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SOLSTREAM™ Complete Thermal Exchange Gas Fired Water Heater
Installation, Operation, and Maintenance Manual
Certified to
5
U.S. patent 5,924,391
Keep this manual with
Hamilton Engineering Company, Inc.
heater for future reference.
34000 Autry Street, Livonia, MI 48150 | hamiltonengineering.com
Ph. 734.419.0200 | Toll Free 800.968.5530 | Fax 734.419.0209
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Table of Contents
Related Manuals for Hamilton Engineering SOLSTREAM DCH-1000
Summary of Contents for Hamilton Engineering SOLSTREAM DCH-1000
- Page 1 SOLSTREAM™ Complete Thermal Exchange Gas Fired Water Heater Installation, Operation, and Maintenance Manual Certified to U.S. patent 5,924,391 Keep this manual with Hamilton Engineering Company, Inc. heater for future reference. 34000 Autry Street, Livonia, MI 48150 | hamiltonengineering.com Ph. 734.419.0200 | Toll Free 800.968.5530 | Fax 734.419.0209...
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Page 2: Table Of Contents
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Page 3: Safety
Improper installation or operation may cause a � Generally applicable codes in the US fire or explosion resulting in property damage, include: personal injury, or death. Hamilton Engineering · NEC strongly recommends that a qualified installer be · NFPA #86 used. -
Page 4: The Solstream™ System
Heat water up to 185°F maximum � Typical System Heater Transfer Storage Tank Pump Hamilton Engineering reserves the right to make design or specification changes without notification. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Typical System and Maintenance Manual Water Heater... - Page 5 � Energy conservation measures (ECM) � For further information, visit http://www.hamiltonengineering.com or contact Hamilton Engineering. Note: Hamilton provides separate IOMs for the burner, blower, and for optional components. Consult the appropriate document for more information. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation,...
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Page 6: Specifications
· May be manufactured to comply with various other electrical or water quality standards · Three-phase power is required; most available voltages may be accommodated *Consult factory for additional information. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications — Heater... -
Page 7: Dimensions
*DCH capacity ratings are subject to a +/- 5% total output variance based on supply conditions variables and combustion requirements. If actual installation conditions differ from those listed in the product IOM then the 5% variance may be additionally impacted. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications —... -
Page 8: Orientation
Gas inlet (behind pipe) Water inlet High temp shut-off switch Lower Canister Level switches Hot water outlet Anchoring tab Drain plug Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications — Heater and Maintenance Manual Water Heater Page 6 of 49... - Page 9 Low gas pressure switch Dual blocking valves Visual display of valve state (white = closed red = open) Regulator Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications — Heater and Maintenance Manual Water Heater Page 7 of 49...
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Page 10: Transfer Pump Assembly
2-1/2 2-1/2 7.46 TP-350 79.5 7.46 Orientation Bypass Water outlet Throttling valve Actuated valve Pump Water inlet Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications — Transfer Pump Assembly and Maintenance Manual Water Heater Page 8 of 49... -
Page 11: Storage Tank
Wind load 0 mph/kph Immersion heater port 4" NPT Sight glass port 1" NPT Insulation thickness 2" (50 mm) Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications — Storage Tank and Maintenance Manual Water Heater Page 9 of 49... -
Page 12: Orientation
(1" NPT) cutoff (if used) (optional tank level sensor) Outlet Outlet for immersion heater (4" NPT) Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Specifications — Storage Tank and Maintenance Manual Water Heater Page 10 of 49... -
Page 13: Assembly And Installation
Remove cable ties from wiring and unbolt top plate from lower canister. Note: Long bolt in blower motor bracket must be reinstalled in that hole. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Unpacking | Installing Large Heaters and Maintenance Manual Water Heater... - Page 14 16 bolts. 24-bolt patterns should be tightened similarly. Attach canister sections as for a small heater below. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Installing Large Heaters and Maintenance Manual Water Heater Page 12 of 49...
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Page 15: Installing Small Heaters
Liberal application of an anti-sieze compound is strongly recommended. Raise entire heater slightly above floor to allow self-aligning. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Installing Small Heaters and Maintenance Manual Water Heater Page 13 of 49... - Page 16 Repeat tightening sequence after several hours and after a few days of operation or as leaks occur. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Installing Small Heaters and Maintenance Manual Water Heater Page 14 of 49...
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Page 17: Installing Exhaust Ducting
All other models have a flange (shown). Joint should be sealed with RTV (clear silicone). Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Installing Exhaust Ducting and Maintenance Manual Water Heater Page 15 of 49... -
Page 18: Installing Intake Air Ducting
· CPVC recommended every 10 feet required. · Galvanized sheet metal removed from heater. · Single wall stainless steel Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Installing Intake Air Ducting and Maintenance Manual Water Heater Page 16 of 49... -
Page 19: Water Connections
Lower canister Transfer pump assembly must be installed on level surface and at or below heater level to maintain pump's prime. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Water Connections and Maintenance Manual Water Heater Page 17 of 49... -
Page 20: Fuel Connection
Failure to do so may damage fuel regulator. With ball valve entering fuel train closed, purge air from fuel line. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Fuel Connection and Maintenance Manual Water Heater... -
Page 21: Electrical Panels
Power supply Programmable 24 VDC logic controller (PLC) Ethernet switch Control relay Fuse 1 (5A) Terminal block Control Panel Cover Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Control Panel and Maintenance Manual Water Heater Page 19 of 49... -
Page 22: Disconnect Panel
Note: This is a sample label. All electrical work must conform to the specifications on this label as found on your heater. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Heater Label and Maintenance Manual Water Heater Page 20 of 49... -
Page 23: Electrical Connections
In disconnect panel, connect and into wires to motor overload control panel. disconnect panel. connection terminals below motor starter. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Electrical Connections and Maintenance Manual Water Heater Page 21 of 49... -
Page 24: Upper To Lower Canister
Reconnect conduit. Connect wires to corresponding number locations in terminal block. Repeat for float switch wiring from standpipe. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Electrical Connections and Maintenance Manual Water Heater Page 22 of 49... -
Page 25: Transfer Pump
Connect numbered wires to corresponding terminals on terminal block. Cycle Start Power * For float orientation consult wiring diagram supplied with unit. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Electrical Connections and Maintenance Manual Water Heater Page 23 of 49... -
Page 26: Main Power Connection
Main Power Connection Solstream™ Installation, Operation, and Maintenance Manual Note: If facility does not have surge and lightning protection, Hamilton Engineering recommends both for heater. Connect supply voltage to top terminals of main fuse disconnect inside disconnect panel. Manually test each starter ("bump the starter") to check for correct motor rotation,... -
Page 27: Operation
Pump runs in lower continuously canister. during heating cycle. Water level is controlled by four float switches in standpipe connected to bypass loop. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 25 of 49... -
Page 28: Sequence Of Operation
A. Note: PLC is preset. Re-progamming it without written permission will void the warranty and absolve Hamilton Engineering of all service commitments. If low gas pressure, high gas pressure, and high temperature switches are all closed (no fault conditions), power will be supplied to Veri-Flame controller. -
Page 29: Pre-Start-Up Checklist
· Float switches correctly wired to heater … Main power supply properly connected · Three phase · Voltage as specified on nameplate and connections Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 27 of 49... -
Page 30: Commissioning
Note: Start-up process requires running heater in "MANUAL" mode, which overrides all automation and produces hot water continuously until heater is manually turned off. Never leave heater unattended in "MANUAL" mode. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Commissioning and Maintenance Manual Water Heater... - Page 31 Run heater in "AUTOMATIC" mode to confirm proper operation in that mode. Allow heater to sit and cool for several hours, then check for cold start. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Inspecting Installation...
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Page 32: Periodic Maintenance
· Dump all water again (including in the DCH basin) when · Fill with fresh clean water warmer is · Run unit cleaned) Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 30 of 49... -
Page 33: High Temperature Switch Check
If not, contact Hamilton. Press reset button and replace cover. Caution: Wiring is live! Avoid touching connections! Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 31 of 49... -
Page 34: Troubleshooting
Turn regulator adjustment screw CCW to reduce High Gas Pressure pressure. Defective pressure regulator spring Replace spring. Defective pressure regulator Replace regulator. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Troubleshooting Table and Maintenance Manual Water Heater Page 32 of 49... - Page 35 ("MANUAL" stays lit after flame is established) Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, Troubleshooting Table and Maintenance Manual Water Heater Page 33 of 49...
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Page 36: Plc I/Os
E-Stop - Run Relay Chain IN 16 Interlocks Closed IN 17 AIr Flow IN 18 Main Fuel P.O.C. IN 19 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, PLC I/Os and Maintenance Manual Water Heater Page 34 of 49... -
Page 37: Parts Lists
For burner parts, contact MAXON Corp., 765-284-3304 (fax: 765-286-8394) For blower assembly parts, contact Cincinnati Corp., DCH-5000 to15000 D26712 513-573-0600 (fax: 513-573-0640) Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 35 of 49... -
Page 38: Water Train
Actuacted Valve Assembly 1-1/2" D53229 2" D30041 Welded 2-1/2" D76536 Stainless Steel 3" D76537 4" D76750 VB030 Electric Actuator D76170 VB060 Electric Actuator D70728 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 36 of 49... -
Page 39: Disconnect Box
Relay 4PDT 24VDC Coil D56376 Relay Slim 2PDT 120VAC Coil D30776 Power Supply 24VDC 90W D34094 Ethernet Switch Unmanaged 5 Port D60074 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 37 of 49... - Page 40 750VA 480 x 240 – 120 D17409 10 HP D7657 750VA 575/380 – 115 D13662 15 HP D7658 20 HP D7659 25 HP D7660 30 HP D7661 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 38 of 49...
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Page 41: Fuel Train
Visual Proof of Closure Indicator D11573 Electrical Proof of Closure Indicator (CPI-400) D14826 DIN Connector (D210319) D14827 Pressure Gauge, 1"–100" w.c. D14828 DCH-1000 to DCH-4000 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 39 of 49... -
Page 42: Lower Canister
DCH-2000 D7566 DCH-3000 D7567 DCH-4000 D7568 DCH-5000 D7569 DCH-6000 D7570 DCH-7000 & 8000 D7571 DCH-9000 to DCH-12000 D7576 DCH-13000 to DCH-15000 D7579 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 40 of 49... -
Page 43: Appendix: Modulating Burner
Float Switch, Polypropylene D16907 Thermometer, Back Mount, 4" Stem D8969 Plug, 2" NPT, 304 SS D18789 Plug, 1" NPT, 304 SS D16918 Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 41 of 49... -
Page 44: Operation
RUN button will switch to auto run mode and the heater will start and stop via an external input. This can be float switches in a storage tank, a remote run control relay or a remote run bit via Ethernet connection. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation,... - Page 45 Gas system faults must be reset manually at the switch which is faulted (see troubleshooting section). Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater...
- Page 46 Press the setpoint button to bring up the local setpoint menu shown below. Use this menu to increase or decrease the local setpoint. Press the MOD/POS button to toggle between modulating temperature mode and direct positon control. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater...
- Page 47 HMI for ten minutes the current user will be automatically logged out and the HMI will return to the main display screen. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater...
- Page 48 Pressing the BACK button will return the Menu screen. This screen is useful for troubleshooting wiring issues and to help determine the heater run state as it progresses through its sequence of operation. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater...
- Page 49 Clear button, or all at once by pressing the Clear All button. Then the display can be dismissed by pressing the Close button. Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation,...
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Page 50: Limited Warranty And Remedy
Limited Warranty and Remedy Hamilton Engineering warrants to the original user of those products supplied by it and used in the service and in the manner for which they are intended, that such products shall be free from defects in material and workmanship for a period of one (1) year from the date of installation, but not longer than 15 months from the date of shipment from the factory [unless a special warranty period applies, as listed below]. -
Page 51: Notes
Solstream™ Installation, Operation, and Maintenance Manual Notes Hamilton Engineering Company, Inc. LIT97000 | Solstream™ Installation, Operation, and Maintenance Manual Water Heater Page 49 of 49...
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