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Alpha SolarSmart 90 Installation And Servicing Instructions

Pre-heat drain back solar system and wall mounted unvented hot water solar cylinder for use with an alpha combination boiler
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Installation and Servicing

Instructions
Alpha SolarSmart 90
Pre-Heat Drain Back Solar System and Wall Mounted
Unvented Hot Water Solar Cylinder
for use with an Alpha Combination Boiler
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Leave these instructions with the User

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Summary of Contents for Alpha SolarSmart 90

  • Page 1: Installation And Servicing

    Instructions Alpha SolarSmart 90 Pre-Heat Drain Back Solar System and Wall Mounted Unvented Hot Water Solar Cylinder for use with an Alpha Combination Boiler For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road,...

  • Page 2: Table Of Contents

    Alpha Solar valve which is supplied with the system. The SolarSmart 90 system consists of a 90 litre cylinder, a 2.5 m² flat plate drain back solar collector, drain back unit, unvented kit and solar valve. The 90 litre unvented cylinder is fitted with a pump, control box and temperature sensors.

  • Page 3: Technical Data

    Temperature Sensor Type - NTC 10 k Connections Pre-mounted Flexible Hoses Return to DBU mm 12 mm Flow from DBU mm 15 mm Minimum Roof Slope 20° Energy Performance (System with 90L tank) GJ/yr Alpha SolarSmart 90 - Technical Data...
  • Page 4 Max. Distance Between DBU and Bottom of Solar Cylinder Max. Distance Between Top of Solar Collector and Bottom of Solar Cylinder ELECTRICAL CONNECTIONS Notes: This Appliance Must Be Earthed. Do Not Connect Any Other Controls. Fig. 1 Alpha SolarSmart 90 - Technical Data...
  • Page 5 Diffuser 21 Temperature and pressure relief valve 10 DHW outlet pipe 22 Expansion vessel 11 Solar valve 23 Pressure reducing valve with filter 12 Flow to boiler 24 Drain point for cylinder Fig. 2 Alpha SolarSmart 90 - Technical Data...

  • Page 6: General Information

    Note: The hot water control thermostat on the combination boiler must always be turned to maximum. To ensure economic use, the pipe runs to the Alpha combination boiler and taps should be in 15 mm copper pipe and be as short as possible. Where possible the pipework should be insulated to reduce heat loss.
  • Page 7 Water temperature more than 60°C Cold water supply Expansion vessel Filter Check Expansion Pressure valve relief valve reducing valve Unvented kit Tundish Discharge Stop pipe valve Mains water supply Fig. 3 Alpha SolarSmart 90 - General Information...
  • Page 8 Therefore the maximum permitted length equates to 18 - 4 = 14 m End of pipe to be As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory. clearly visible Fig. 4b Alpha SolarSmart 90 - General Information...
  • Page 9 The connections at the bottom of the cylinder are shown in Fig. 5b. Cylinder Connections A Water outlet to boiler 15 mm B Cold water inlet 15 mm C Return from DBU 15 mm D Flow from cylinder to DBU 15 mm Fig. 5b Alpha SolarSmart 90 - General Information...
  • Page 10 A Return from collector to DBU 12 mm Bottom B Flow from DBU to collector 15 mm C Flow from cylinder to DBU 15 mm D Return from DBU to cylinder 15 mm Fig. 6 Alpha SolarSmart 90 - General Information...
  • Page 11 The solar collector can be installed using one of the following methods: Integration of the collector into the tiles of a pitched roof: Using the Alpha Flashing Kit (Part No. 6.4000750 portrait or Part No. 6.4000650 landscape), landscape or portrait collectors can be integrated into the structure of a pitched roof as shown in Fig.

  • Page 12: Installation

    INSTALLATION UNPACKING Top cover The SolarSmart 90 system is supplied in three boxes as follows: Clamping bracket Top wall Box 1 - Solar cylinder mounting bracket Contents: Solar cylinder Inlet pipework assembly Temperature/pressure relief valve with discharge pipe Casing and insulation...
  • Page 13 Fig. 11a wall. Secure the top of the cylinder to the top mounting bracket using closing bracket as shown in Fig. 11c. Rear view Clamping bracket Wall bracket Solar cylinder Fig. 11b Fig. 11c Alpha SolarSmart 90 - Installation...
  • Page 14 Mark the position of the three fixing holes. Drill the holes approximately 40 mm deep using a 6 mm dia. drill. Plug the holes and secure the unit to the wall, using the plugs and screws supplied. Replace the DBU front cover. Fig. 12b Alpha SolarSmart 90 - Installation...
  • Page 15 Fig. 13 FIT THE BOILER AND THE SOLAR VALVE Only an Alpha combination boiler may be used with the SolarSmart 90 system. Install the boiler as described in the instructions supplied with the boiler. Connect the solar valve directly to the boiler cold water inlet connection, then connect the pipework to the solar valve as shown in Figs.
  • Page 16 Note: The User must be informed of the purpose of this label, which must not be removed. IMPORTANT This Combi boiler is fitted to an Alpha Solar system and the hot water thermostat MUST always be set at maximum (No.9).
  • Page 17 Do not switch on the electrical supply at this stage. Do not make any connections to terminals 4, 5, 6, or 7 and do not fit any other controls. Alpha SolarSmart 90 - Installation...

  • Page 18: Commissioning

    Replace the plug in the fill/overflow point. DBU pump Switch on the electrical supply and 'start up' the Solar system as described in Section 5.3. Check for any leaks and replace the front cover. Drain point Cylinder Fig. 19 Alpha SolarSmart 90 - Commissioning...
  • Page 19 The flashing dot in the middle of the display shows that only the cylinder pump is running. Flashing fault codes (71 to 84). Refer to Section 7 for a list of fault codes and possible solutions. Alpha SolarSmart 90 - Commissioning...

  • Page 20: System Operation

    Solar cylinder Collector sensor Lower cylinder temperature Drain back unit sensor Drain back unit pump Heat exchanger Cylinder pump Hot water to taps Warm water to boiler Solar valve Mains cold water inlet Fig. 21 Alpha SolarSmart 90 - System Operation...
  • Page 21 24 hours when it returns to normal. Pumps If the electrical supply is on and the solar system has not operated for 24 hours, the pumps will operate automatically every 24 hours, providing the collector temperature is above 10°C. Alpha SolarSmart 90 - System Operation...

  • Page 22: Routine Inspection

    Check the charge in the domestic hot water expansion vessel and re-pressurise, if necessary. Note: Only check the expansion vessel charge when the system pressure is zero. Record details of the inspection in the Inspection History Section 11. Alpha SolarSmart 90 - Routine Inspection...

  • Page 23: Wiring Diagram

    Lower Cylinder Sensor Cylinder Pump Pump N L 8 9 10 11 DO NOT Solar Collector Supply Sensor 230/240 V ~ 50 Hz Fused at 3 A NOTE: Do not connect any other external controls Alpha SolarSmart 90 - Wiring Diagram...

  • Page 24: Diagnostics And Fault Codes

    Check the collector tubes, are they blocked with dirt? Is the decline of the pipes within the 40 mm per metre requirement. Check the electrical connection and operation of the drain back unit pump and the cylinder pump. Alpha SolarSmart 90 - Diagnostics and Fault Codes...
  • Page 25 Ω Ω Ω Ω Ω (Ohm) Ω Ω Ω Ω Ω (Ohm) °C °C °C 32.15 6.53 1.75 26.31 5.33 1.48 19.86 4.37 1.26 15.89 3.60 1.07 12.49 2.99 0.92 10.00 2.49 0.79 8.06 2.09 0.68 Alpha SolarSmart 90 - Diagnostics and Fault Codes...

  • Page 26: Short Parts List

    Expansion relief/ check valve - 6 bar 6.0001020 Tundish 1.018148 Solar valve 3.017409 Collector temperature sensor kit 4.1060719 Drain back unit pump 4.1060730 Drain back unit heat exchanger 4.1060509 Front and back housing - drain back unit 4.1060506 Alpha SolarSmart 90 - Short Parts List...

  • Page 27: 11 Inspection History

    ........................................................................................................................................................................................................................................................................................................................................................................................................................................Alpha SolarSmart 90 - Inspection History...
  • Page 28 These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2006. Tel: 0870 3001964 email: info@alphatherm.co.uk website: www.alpha-boilers.com...

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