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Installation and Servicing
Alpha SolarSmart 100
Pre-Heat Drain Back Solar System and Wall Mounted
Unvented Hot Water Solar Cylinder
for use with an Alpha Combination Boiler
These instructions have been carefully prepared but we reserve the right
to alter the specification at any time in the interest of product improvement.
© Alpha Therm Limited 2014.
Instructions
Also includes User's instructions at back
For Technical help or for Service call ...
ALPHA HELPLINE Tel: 0844 871 8764
email: info@alpha-innovation.co.uk
website: www.alpha-innovation.co.uk
Alpha Therm Limited
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
SOLAR Key Mark Certificated
Leave these instructions with the User
Part No. 1.032744 ST15.000233
0314/D337
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Summary of Contents for Alpha SolarSmart 100
- Page 1 Also includes User's instructions at back Alpha SolarSmart 100 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: 0844 871 8764 email: info@alpha-innovation.co.uk website: www.alpha-innovation.co.uk...
- Page 2 Telephone: 01926 513747 E-mail: info@hhic.org.uk Website: www.hhic.org.uk Useful contact details; Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk Alpha Heating Innovation; General Sales Enquiries - 0844 871 8760 Technical Helpline - 0844 871 8764 Alpha SolarSmart 100 - Benchmark Scheme...
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Page 3: Table Of Contents
The Alpha SolarSmart 100 system is a pre-heat drain back solar collector system which includes an unvented 103 litre cylinder to store water heated by the solar collector. It is recommended that the system is used in conjunction with an Alpha combination boiler fitted with the Alpha solar inlet sensor which is supplied with the system. -
Page 4: Technical Data
Collector Heat Loss Coefficient (a1) W/m²k 3.260 3.606 Aperture to Gross Collector Area Ratio 0.96 Max. Wind and Snow Load Pitched roof Same as Supporting Roof Structure Flat roof Wind Speed 25 m/s - Snow Load 1.9 kN/m Alpha SolarSmart 100 - Technical Data... - Page 5 INSTALLATION The collector installation must be carried out using the kits and connections supplied by Alpha. A maximum of two collectors can be connected together using the additional collector connection kit. Solar Cylinder Min. Clearances for Servicing Top 100 mm...
- Page 6 Cold water inlet Solar collector 11 Expansion vessel Collector temperature sensor 12 Immersion heater boss (use Alpha immersion kit only) Drain back unit (DBU) 13 Drain point for cylinder DBU pump 14 Pressure relief valve DBU heat exchanger...
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Page 7: General Information
5. Shall have a minimum of 300 mm straight pipework directly from the tundish. Note: Where children may play or otherwise come into contact with discharges, a wire cage or similar guard must be positioned to prevent contact whilst maintaining visibility. Alpha SolarSmart 100 - 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. 3 Alpha SolarSmart 100 - General Information...
- Page 9 SOLAR CYLINDER DESCRIPTION - Figs. 4 Positioning The SolarSmart 100 cylinder must be installed on a flat vertical wall which is capable of supporting the weight of the cylinder when full (140 kg). The cylinder may be installed in any room or internal frost free space, although particular attention is drawn to the...
- Page 10 Water connections The connections at the top and bottom of the DBU are shown in Fig. 5. Note: Use copper pipe and compression fittings only on the pipework between the DBU and solar collector. Alpha SolarSmart 100 - General Information...
- Page 11 Integration of the collector into the tiles of a pitched roof. Using the Alpha In Roof Flashing kit (portrait or landscape) collectors can be integrated into the structure of a pitched roof as shown in Fig. 7. The roof must have an inclination of more than 15° and the tiles used with the flashing kit must be suitable to ensure that the installation is weatherproof.
- Page 12 Collector mounted on a pitched roof. Using the Alpha On Tile Kit portrait or landscape collectors can be mounted on a pitched roof as shown in Fig. 8. The roof must have an inclination of more than 15°. Full details of this type of installation are provided in the instructions supplied with the kit.
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Page 13: Installation
INSTALLATION UNPACKING The SolarSmart 100 system is supplied in two boxes as follows: Mounting bracket Case fixing screws Drain back Control panel unit Solar cylinder Data label Data label Screws Fig. 10 - Box 1 Fig. 11 - Box 2... - Page 14 Fig. 14. MINIMUM BOTTOM CLEARANCE 300 mm FOR USE WITH 103 LITRES WALL HUNG UNVENTED SOLAR CYLINDER 132.5 50 50 50 82.5 Fig. 12 Bottom fixing holes and screws Fig. 13 Fig. 14 Alpha SolarSmart 100 - Installation...
- Page 15 (at least 40 mm per metre). There must not be any part of the pipework that will allow water to collect. Fig. 15 Keyhole slots Fixing holes Fixing holes Fig. 16 Fig. 17 Alpha SolarSmart 100 - Installation...
- Page 16 FIT THE BOILER AND CONNECT THE PIPEWORK An Alpha combination boiler should be used with the SolarSmart system. Install the boiler as described in the instructions supplied with the boiler. Connect the outlet from the solar cylinder directly to the boiler cold water inlet connection, as shown in Fig. 1.
- Page 17 Note: Ensure that the length of the earth wire is such that if the supply cable is pulled out of its clamp the live and neutral wires become taut before the earth wire. Fitting the optional Alpha immersion heater Terminal block Remove the blanking plug and washer as shown in Fig. 21.
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Page 18: Commissioning
If there is enough solar light at the collector the cylinder pump will run, shortly followed by the drain back unit pump. Alpha SolarSmart 100 - Commissioning... - Page 19 Solar system operational Degrees celsius Unit of temperature Digits Display temperature, parameters values and fault codes S1 S 2 3 S Temperature sensors Active sensors Solar cylinder Cylinder state correct Solar collector Solar collector state correct Alpha SolarSmart 100 - Commissioning...
- Page 20 Ensure the Checklist at the back of these instructions has been completed after the unit has been installed and commissioned. Leave these instructions with the User for use on future calls and for recording details in the Service Record at the back of these instructions. Alpha SolarSmart 100 - Commissioning...
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Page 21: System Operation
If a fault occurs, a flashing warning symbol (see Fig. 23 and Section 5.4) appears in the display and a fault code will be displayed. Refer to Section 10 for a list of fault codes and possible solutions. Alpha SolarSmart 100 - System Operation... -
Page 22: Routine Inspection
Record details of the service in the Service Record at the back of these instructions. It is recommended that any service work is carried out by a competent person. Warning: Before removing any covers or working on the system, isolate the electrical supply. Alpha SolarSmart 100 - System Operation/Routine Inspection... -
Page 23: Component Replacement
Upper cylinder sensor Expansion vessel Expansion vessel union and locknut Control unit fixing screws Fixing screws Terminal block cover Lower cylinder sensor Pressure relief valve (safety manifold assy.) Drain point Pump union (each side) Fig. 27 Alpha SolarSmart 100 - Component Replacement... - Page 24 Refer to Section 5.2 to refill the drain back unit. Retaining bracket fixing screws Pump unions Heat exchanger Cylinder bottom connection Heat exchanger connections (4 off) Drain point Connection and locknut Connection and locknut Fig. 28 Alpha SolarSmart 100 - Component Replacement...
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Page 25: Wiring Diagram
Bk Black Bl Blue G/Y Green/Yellow Gy Grey 12 46 45 70 69 Solar Upper Collector Cylinder Probe Sensor Lower Supply Cylinder 230 V ~ 50 Hz DBU Solar Pump Sensor Optional Immersion Heater Alpha SolarSmart 100 - Component Replacement/Wiring Diagram... -
Page 26: Diagnostics And Fault Codes
The built in overheat thermostat function has activated. Cylinder overheat fault Check cylinder pump function. Check immersion heater setting (if fitted). Cylinder temperature 85°C Check immersion heater thermostat is correctly set and switching off (approx. 60°C). or greater Alpha SolarSmart 100 - Diagnostics and Fault Codes... - Page 27 Collector Sensor Resistance Table Cylinder Sensor Resistance Table Resistance (Ohm) Resistance (Ohm) Temperature Temperature +/- 20 Ohm +/- 20 Ohm (°C) (°C) 1000 10000 1100 8500 1200 2500 1300 1500 1400 1500 1600 Alpha SolarSmart 100 - Diagnostics and Fault Codes...
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Page 28: Parts List
Seal kit - interconnecting pipework 3.0237791 Inlet safety manifold assembly 3.022662 Boiler inlet sensor 3.022467 Note: Washers and seals are not supplied with the replacement components and the relevant seals kit should also be used. Alpha SolarSmart 100 - Short Parts List... - Page 29 Drain Back Unit Ref. Description Qty. Part No. Top connection pipe - collector return (22 mm) 1.026759 Top connection pipe - collector flow (15 mm) 1.033644 Drain back circulation pump 1.033420 Pump flange seal 1.023511 Plate heat exchanger 1.032492 Vent plug 1.4275 Front insulation casing 1.033200...
- Page 30 SOLAR THERMAL COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the Solar Thermal System and associated equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
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Page 31: Service Record
Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
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