Solahart Thermosiphon Owner's Manual
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Solahart Thermosiphon Owner's Manual

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Thermosiphon
Solar Water Heaters
Owner's Guide
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Installation Instructions
This water heater must be installed and serviced by a qualified person.
Please leave this guide with the householder.

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Summary of Contents for Solahart Thermosiphon

  • Page 1 Thermosiphon Solar Water Heaters Owner’s Guide Installation Instructions This water heater must be installed and serviced by a qualified person. Please leave this guide with the householder.
  • Page 2 An electronic copy of these Owner’s Guide and Installation Instructions can be downloaded from solahart.com.au. PATENTS This water heater may be protected by one or more patents or registered designs in the name of Solahart Industries Pty Ltd. TRADE MARKS ®...

  • Page 3: Table Of Contents

    Solahart warranty. We recommend you read pages 6 to 19, and the terms of the Solahart warranty on pages 4 to 5. The other pages are intended for the installer but may be of interest.

  • Page 4: Solahart Thermosiphon Solar Water Heater Warranty

    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 5 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: The period from the date of...

  • Page 6: Safety, Warnings, Installation Notes

    The Solahart warranty may not cover faults if relief valves or other safety devices are tampered with or if the installation is not in accordance with these instructions.
  • Page 7 Refer to on page 18. If the relief valve easing lever is not readily and safely accessible, contact your nearest Solahart Dealer. Do not attempt to climb onto a non-trafficable roof to operate the relief valve lever.
  • Page 8 SAFETY, WARNINGS, INSTALLATION NOTES Installation Notes This water heater must be installed: • by a qualified person, • in accordance with the installation instructions, • in Australia in compliance with the Plumbing Code of Australia (PCA) and Plumbing Standard AS/NZS 3500.4, and in other countries in compliance with their national plumbing Standards, ▪...

  • Page 9: Here's How It Works

    Solar Operation The solar water heater uses the thermosiphon principle, without the need for a pump, circulator or sensors. It works on the simple scientific fact that hot fluid rises. The solar collector’s low-iron content solar glass allows more solar energy from the sun to pass through and be used to heat the collector’s absorber plate than conventional glass.

  • Page 10: Facts You Should Know About Your Water Heater

    ‘Hartgard’ Solution – Freeze Protection Solahart Closed Circuit Systems are protected against freezing or harsh water conditions by our exclusive ‘Hartgard’ fluid. ‘Hartgard’ is a blue, non-toxic, propylene glycol fluid which, when mixed with water, provides the Heat Transfer Fluid contained in the solar collectors and the heat exchanger jacket around the tank.
  • Page 11 During the water heater's first summer season, fluid will discharge from the relief valve until the ideal closed circuit fluid volume is established. Discharges from the valve after this time could indicate the water heater is not operating efficiently. Under these circumstances contact your nearest Solahart dealer immediately. Do not attempt to service the water heater yourself.

  • Page 12: Operating Your Solar Water Heater

    AS 3498. The overall performance and energy savings that you will obtain from your Solahart water heater will depend on your hot water usage pattern and your operation of the in-tank booster. A time clock can increase energy savings.
  • Page 13 OPERATING YOUR SOLAR WATER HEATER Timer Control of the Tank Boosting A timer control switch can be installed and will help maximise energy savings with an electrically boosted solar water heater connected to a continuous, time of use or extended Off-Peak (overnight and day) electricity supply. Further “Timer Control Switch”...
  • Page 14 Note: With flow-controlled water heaters the Solahart water heater can act as a supplementary heat source only not as a pre-heater. The Solahart heater can be connected in a parallel circuit only via a changeover valve(s).

  • Page 15: Save A Service Call

    Electric meter speeds up when the booster switch is turned ON after being OFF. Contact your local Solahart Dealer if all of the above have been checked and there is still no hot water. TEMPERATURE PRESSURE RELIEF VALVE OR EXPANSION CONTROL VALVE RUNNING •...

  • Page 16: Water Supplies

    (TDS) content in the water is less than 2500 mg/L and when the correct colour coded anode is used. If an incorrect colour coded anode is used in the water heater, any resultant faults will not be covered by the Solahart warranty. In addition, the use of an incorrect colour coded anode may shorten the life of the water heater cylinder.
  • Page 17 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 very corrosive and the Solahart warranty does not apply to a copper sheathed heating unit or a solar collector in an open circuit solar water heater system. A corrosion resistant heating unit must be used for the Solahart warranty to apply to the heating unit.

  • Page 18: Maintenance Requirements

    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...
  • Page 19 Note: The five year service and routine replacement of any components, such as the anode and relief valve(s), 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 20: Installation Instructions - All Models

    NOTE: Sufficient space should be left around the thermosiphon solar water heater to allow for safe service access. A distance equal to the length of the tank should be left at the water supply connections end of the tank to any wall or obstruction so that the anode can be removed and replaced during a service.
  • Page 21 However, the optimum inclination of solar collectors is not always practical or achievable. Solar collectors may be installed at the roof angle for simplicity of installation and appearance, but must never be less than 10° for a thermosiphon water heater installation.
  • Page 22 INSTALLATION INSTRUCTIONS - ALL MODELS Electrical ELECTRICAL CONNECTION AND CODES The power supply to the water heater must not be switched on until the water heater is filled with water and a satisfactory megger reading is obtained, or damage to the heating unit will result. All electrical work and permanent wiring must be carried out by a qualified person and in accordance with national and local codes and regulatory authority requirements applicable in your area.
  • Page 23 INSTALLATION INSTRUCTIONS - ALL MODELS Booster Control The isolating switch(s) installed at the switchboard and adjacent to the solar storage tank (if installed) should be left switched on. Leaving the isolating switch(s) switched on will also provide a sufficient period of time each day for the booster heating unit to operate, if required, to satisfy the requirements of AS 3498.
  • Page 24 EXPANSION CONTROL VALVE An RMC H50 Expansion Control Valve (part no 451103) is supplied in the pipe kit and Solahart recommend its fitment in all instances. Install the expansion control valve using a brass Tee, brass union and brass nipple on the cold water line to the water heater.
  • Page 25 93°C. Failure to observe this precaution may result in damage to pipe work and property. WATER PRESSURE Solahart advises the limiting of water pressure to 500kPa with a pressure limiting valve to suit this solar water heater and its associated pressure relief valves. Refer to local plumbing codes (e.g. AS/NZS3500.4) for specific requirements of permissible supply pressure and associated reduction/limiting valve type applicability.
  • Page 26 PACKING, STORAGE & TRANSPORTATION All Thermosiphon products are to be kept in the original packaging materials and should be transported or stored in the vertical position - note there is an arrow to indicate the ‘UP’ direction for Tanks. They may be stored horizontally in the correct orientation, as shown on the packaging, if handled carefully with correct lifting equipment.
  • Page 27 Thermosiphon Pipe Shroud Cover The function of the Pipe Shroud Cover is to cover the plumbing pipe-work and electrical connections to the thermosiphon tank, including the drain line from the temperature pressure relief valve, without restricting pipe runs for the installation or the operation of the TPR valve.
  • Page 28 INSTALLATION INSTRUCTIONS - ALL MODELS FITTING THE PIPE SHROUD COVER The Pipe Shroud Cover contains a number of preformed cut outs. • Each cut-out can be removed using a pair of snips by following the preformed cut-out lines. • Remove only the necessary cut-outs to suit the installation.

  • Page 29: Installation Instructions - Closed Circuit Series

    INSTALLATION INSTRUCTIONS – CLOSED CIRCUIT SERIES Warning: The tanks and collectors are heavy. Improper lifting techniques could result in personal injury during installation. It is the installer’s responsibility to use only approved lifting and safety devices and techniques when lifting collectors and tanks on roofs.
  • Page 30 In locations frequently subject to atmospheric temperature below -10ºC, hot and cold pipes and valves may freeze even when insulated. It is recommended that in these locations, the cold pipes and valves to the Solahart storage tank and the hot pipe from the tank should have electric heater tape under the insulation.
  • Page 31 ‘Hartgard’. If potable water cannot be sourced, then distilled or deionised water should be used. Only Solahart trained and authorised installers are permitted to fill the closed fluid circuit. Refer to your Solahart dealer for more information. For authorised installers, a special set of instructions and installation tools are provided.
  • Page 32 If this is the case, then the section of gutter immediately beneath the proposed location of the new Solahart system should be isolated from the rainwater collection system. This can be done by blocking that section of gutter from the remaining gutter, and fitting a separate down pipe to take any run-off water from that section of roof away to waste.
  • Page 33 INSTALLATION INSTRUCTIONS – CLOSED CIRCUIT SERIES CLOSED CIRCUIT COMMISSIONING PROCEDURE It is necessary to fill the heat exchanger and solar collectors with closed circuit fluid before the water heater can be operated and solar contribution achieved. Ensure the solar storage tank is filled with water and the solar collectors are covered with an opaque material.
  • Page 34 INSTALLATION INSTRUCTIONS – CLOSED CIRCUIT SERIES • With the ½” hose connected to the Valve Drain port of the Fill Drain Valve Assembly, loosen (but do not remove) the Valve Screw in the Fill Drain Valve Assembly. Important: There should be no water spillage, however if more than 0.5 litres of water is spilled, repeat steps 1-5. •...

  • Page 35: Installation Instructions - Open Circuit Series

    36). Fit the cold pipe to the tank cold inlet socket. Refer to Circuit Systems – Thermosiphon Restrictor Valve (TRV)” on page 37 if a Thermosiphon Restrictor Valve (TRV) is to be installed in the cold pipe. Secure the tank to the roof rafters in a similar manner to that for the collectors, using the tank straps (Part No. 204600) and the aluminium clamps (Part No.
  • Page 36 INSTALLATION INSTRUCTIONS – OPEN CIRCUIT SERIES FIBRO CEMENT OR METAL SHEET ROOFING Select a location for the storage tank close to a purlin. Avoid locating tank at mid-span of sheeting. Fixing and assembly procedures are similar to that detailed for tiled roofs, with the exception that the tank straps and the collector straps are fixed with coach screws to the purlins below (refer to drawings, Page 49).
  • Page 37 OPEN CIRCUIT SYSTEMS – THERMOSIPHON RESTRICTOR VALVE (TRV) A Thermosiphon Restrictor Valve (TRV) is available for use on an open circuit system to assist with over temperature protection of the system. The TRV locates in the top end of the cold pipe assembly. A non-standard cold pipe arrangement is required to accommodate the TRV.
  • Page 38 INSTALLATION INSTRUCTIONS – OPEN CIRCUIT SERIES INSTALLATIONS INCLUDING TEMPERATURE LIMITING DEVICES In the event of the collectors stagnating and generating steam, it is possible that high temperature water may by-pass the temperature limiting device. To prevent this from occurring please follow the connection details shown below. Where a temperature limiting device is installed adjacent to the solar 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 and pressure limiting valve to the solar storage tank, but it MUST BE before the non-return valve prior to an open circuit system.

  • Page 39: Technical Specifications - Systems

    TECHNICAL SPECIFICATIONS – SYSTEMS Systems 151L 151J 181L 181AP07D 181J 181SP 181CS07C 181CS13C 181BTC Capacity litres US gal. Auxiliary litres boost US gal. Weight (full) Weight (empty) Length 2.49 2.49 2.49 2.49 2.49 2.49 2.63 2.63 2.49 98.0 103.5 103.5 Height 0.51 0.51...

  • Page 40: Technical Specifications - Tanks And Collectors

    TECHNICAL SPECIFICATIONS – TANKS AND COLLECTORS 180L & 300L & Tanks 150L 150J 180J 180F 300J 300F Tank Material Information 180LX 300LF Cylinder material Steel, low carbon, 2.5 mm (0.1") Capacity litres US gal. Weight Cylinder lining Brilliant Cobolt Blue (full) ceramic vitreous enamel Weight...

  • Page 41: Annual Performance Calculations For Europe

    These collectors and systems are routinely used in Australian Cyclonic regions. J SYSTEMS Annual performance calculations of Solahart thermosiphon J systems with the J collector according to EN12976 SolarKeyMark Systems ITW Test Report 10SYS82-1 for the 151J (150 tank, 1 collector), 181J (180 tank, 1 collector), 302J (300 tank, 2 collectors) and 303J (300 tank, 3 collectors) systems.
  • Page 42 ANNUAL PERFORMANCE CALCULATIONS FOR EUROPE L SYSTEMS Annual performance calculations of Solahart thermosiphon L systems with the L collector according to EN12976 SolarKeyMark Systems ITW Test Report 11SYS92-01 for the 151L (150 tank, 1 collector), 181L (180 tank, 1 collector), and 302L (300 tank, 2 collectors) systems.

  • Page 43: South African System Sans 1307 Details

    SOUTH AFRICAN SYSTEM SANS 1307 DETAILS System 181J 302J Tank 180J / 180F 300J / 300F Collector 1 x J 2 x J This is a dual purpose water heater. Type For solar heating, this is an indirect heated tank. Moisture Resistance Classification IP34 IP34...

  • Page 44: Installation Diagrams - Models 151J, 181J, 181Lcsc, 181Btc

    INSTALLATION DIAGRAMS – MODELS 151J, 181J, 181LCSC, 181BTC 151J 181J, 181LCSC, 181BTC * J collector illustrated.

  • Page 45: Installation Diagrams - Models 151L, 181L

    INSTALLATION DIAGRAMS – MODELS 151L, 181L 151L 181L...

  • Page 46: Installation Diagrams - Models 302J, 302Lcsc, 302Btc, 303J

    INSTALLATION DIAGRAMS – MODELS 302J, 302LCSC, 302BTC, 303J 302J, 302LCSC, 302BTC 303J * J collectors illustrated.

  • Page 47: Installation Diagrams - Models 302L, 303L

    INSTALLATION DIAGRAMS – MODELS 302L, 303L 302L 303L...

  • Page 48: Connection Details

    CONNECTION DETAILS Closed Circuit Systems Water Connections (All Potable water & drain lines are ½” BSP) Open Circuit Systems Water Connections (All Potable water & drain lines are ½” BSP)
  • Page 49 CONNECTION DETAILS Assembly Drawings HOOKING COLLECTOR / TANK STRAP TO COLLECTOR RAIL If three solar collectors are to be installed, locate the additional collector rail adjacent to the first collector rail and join together using the drive cleat supplied in the parts kit (refer to Detail Determine which slots in the collector rail will be used for the roof straps after locating the rafters and taking note of the rafter spacing.
  • Page 50 CONNECTION DETAILS 20-4600 DETAIL B BOTTOM COLLECTOR RAIL – COLLECTOR STRAP INSTALLATION HOOKING COLLECTOR / TANK STRAP TO TANK CLAMP The tank clamp (330872) is supplied as a single Loosely pre-assemble bolt, washer and nut as shown. extruded part and must be snapped into two. Snap by Ensure the bolt head fits into the valley of the tile or bending the clamp on the groove location.
  • Page 51 CONNECTION DETAILS With Pitch Tiled Roof Mounting...

  • Page 52: Installation Check List

    INSTALLATION CHECK LIST Prior to handover, complete the installation check list: System is installed as per the installation instructions .................... [ ] Water is connected, turned on and solar storage tank is filled ................[ ] Closed circuit is filled with correct concentration of fluid and has been commissioned ........[ ] All mechanical fixings are secured .........................

  • Page 53: Servicing

    SERVICING Draining the Closed Circuit Fluid It may be necessary to drain the solar collectors and heat exchanger of a closed circuit system during maintenance. Draining the solar collectors and heat exchanger of closed circuit fluid should be conducted within three (3) hours of sunrise when the sun is low in the sky.
  • Page 54 SERVICING Draining and Flushing the Solar Storage Tank and Collectors It may be necessary to drain or flush the solar storage tank of an open or closed circuit system or the solar collectors of an open circuit system during maintenance or if there is sediment in the water supply. This should be conducted in the morning, within three (3) hours of sunrise when the sun is low in the sky.
  • Page 55 SERVICING Open and Closed circuit system 14. Open the temperature pressure relief valve by holding the lever in the raised position. This will let air into the solar storage tank and allow the water to drain through the hose. 15. If flushing the solar storage tank: ▪...
  • Page 56 SERVICING Anode Replacement It may be necessary to change the anode in the solar storage tank either: • Prior to or during the installation of the water heater and before the tank is filled with water This may occur if changing from a standard black (magnesium) anode to a blue (aluminium) anode to suit the chemistry of the water supply.

  • Page 57: Solahart Installation Report

    (please circle) Gas Booster Model No Serial No (if installed) If replacing a water heater, please give details Brand Model No Electric If a Solahart unit Tank Serial No Date of manufacture Collector Serial No’s Comments Signature: Installer: Customer: Date...
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  • Page 60: Solahart Offices

    55 Brodie Street Rydalmere, New South Wales, 2116 Australia www.solahart.com.au Australia For SERVICE Telephone - 1800 638 011 or your nearest Solahart Dealer For Sales Telephone - 1300 769 475 or your nearest Solahart Dealer Revision Date: 2021 May 331197 Rev K...

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