Solahart Streamline Owner's Manual

Indirect closed circuit gas boosted solar water heater

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Owner's manual (60 pages)

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Page 1 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 a qualified person.
Page 2 Solahart Industries Pty Ltd, Rheem Australia Pty Ltd or Paloma Co., Ltd. Solahart Industries Pty Ltd is the supplier of the Solahart range of continuous flow gas water heaters, manufactured by Paloma Co., Ltd., a world leader in water heater technology and manufacture.
Page 3: Table Of Contents
Installation – Solar Storage Tank ..................... 20 Installation – Solar Collectors ....................29 Connections – Plumbing ......................37 Connections – Electrical ......................41 Auxiliary Pump .......................... 43 Commissioning .......................... 46 Draining The Water Heater ....................... 60 Warranty ............................. 65 Solahart Offices ......................... 68...
Page 4: About Your Water Heater
The solar storage tank is suitable for outdoor installation only and with either Solahart „J‟, „KF‟, „LC‟, „LCS‟ or „BT‟ solar collectors. The system is suitable for installation in areas subject to frost or freeze conditions. Freeze conditions occur below 6°C.
Page 5 The preset outlet booster temperature setting of the gas booster cannot be adjusted by the householder. The setting can maximum recommended only be adjusted by your nearest Solahart Dealer. The factory preset supply temperature to outlet temperature setting of the gas booster is 60°C.
Page 6 Should the water from the water heater appear blue or if blue closed circuit fluid is noticed around the base of the water heater, this indicates a leak of the closed circuit fluid from the heat exchanger. The closed circuit fluid is non-toxic and not hazardous to health. Phone your nearest Solahart Dealer to arrange for an inspection.
Page 7 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 the Solahart warranty (refer to “Terms of the Solahart Warranty”...
Page 8: Regular Care
The red LED may emit up to six flashes in each series of flashes. Count the number of flashes and phone your nearest Solahart Dealer to arrange for an inspection. PRECAUTIONS Where damage to property can occur in the event of the water heater leaking, the water heater must be installed in a safe tray.
Page 9 ABOUT YOUR 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 outlets to the solar storage tank and gas booster if there is no risk of freezing conditions occurring (refer to note below).
Page 10 ABOUT YOUR WATER HEATER 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”...
Page 11: Regular Care
Note: The five year service and routine replacement of any components, such as the anodes and relief valves, are not included in the Solahart warranty. A charge will be made for this work. Only genuine replacement parts should be used on this water heater.
Page 12 Have any trees trimmed which may shade the solar collectors. Solahart solar collectors have passed the AS/NZS 2712 requirements for resistance to hailstone damage, so it is not normally necessary to fit a guard to a collector. Stone Guards are available to provide a level of protection to the collectors against vandalism or accidental damage.
Page 13: Water Supplies
Solahart warranty to apply. ANODE The vitreous enamel lined cylinder of the water heater is only covered by the Solahart warranty when the total dissolved solids (TDS) content in the water is less than 2500 mg/L and when the correct colour coded anode is used.
Page 14 Where the saturation index exceeds +0.40, the water is very scaling. An expansion control valve must be fitted on the cold water line after the non-return valve to protect and for the Solahart warranty to apply to the temperature pressure relief valve and water heater cylinder.
Page 15: Water Supplies
The water heater, solar collectors and their components are not suitable for certain water chemistries. Those chemistries are listed below. If the water heater is connected at any time to a water supply with the following water chemistry, the Solahart warranty will not cover any resultant faults on the components listed below: Water Chemistry Component Total Dissolved Solids (TDS) >...
Page 16: Save A Service Call
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.
Page 17 12). 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.
Page 18: Save A Service Call
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 numerical code and turn off the hot tap. Phone your nearest Solahart Dealer to arrange for inspection.
Page 19 Has your water heating tariff rate been increased by your gas retailer since your previous account? COLLECTOR GLASS The Solahart warranty DOES NOT cover breakage of solar collector glass. Check your household insurance policy covers collector glass breakage. Warning: No attempt should be made to remove or replace broken collector glass.
Page 20: Installation - Solar Storage Tank
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‟, „KF‟, „LC‟, „LCS‟ or „BT‟ solar collectors. IMPORTANT NOTES Working on roofs is and should always be considered a hazardous activity, particularly early in the morning, late in the evening, when the roof is wet or during and after periods of rain.
Page 21 INSTALLATION – SOLAR STORAGE TANK Victorian Installers Notice to Victorian Installers from the Victorian Plumbing Industry Commission if this solar water heater is installed in a new Class 1 dwelling in the State of Victoria. The system model number is to be recorded on the Certificate of Compliance.
Page 22 INSTALLATION – SOLAR STORAGE TANK The water heater must be located to ensure that the location of the flue terminal complies with the requirements of AS 5601 or AS/NZS 5601.1, as applicable under local regulations. As a guide the following requirements are extracted from the Gas Installations Standard.
Page 23 Damage to the gas booster caused by freezing of the pipe work to or from the gas booster is not covered under the Solahart warranty. Refer to AS/NZS 3500.4 for precautions to be taken for installations in frost prone areas.
Page 24 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.
Page 25 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.
Page 26 31. ANODE The vitreous enamel lined cylinder of the water heater is only covered by the Solahart warranty when the total dissolved solids (TDS) content in the water is less than 2500 mg/L and when the correct colour coded anode is used.
Page 27 INSTALLATION – SOLAR STORAGE TANK DIMENSIONS AND TECHNICAL DATA Model tank DBV 270 SM Capacity 270 litres Mass 141 kg (empty) 411 kg (full) gas booster 10143272 Delivery 27 L/min Mass 24 kg 435 kg incl booster 10143273 Test Point Delivery Hourly Gas Min.
Page 28 INSTALLATION – SOLAR STORAGE TANK TYPICAL INSTALLATION – OUTDOOR LOCATION...
Page 29: Installation - Solar Collectors
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.
Page 30 INSTALLATION – SOLAR COLLECTORS LATITUDE OF SOME AUSTRALIAN CITIES Adelaide 35°S Cairns 17°S Hobart 42°S Port Hedland 20°S Alice Springs 24°S Canberra 35°S Mildura 34°S Rockhampton 24°S Brisbane 27°S Darwin 12°S Melbourne 38°S Sydney 34°S Broken Hill 31°S Geraldton 28°S Perth 32°S Townsville...
Page 31 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. All compression fittings must use brass or copper olives. The full length of the solar hot and solar cold pipes MUST BE insulated. The insulation must: ...
Page 32 INSTALLATION – SOLAR COLLECTORS 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 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.
Page 33 INSTALLATION – SOLAR COLLECTORS Pressure Testing The solar water heater, including the collector circuit and solar collectors, is to be isolated during the testing and commissioning of the heated water reticulation system in a building, in accordance with Clause 11.1 and 11.3 (a) of AS/NZS 3500.4.
Page 34 STORAGE TANK AND GAS BOOSTER ASSEMBLY GAS BOOSTER BRACKETS It is necessary to remove, reposition and refit the top and bottom mounting brackets of the gas booster so it can be mounted onto the storage tank. Remove the screws securing the top bracket at the rear of the gas booster, rotate the bracket through 180°...
Page 35 STORAGE TANK AND GAS BOOSTER ASSEMBLY MOUNTING THE GAS BOOSTER TO THE STORAGE TANK The gas booster is required to be mounted on the solar storage tank. They are connected together with the supplied fittings. Use thread sealing tape or approved thread sealant on all fittings. Numbers in parentheses refer to items shown in the diagram on page To mount the gas booster to the storage tank:...
Page 36 STORAGE TANK AND GAS BOOSTER ASSEMBLY ITEM DESCRIPTION Components for Assembly of Storage Tank and Gas Booster Hot connection assembly Flexible hose (cold inlet connection) 550 mm long HOT CONNECTION ASSEMBLY Cold connection assembly Elbow fitting ¾” M x ¾” F Rye 2504 COLD CONNECTION ASSEMBLY Gas booster water heater Flexible hose (solar outlet connection) 425 mm long...
Page 37: Connections - Plumbing
CONNECTIONS – PLUMBING All plumbing work must be carried out by a qualified person and in accordance with the requirements of the Standard AS/NZS 3500.4, and all local codes and regulatory authority requirements. In New Zealand, the installation must conform with Clause G12 of the New Zealand Building Code. All gas work must be carried out by a qualified person and in compliance with the Standard AS 5601 or AS/NZS 5601.1, as applicable under local regulations, and all local codes and regulatory authority requirements.
Page 38 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.
Page 39 The Solahart warranty does not cover damage of any nature resulting from failure to observe this precaution. Refer to rating label for gas...
Page 40 CONNECTIONS – PLUMBING 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.
Page 41: Connections - Electrical
CONNECTIONS – ELECTRICAL The power supply to the water heater must not be switched on until the solar storage tank 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.
Page 42: Wiring Diagram
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.
Page 43: Auxiliary Pump
AUXILIARY PUMP 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 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.
Page 44 AUXILIARY PUMP Auxiliary Pump Installation Auxiliary Pump Typical Installation Solar Drain Back...
Page 45 AUXILIARY PUMP AUXILIARY PUMP – ELECTRICAL CONNECTION The auxiliary pump, if installed, must be wired to the control board. The flexible cord supplied with the pump must be housed in a 20 mm flexible conduit. The flexible conduit should be secured to the insulated pipe work with the cable ties provided, to the side of the solar storage tank using the adhesive backed cable tie mounts and cable ties provided and to the penetration in the solar storage tank jacket using the cable gland provided.
Page 46: Commissioning
COMMISSIONING TO FILL AND TURN ON THE WATER HEATER The power supply to the water heater must not be switched on until the solar storage tank is filled with water. To fill the solar storage tank with water and turn on the water heater: Open all of the hot water taps in the house (don‟t forget the shower).
Page 47 COMMISSIONING SOLAR CIRCUIT It is necessary to commission and check the operation of the solar circuit as part of the installation. The water heater is supplied charged with closed circuit fluid. The commissioning procedure includes checking the: circulation of closed circuit fluid through the solar circuit. drain back function of the solar circuit.
Page 48 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.
Page 49 COMMISSIONING Commissioning the Solar Circuit To commission and check the solar circuit: Switch off the electrical supply at the power outlets to the solar storage tank and gas booster. If the pump has been operating, wait five minutes to allow the drain back of the closed circuit fluid in the solar circuit.
Page 50 COMMISSIONING 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. disconnect Take care when removing the solar circuit relief valve, as drain line...
Page 51 COMMISSIONING Check the closed circuit fluid is circulating around the solar circuit. To check circulation:  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.
Page 52 COMMISSIONING Drain Back Function Switch off the electrical supply at the power outlet to the solar storage tank. The red LED on the solar monitor label will stop flashing. 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.
Page 53 COMMISSIONING Closed Circuit Fluid Level 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 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”...
Page 54 COMMISSIONING 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.
Page 55 COMMISSIONING Measure into a container the amount of water to be added to top up the level of the closed circuit fluid in the heat exchanger if required. To add water to the closed circuit fluid:  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 Warning: The solar circuit may be under pressure.
Page 56 COMMISSIONING Pressure Testing the Solar Circuit Close the heat exchanger drain valve. heat exchanger drain valve Refit the solar circuit relief valve, orientating the valve closed outlet to the rear of the solar storage tank. Secure with the spring clip. Reconnect the drain pipe to the valve. Switch on the electrical supply at the power outlet to the solar storage tank.
Page 57 COMMISSIONING Remove Closed Circuit Fluid Level Hose Remove the clear hose from the solar storage tank when satisfied the commissioning procedure is complete. To remove the hose:  Ensure the heat exchanger drain valve is closed. heat exchanger  Remove the hose from the side of the storage tank drain valve closed and place the end into a container to collect the...
Page 58 COMMISSIONING DIAGNOSTIC FEATURES OF THE SOLAR CONTROLLER The solar storage tank incorporates a solar monitor which is connected to the solar control module by a ribbon cable. The solar monitor is located on the lower front cover and houses both a green and a red LED. The green LED, marked “Solar”, indicates the current operational mode of the solar water heater and the red LED, marked “Attention”, indicates a fault mode.
Page 59 Damage caused by freezing due to the unavailability of power at the gas booster is not covered by the Solahart warranty (refer to “Terms of the Solahart Warranty” on page 65). If the power has been switched off to the gas booster and there is a risk of freezing, then it is necessary to drain the gas booster (refer to “Draining the Water Heater”...
Page 60: Draining The Water Heater
DRAINING THE WATER HEATER GAS BOOSTER WATER HEATER To drain the gas booster water heater: Turn off the water heater (refer to “To Turn Off The Water Heater” on page 59). 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.
Page 61 DRAINING THE WATER HEATER HEAT EXCHANGER Warning: Exercise care, as fluid discharged from the heat exchanger may be of a very high temperature. To drain the heat exchanger: Switch off the electrical supply at the power outlet to the solar storage tank. Remove the lower front cover from the solar storage tank.
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Page 65 2.1 The decision of whether to repair or replace a faulty component is at Solahart’s sole discretion. 2.2 If you require a call out and we find that the fault is not covered by the Solahart warranty, you are responsible for our standard call out charge.
Page 66 3. WHAT IS COVERED BY THE SOLAHART WARRANTY FOR THE WATER HEATERS DETAILED IN THIS DOCUMENT 3.1 Solahart will repair or replace a faulty component of your water heater if it fails to operate in accordance with its specifications as follows:...
Page 67: Warranty
If a Solahart unit Tank Serial No Date of manufacture Collector Serial No’s 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...
Page 68: Solahart Offices
+ 1 334 260 1586 Australia For SERVICE Telephone - 1800 638 011 Facsimile International: + 1 334 260 1514 or your nearest Solahart Dealer For Sales Telephone - 1300 769 475 or your nearest Solahart Dealer Revision Date: 2012 January 126579D...

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Solahart Streamline Owner's Manual

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