap.
Note: It is recommended not to screw the drain plugs back in, until the water heater is to be turned on
again.
Solar Storage Tank
•
•
•
Close all hot water taps.
Operate the relief valve release lever - do not let the lever snap back or you will damage the valve
seat.
Operating the lever will release the pressure in the water heater.
•
•
Undo the union at the cold water inlet to the solar storage tank and attach a hose to the water
heater side of the union.
Let the other end of the hose go to a drain.
Operate the relief valve again.
This will let air into the water heater and allow the water to drain through the hose.
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WATER SUPPLIES
Your water heater is manufactured to suit the water conditions of most Australian metropolitan supplies.
However, there are some known water supplies which can have detrimental effects on the water heater
and its operation and/or life expectancy. If you are unsure of your water quality, you can obtain
information from your local water supply authority. The water heater should only be connected to a
potable water supply.
ANODE
By using the correct colour coded anode this water heater can be used in areas where the total
dissolved solids (TDS) content in the water is up to 2500 mg/L. In areas where the TDS exceeds
600 mg/L it is possible the black anode, which is the standard anode fitted to the water heater, may be
excessively active. To alleviate this, the black anode should be replaced with one colour coded blue.
Where the TDS of the water is less than 40 mg/L, such as when the water has been deionised or is
from an alpine supply, a high potential anode, colour coded green, should be used. The changing of
anodes must be carried out by a plumber or authorised service person.
CAUTION
If your water supply has a TDS greater than 600 mg/L and the anode has not been changed to a blue
one, there is the possibility hydrogen gas could accumulate in the top of the water heater during long
periods of no use. In areas where this is likely to occur, the installer should instruct the householder on
how to dissipate the gas safely.
If, under these conditions, the water heater has not been used for two or more weeks the following
procedure should be carried out before using any electrical appliances (automatic washing machines
and dishwashers) which are connected to the hot water supply.
The hydrogen, which is highly flammable, should be vented safely by opening a hot tap and allowing
the water to flow. There should be no smoking or naked flame near the tap whilst it is turned on. Any
hydrogen gas will be dissipated. This is indicated by an unusual spurting of the water from the tap.
Once the water runs freely again, any hydrogen in the system will have been released.
SATURATION INDEX
The saturation index is used as a measure of the water’s corrosive or scaling properties. In a corrosive
water supply, the water can attack copper parts and cause them to fail. Where the saturation index is
less than –1.0, the water is corrosive.
In a scaling water supply calcium carbonate is deposited out of the water onto any hot metallic surface.
Where the saturation index exceeds +0.40, the water is scaling and an expansion control valve* must
be fitted on the cold water line after the non-return valve.
WATER HEATERS NOT INSTALLED IN ACCORDANCE WITH THE ABOVE ADVICE WILL NOT BE
COVERED BY THE WARRANTY.
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SOLAHART STREAMLINE, SYNERGY, GAS BOOSTER
SOLAR WATER HEATER WARRANTY – AUSTRALIA ONLY
WARRANTY CONDITIONS
1. This warranty is applicable only to water heaters manufactured
from 1st July 2006.
between the nearest Solahart Dealer’s premises and the installed
site shall be the owner’s responsibility.
2. The water heater must be installed in accordance with the 5. Where the water heater is installed in a position that does not
Solahart water heater installation instructions, supplied with the
water heater, and in accordance with all relevant statutory and
local requirements of the State in which the water heater is
installed.
allow safe, ready access, the cost of accessing the site safely,
including the cost of additional materials handling and / or safety
equipment, shall be the owner’s responsibility.
6. The warranty only applies to the water heater and original or
genuine (company) component replacement parts and therefore
does not cover any plumbing or electrical parts supplied by the
installer and not an integral part of the water heater, e.g. pressure
limiting valve; isolation valves; non-return valves; electrical
switches; pumps or fuse.
3. Where a failed component or water heater is replaced under
warranty, the balance of the original warranty period will remain
effective. The replaced part or water heater does not carry a new
warranty.
4. Where the water heater is installed outside the boundaries of a
metropolitan area as defined by Solahart or further than 30 km 7. The water heater must be sized to supply the hot water demand
from a regional Solahart Dealer from whom the water heater was
purchased, the cost of transport, insurance and travelling costs
in accordance with the guidelines in the Solahart water heater
literature.
WARRANTY EXCLUSIONS
1. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE SOLAHART WATER HEATER
WARRANTY, HOWEVER THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO
BECOME VOID AND MAY INCUR A SERVICE CHARGE AND / OR COST OF PARTS.
a) Accidental damage to the water heater or any component,
including: Acts of God; failure due to misuse; incorrect
installation; attempts to repair the water heater other than by the
Solahart Dealer.
or incorrectly mixed closed circuit fluid being used; a Streamline
closed circuit system where there is insufficient or incorrect fall in
the pipe work preventing complete drain back of the closed circuit
fluid.
b) Where it is found there is nothing wrong with the water heater; e) Where the electronic instantaneous gas booster water heater or
where the complaint is related to excessive discharge from the
temperature and / or pressure relief valve due to high water
pressure; where the complaint is related to insufficient or
incorrect fall in the pipe work preventing complete drain back of
the closed circuit fluid of a Streamline closed circuit system;
where there is no flow of hot water due to faulty plumbing; where
water leaks are related to plumbing and not the water heater or
water heater components; where there is a failure of gas,
electronic instantaneous gas booster water heater component
has failed directly or indirectly as a result of ice formation in the
water ways of a water heater: where the water heater has not
been installed in accordance with the water heater installation
instructions; where the electricity has been switched off or has
failed and the water heater has not been drained in accordance
with the instructions; due to an ambient temperature below -20°C
(including wind chill factor).
electricity or water supplies; where the supply of gas, electricity or f) Where the water heater is located in a position that does not
water does not comply with relevant codes or acts.
comply with the Solahart water heater installation instructions or
relevant statutory requirements, causing the need for major
dismantling or removal of cupboards, doors or walls, or use of
special equipment to bring the water heater to floor or ground
level or to a serviceable position.
c) Where the water heater or water heater component has failed
directly or indirectly as a result of: excessive water pressure;
excessive temperature and / or thermal input; blocked
overflow / vent drain; corrosive atmosphere; non Solahart
approved or incorrectly mixed closed circuit fluid being used; g) Repair and / or replacement of the water heater due to scale
incorrect or insufficient filling of the closed circuit system with the
closed circuit fluid; ice formation in the pipe work to or from the
water heater.
formation in the waterways or the effects of either corrosive water
or water with a high chloride or low pH level when the water
heater has been connected to a scaling or corrosive water supply
or a water supply with a high chloride or low pH level as outlined
in the Owner’s Guide and Installation Instructions booklet.
d) Where the solar water heater or solar water heater component
has failed directly or indirectly as a result of ice formation in the
water ways of: a Streamline open circuit system; a Streamline h) Breakage of collector glass for any reason including hail damage.
closed circuit system where the system has not been installed in
accordance with the water heater installation instructions; a
Streamline closed circuit system due to non Solahart approved
(We suggest that the collector glass be covered by your home
insurance policy).
2. SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY EXCLUDES ANY AND ALL
CLAIMS FOR DAMAGE TO FURNITURE, CARPETS, WALLS, FOUNDATIONS OR ANY OTHER CONSEQUENTIAL
LOSS EITHER DIRECTLY OR INDIRECTLY DUE TO LEAKAGE FROM THE WATER HEATER, OR DUE TO LEAKAGE
FROM FITTINGS AND / OR PIPE WORK OF METAL, PLASTIC OR OTHER MATERIALS CAUSED BY WATER
TEMPERATURE, WORKMANSHIP OR OTHER MODES OF FAILURE.
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SOLAHART STREAMLINE, SYNERGY, GAS BOOSTER
SOLAR WATER HEATER WARRANTY – AUSTRALIA ONLY
WARRANTY
Solahart* will:
a) Repair or, if necessary replace any Solahart water heater; or
b) Replace any component (or, if necessary, arrange the installation of a new water heater),
which falls within the Warranty Periods specified below, subject to the warranty conditions and exclusions.
Installation
Model
Period
Warranty
All Components (from date of installation)
New component, solar collector or water heater (at
Solahart’s sole discretion), free of charge, including
labour.**
Year
1
All installations
All models
Sealed System *** (from date of installation)
Water heater installed in a
“single-family domestic dwelling”
Year New sealed system component, free of charge, including
Synergy
2
labour.**
Cylinder (from date of installation)
Streamline,
Streamline
Years
2 & 3
New water heater, free of charge, including labour.**
Water heater installed in a
“single-family domestic dwelling” Closed Circuit,
Synergy
Years New water heater, free of charge, with installation and
4 & 5 labour costs being the responsibility of the owner.
Streamline,
Water heater installed in any other
Streamline
Years New water heater, free of charge, with installation and
2 & 3 labour costs being the responsibility of the owner.
than a
Closed Circuit,
“single-family domestic dwelling”
Synergy
Heat Exchanger Electronic Instantaneous Gas Booster (from date of installation)
Years
2 & 3
New heat exchanger, free of charge, including labour.**
Water heater installed in a
Streamline
“single-family domestic dwelling” Closed Circuit
Years New heat exchanger, free of charge, with installation and
4 & 5 labour costs being the responsibility of the owner.
Solar Collector (from date of installation)
L
J
KF
Years New solar collector, free of charge, with installation and
2 to 5 labour costs being the responsibility of the owner.
All installations
Notes:
* Solahart is the supplier of Solahart electronic instantaneous solar gas booster water heaters, manufactured by Paloma
Industries, a world leader in water heater technology and manufacture.
** Refer to items 4 and 5 of warranty conditions.
*** The Sealed System includes components that carry refrigerant only, e.g. Compressor, Condenser, TX Valve,
Receiver/Drier, Evaporator and associated pipe work.
Solahart reserves the right to transfer fully functional components from the defective water heater to the replacement water
heater if required. The term “water heater” used in the Warranty, Warranty Conditions and Warranty Exclusions means the
Solahart supplied water heater(s), solar storage tank(s), solar collector(s), kit(s) and components.
In addition to this warranty, the Trade Practices Act 1974 and similar laws in each state and territory provide the owner under
certain circumstances with certain minimum statutory rights in relation to your Solahart water heater. This warranty must be
read subject to that legislation and nothing in this warranty has the effect of excluding, restricting or modifying those rights.
FOR SERVICE TELEPHONE
SOLAHART INDUSTRIES PTY LTD
Your Nearest Solahart Dealer or
ABN 45 064 945 848
1800 638 011 AUSTRALIA
or refer local Yellow Pages
Note: Every care has been taken to ensure accuracy in preparation of this publication. No liability can be accepted for any
consequences, which may arise as a result of its application.
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SOLAHART INSTALLATION AND WARRANTY REPORT
Dear Customer – To register your warranty please ensure the following information is correct
then sign and return to our Solahart Industries Pty Ltd freepost address:
Solahart Industries Pty Ltd.
Reply Paid Perth 354,
Welshpool, Western Australia 6106
WARRANTY
Please complete all details below
Owner’s Name
Installation Address
Suburb
State
Country
Postcode
Telephone
Solahart Dealership
(H)
(W)
Consultant
Installer’s Name
Installation Date
Type of Installation
New
Solar to Solar Tank Replacement
Other
(please circle)
Work Delivery Details
System Model No
Tank Model No
System Type
Tank Serial No
No of Collectors
Collector Model No
Collector Serial No’s
1)
2)
3)
4)
Booster Type
Electric
continuous
Off Peak 1
(night)
Off Peak 2
(night & day)
In-Tank Gas
Booster
In-Line
Booster
Solar Preheat
only
(please circle)
Booster Control
None
Timer
Manual Switch
One Shot Control
(please circle)
In-Line Booster
Model No
Serial No
(if installed)
Service’s Due
1)
2)
3)
4)
If replacing a water heater, please give details
Brand
Model No
Electric
Gas
If a Solahart unit
Tank Serial No
Date of manufacture
3) 4)
Collector Serial No’s
1)
2)
Comments
Installer Certification – I certify this installation has been installed and tested in accordance with Solahart Industries Pty Ltd specifications
Signature:
Installer
Customer
Date
White Copy: Head Office
Yellow Copy: Dealer
Blue Copy: Sales Office
Green Copy: Manual
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SOLAHART OFFICES
Corporate Headquarters
112 Pilbara St
Telephone International:
Welshpool
Western Australia 6106
+ 61 8 9351 4600
Facsimile International:
+ 61 8 9351 4698
Email:
Postal Address:
PO Box 95
Internet:
State Parcel Centre
Welshpool WA 6986
Australian Offices
Western Australia
Phone:
New South Wales
Phone:
08 9351 4600
08 9351 4635
02 9684 9333
02 9684 9187
Facsimile:
Facsimile:
Queensland
Phone:
South Australia
Phone:
07 3255 5185
07 3255 5189
08 8262 7825
08 8359 6004
Facsimile:
Facsimile:
Victoria / Tasmania
Phone:
Northern Territory
Phone:
03 9212 8950
03 9212 8940
08 8947 0274
08 8947 1944
Facsimile
Facsimile:
International Offices
Europe
Rest of the World
Phone International:
Facsimile International:
+ 31 492 579 696
+ 31 492 579 694
Phone International:
Facsimile International:
+ 61 8 9351 4600
+ 61 8 9351 4698
USA
Phone International:
Facsimile International:
+ 1 334 260 1586
+ 1 334 260 1514
Revision Date: 2006 July
126537A
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