INSTALLATION GUIDE
SolaSmart Plus
™
www.senztek.com
© Senztek Holdings Ltd. 2011
Page 1: ...INSTALLATION GUIDE SolaSmart Plus www senztek com Senztek Holdings Ltd 2011 ...
Page 2: ... the Sensors and Connecting Wiring 7 Powering Up 10 Plumbing Tips 14 About the Pump Settings 16 BioSafe Reheat and Boost Functions 18 Operational Settings 20 Tariff Table 21 Display and Diagnostics 22 Sensor Maintenance 25 Trouble Shooting Guide 27 Specifications 29 For technical help contact your distributor Distributor Details www senztek com Senztek Holdings Ltd 2009 ...
Page 3: ...e 1 BEFORE YOU BEGIN INSTALLATION Assemble the Components You Will Need The SolaSmart Controller is supplied with the following components Plug In Roof sensor Tank sensor Inlet sensor Mains cable Pump cable Associated screws Screw covers Continued on next page ...
Page 4: ...e following pages contain instructions for qualified personnel only They involve potentially hazardous adjustments and high voltage mains wiring information General Safety Precautions The following general safety precautions should be noted This installation guide is for the installation of SolaSmartTM The complete installation should be checked at least annually for damage or malfunction Controll...
Page 5: ...rds Ensure the controller is in a safe environment for users to inspect display panel Follow instructions carefully when mounting sensors Incorrect sensor mounting can lead to a poorly controlled solar hot water system with safety issues e g overheating over pressure damage to the plumbing freezing damage to the solar collector The unit settings are factory programmed to optimise efficiency and sa...
Page 6: ...upply wiring and is not isolated from it Supply voltages will be output through that outlet during activation The HWC outlets are isolated contacts A supply wire and an output wire will need to be wired to each HWC outlet Always use the unit within specified voltage and load ranges Never use with damaged leads plugs or sockets Do not allow the sensor cable to come within 10mm of the high voltage c...
Page 7: ...Version 1 1 Mar 2012 Page 5 INSTALLING THE SOLASMART CONTROLLER Overview The diagram below shows how the SolaSmart is connected to the hot water cylinder HWC the collector and the three sensors ROOF TANK and INLET Continued on next page ...
Page 8: ...5mm 1 5 inch from screw centres once mounted keyhole mounting 2 Place the drill guide template against the wall checking for level alignment Four screws are supplied two chipboard screws and two combination plasterboard wood screws All four mounting holes should be used with at least two firmly secured into wood The outer plastic plasterboard anchors will self tap into plasterboard and their inner...
Page 9: ...ng the ROOF Sensor The ROOF sensor should be fitted into a metal immersion pocket in the hot water outlet pipe Apply plenty of heat transfer compound available from your distributor between the sensor and the lining of the hot water outlet pipe Seal the sensor with neutral cure sealant and install external lagging The cable should also be insulated from the bare pipe Ensure that the sensor cable i...
Page 10: ...s then seal where the cable exists the hot water tank with neutral cure silicon The Inlet Lower Tank sensor should be fitted into a metal immersion pocket above the HWC electric element near the bottom of the tank usually just above the element Labelled INLET on the circuit board If a pocket is not available then bond the sensor against the metal wall of the tank not the outside cladding or insula...
Page 11: ...the hot water cylinder element Lower element or single element Make sure that the electric element has a fuse that is rated within the stated maximum of the relay driving the element This is a simple clean set of normally open contacts that interrupt the Active Phase wire that powers the element Do not bypass any thermostats or cut outs Ensure mechanical thermostat is adjusted to maximum so contro...
Page 12: ...lectrical hazards are anywhere near the plug socket and or surrounding environment NOTE The power outlet socket must be installed by a registered electrician The SolaSmart must be installed by a qualified person Ensure suitable over current protection and RCD protection for the SolaSmart is in place The mechanical hot water thermostat for the electric element should be set to the maximum for the H...
Page 13: ...the electric element should be set to the maximum for the HWC Control Mode to operate correctly The hot water thermostat is only used as a failsafe feature and normally will not operate Continued on next page The CONTROLLER OK light is on when the controller is operating correctly The PUMP light comes on when the pump is on in normal or FROST operation or when the PUMP button is pressed For Dual E...
Page 14: ...re dangerous voltages present around the high voltage section of the PCB There is a plastic sheath fitted around this area under normal conditions The Setting Time and Date procedure is also printed on the plastic sheath Procedure 1 Press the Set Button 2 Press the Hour and Min buttons to adjust time 3 Press the Set Button 4 Press the Day and Month buttons to adjust date Year not set 5 Press the S...
Page 15: ...g It is best to observe some solar hot water pump cycles but this will depend on the sun shining Check all functions are working correctly before leaving the installation The SolaSmart settings have been factory set to the standard settings for your area and requirements See Trouble Shooting section on pages 27 28 of this guide if the system is not working correctly ...
Page 16: ...ixing valve must be installed if required by local regulations It is used to ensure the supply from the tank does not burn end users The tempering valve must be appropriately rated to handle extreme temperatures Installation must be to best plumbing practice and the manufacturer s specifications Non Return System Hot water rises and cold water falls If the solar collector is colder than the tank e...
Page 17: ... can recommend the best practice solution for each installation for pressure relief valves including the number and placement of them Air Relief Valves Air locks can occur within the piping system as well as the pump These can increase the pressure that the pump is working against to the point where the pump can no longer circulate the water To avoid this an air relief valve should be fitted espec...
Page 18: ...Tank heat up and the temperature in the collector on the ROOF cool down When the difference in the two temperatures reduces to 6 C the pump switches off allowing the water in the collector to heat up again FROST Function The FROST function is designed to protect your collector and hot water system from freezing and bursting When this temperature is reached the pump will come on just enough to rais...
Page 19: ...high until the water in the cylinder has cooled down to a safe level Senztek has also developed an advanced Topout method that delays the onset of collector stagnation and facilitates early recovery if stagnation has occurred This is achieved by using a three stage Topout where the tank is protected at all times and the solar pumping control method is altered progressively If stagnation has occurr...
Page 20: ...et to run every 24 hours to comply with AS 3498 Clause 7 1 j BioSafe uses the Real Time Clock to determine when it should run and is therefore immune to power outages less than 14 days BioSafe Target The controller ensures that the whole tank is above this temperature during BioSafe Mode BioSafe Holdup The time BioSafe Target Temperature will maintain before exiting BioSafe Mode If Lower Tank Temp...
Page 21: ...k based on electricity price fluctuations during the day Reheat Upper Reheat Upper is the temperature that the element will stop heating the tank in the Reheat Mode Reheat Lower Reheat Lower is the temperature that the element will start heating the tank in the Reheat Mode Boost Pressing the HWC button should heat from the lower element until the Inlet Lower Tank sensor reaches Reheat Max setting ...
Page 22: ...mmended for solar installations to set the Tank Max value to as high as safely possible SETTINGS SOLAR Settings Setting names Value Units Differential Pump On 10 ºC Differential Pump Off 5 ºC Frost On 4 ºC Tank Max Topout 80 ºC HWC Settings Settings Value Units BioSafe Target 60 ºC BioSafe Holdup 32 Min BioSafe Band 4 N A BioSafe Period 7 Days Reheat Max 65 ºC Table 1 Controller Operational Settin...
Page 23: ...mfort level is the inverse of efficiency Having a high comfort level minimises the chance of running out of hot water at the expense of greater electricity usage Holiday mode is achieved by setting the comfort level to 0 in which case only BioSafe will turn the element on Band Element Band Sensor These are the element and the sensor that will be used in Reheat Mode Only one element and one sensor ...
Page 24: ...is on the display If the sensor is faulty Opn or Shrt will be displayed depending on the fault condition Screen 2 Tank Upper Tank Temperature The dot next to the TANK will be lit up when the Upper Tank Temperature is on the display If the sensor is faulty Opn or Shrt will be displayed depending on the fault condition Screen 3 Inlet Lower Tank Temperature The dot next to the INLET will be lit up wh...
Page 25: ...G 1 Solar Rule that is currently active IDLE F Frost d Differential t TopOut D1 Stage 1 D2 Stage 2 D1 D2 Stage 3 b Collector BioSafe E Error SEG 2 HWC Rule that is currently active IDLE r Reheat b Collector BioSafe 0 Boost E Error SEG 3 Active Element L Lower U Upper SEG 4 Active Tariff Band 1 to 4 Continued on next page ...
Page 26: ...Off Controller failed power up Built in Test L2 Sensor OK On All sensors ok Flashing Lower or Upper Tank Sensor faulty Off Collector Sensor faulty L3 Pump On Flashing Pump is running Off Pump is not running Flashing Pump switch was held down for 10 seconds pump will run for 1 hour unless cancelled by another press L4 Upper Element On Upper Element is on Off Upper Element is off L5 Lower Element LE...
Page 27: ...d personnel Remove ALL power sources before removing protective cover Replacing a Sensor If a damaged sensor needs to be replaced then the cover of the enclosure will need to be opened unless the choice is made to join the wires externally see Lengthening Sensor Wire section above Remove the mains power supply Make sure no other power source is feeding back through other connections 1 Remove the f...
Page 28: ...power 12 Check that the sensor is reading correctly Sensor Resistances The table below has the correct resistance values of the sensor at different temperatures The sensor must be removed from the SolaSmartTM to measure these values correctly Follow the above procedure to remove a sensor Sensor Resistances Temperature Resistance in kΩ A short circuit can be caused by the sensor wires being connect...
Page 29: ...eck display if in Topout If so then this is normal Check sensor readings If readings do not match real water plumbing temperatures check sensor is making good contact with pocket surface Thermal paste required to make good thermal conductivity Pump is running continuously Pump is cavitating Special Installation Airlock in pipe Setting does not match plumbing used If pump sounds like stones are pas...
Page 30: ...urs Excess water draw off or leak HWC power not getting to controller HWC power not getting to element Element open circuit blown Is HWC circuit drawing expected current typ 16 Amps Qualified personnel only If yes verify excess hot water is not being drawn off If NO then power is not able to heat the water to the target ºC Read tank temperature at controlling sensor If 50ºC issue will be interrupt...
Page 31: ... Output Only for connection to an intelligent variable speed pump e g Grundfos Solar PM 15 85 1kHz 10 pulse repetition rate Max drive 5mA avg at 9 14 volts Peak 1 5Amps Max 5 meter cable to pump Sensors PVC Sensors 20 120 C tip 5 8mm diameter stainless steel 20 105 C cable UV resistant Silicone Sensor 20 250 C peak tip 5 8mm diameter stainless steel 20 180 C cable UV resistant Accuracy 1 C 25 C Re...
Page 32: ...Exceeding these limits can result in damage to the unit and voiding of the warrantee Product Liability This information describes our products It does not constitute guaranteed properties and is not intended to affirm the suitability of a product for a particular application Due to ongoing research and development designs specifications and documentation are subject to change without notification ...
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