Solahart 151J Owner'S Manual Download Page 27 | Manualshive

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INSTALLATION INSTRUCTIONS - ALL MODELS

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.

KIT CONTENTS

The Thermosiphon Pipe Shroud Cover Kit consists of:

Component

Part No

Kit 12104050 Thermosiphon Pipe Shroud Cover Kit

Component Description

Quantity

208002

Pipe shroud cover

1

330370

Screw 8G x ½” pan head stainless steel

5

207501

Installation instructions

1

PIPE WORK AND CONNECTIONS

The installation of the pipe work and electrical connection is to be planned so their position aligns with the cut-outs at the
rear of the Pipe Shroud Cover.

•

The pipe work should also be positioned with any roof penetrations behind the solar storage tank to maintain the
aesthetics of the installation.

•

The pipe work, including the TPR valve drain line, shall not obstruct the hexagonal electrical cover.

•

The pipe work is to be installed to allow the fitting of the Pipe Shroud Cover without any distortion.

•

The TPR valve drain line must have a continuous fall and be installed in accordance with the installation instructions.

•

The installation of valves must be in accordance with national and local codes and regulatory authority requirements.

•

Penetrations through the roofing material must be at the high point of the roof tile or metal sheet, made neatly and
kept as small as practicable and be waterproofed.

Installation of Pipe Shroud Cover with a HartStat Over Temperature Protection System

Installation of Pipe Shroud Cover without a HartStat Over Temperature Protection System

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Summary of Contents for 151J

Page 1: ...This water heater must be installed and serviced by a qualified person Please leave this guide with the householder Thermosiphon Solar Water Heaters Owner s Guide and Installation Instructions ...

Page 2: ... more patents or registered designs in the name of Solahart Industries Pty Ltd TRADE MARKS Registered trademark of Solahart Industries Pty Ltd Trademark of Solahart Industries Pty Ltd Note Every care has been taken to ensure accuracy in preparation of this publication No liability can be accepted for any consequences which may arise as a result of its application ...

Page 3: ...Save A Service Call 15 Water Supplies 16 Maintenance Requirements 18 Installation Instructions All Models 20 Installation Instructions Closed Circuit Series 29 Installation Instructions Open Circuit Series 35 Technical Specifications Systems 39 Technical Specifications Tanks and Collectors 40 Annual Performance Calculations For Europe 41 South African System SANS 1307 Details 43 Installation Diagr...

Page 4: ...to a serviceable position is not covered by this warranty 2 6 This warranty only applies to the original and genuine Solahart water heater in its original installed location and any genuine Solahart replacement parts 2 7 The Solahart warranty does not cover faults that are a result of a Accidental damage to the water heater or any component for example i Acts of God such as floods storms fires lig...

Page 5: ... repair labour costs are the responsibility of the owner 4 ENTITLEMENT TO MAKE A CLAIM UNDER THIS WARRANTY 4 1 To be entitled to make a claim under this warranty you need to a Be the owner of the water heater or have consent of the owner to act on their behalf b Contact Solahart without undue delay after detection of the defect and in any event within the applicable warranty period 4 2 You are not...

Page 6: ... Phone your nearest Solahart Dealer to arrange for an inspection Do not remove the closed circuit relief valve on a closed circuit model as there may be a very high scalding risk present When operating in daylight the heat exchange circuit will be pressurised and can contain superheated fluid and may contain steam At other times the circuit may be pressurised and contain high temperature fluid Sho...

Page 7: ...ne must be insulated and not exceed 300 mm in length before discharging into a tundish through an air gap The easing lever on the temperature pressure relief valve and expansion control valve should be operated once every six 6 months to clear any deposits and ensure the valve and its drain line are not blocked It is very important the lever is raised and lowered gently Refer to Minor Maintenance ...

Page 8: ...ess wire loops inside the front cover The temperature rating of the power supply wires insulation must suit this application or the wiring protected by insulating sleeving with an appropriate temperature rating if it can make contact with the internal storage cylinder The temperature of the internal storage cylinder can reach 95 C during its operation in compliance with all local codes and regulat...

Page 9: ...rk As the water in the solar collector gains the solar energy from the absorber the increase in temperature causes the water to rise through the collector and the solar hot pipe into the solar storage tank As the heated water enters the storage tank cooler water from the bottom of the solar storage tank flows down the solar cold pipe into the solar collectors to be heated by the solar energy This ...

Page 10: ...ts on page 18 If this water heater is to be used where an uninterrupted hot water supply is necessary for your application or business you should ensure that you have back up redundancy within the hot water system design This should ensure the continuity of hot water supply in the event that this water heater were to become inoperable for any reason We recommend you seek advice from your plumber o...

Page 11: ... two weeks or more flammable hydrogen gas may accumulate in the water cylinder To dissipate this gas safely it is recommended that a sink hot tap be turned on for several minutes Do not use a dishwasher clothes washer or other appliance for this purpose During this procedure there must be no smoking open flames or any electrical appliance operating nearby If hydrogen is discharged through the tap ...

Page 12: ...iphon storage tank is 150 model 180 model 300 model 75 litres 90 litres 150 litres The water heater is more suited for the booster heating unit to be connected to either a continuous or a time of use or an extended Off Peak overnight and day electricity supply A timer can also be used to control the boosting periods turning the booster on when required and help maximise solar savings Refer to Time...

Page 13: ... and heat the water The booster heating unit will automatically turn off either when the temperature of the water reaches the thermostat setting or at the end of the timer period whichever comes first The recommended boosting periods are sufficient to allow the booster heating unit to heat up the boost volume of the solar storage tank to 60 C where the winter cold water temperatures do not fall be...

Page 14: ... Check and if required reset the timer if one is installed USING YOUR SOLAHART WATER HEATER AS A PRE HEATER This water heater is designed to be installed as an electric boosted solar water heater with its booster heating unit connected to a power supply however it may be installed with an in series continuous flow or storage booster If this water heater is installed with an in series booster then ...

Page 15: ...igned pressure of the water heater Ask your installing plumber to fit a pressure limiting valve Warning Never replace the relief valve with one of a higher pressure rating Heavy flows of hot water from the temperature pressure relief valve until water heater is cold then stops until water reheats If this occurs when the water heater is being boosted by the electric booster heating unit then the wa...

Page 16: ... vitreous enamel lined cylinder of the water heater is only covered by the Solahart warranty when the total dissolved solids 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 a...

Page 17: ...ration index is used as a measure of the water s corrosive or scaling properties The saturation index figures stated are calculated using a water temperature of 80 C 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...

Page 18: ...cessible wash the collector glass with water and a soft brush when the solar collectors are cool such as early in the morning In extremely dusty areas such as mining towns and locations adjacent to dust forming plants extra attention should be given to this matter Have any trees trimmed which may shade the solar collectors Minor Maintenance Every Six Months It is recommended minor maintenance be p...

Page 19: ...ating unit for excessive calcium build up or corrosion and replace if necessary 5 Drain check and refill or replace if required the closed circuit fluid closed circuit models 6 Visually check the unit for any potential problems e g broken glass excessive dust build up shading 7 Inspect all connections 8 Drain and flush the solar storage tank of sediment build up if required see Draining and Flushi...

Page 20: ...y is necessary for the application or business then there should be back up redundancy within the hot water system design This should ensure the continuity of hot water supply in the event that this water heater was to become inoperable for any reason We recommend you provide advice to the system owner about their needs and building back up redundancy into the hot water supply system LOCATION The ...

Page 21: ...mum orientation Generally improved summer performance is obtained from an angle of inclination less than the optimum angle and improved winter performance is obtained by an angle of inclination greater than the optimum angle If the angle of inclination varies by 20 from the optimum angle the solar collectors will receive about 10 less total annual solar radiation However the optimum inclination of...

Page 22: ... and earth tab connection ensuring there are no excess wire loops inside the front cover The temperature rating of the power supply wires insulation must suit this application or the wiring protected by insulating sleeving with an appropriate temperature rating if it can make contact with the internal storage cylinder The temperature of the internal storage cylinder can reach 95 C during its opera...

Page 23: ...lectricity supply If used with an extended Off Peak overnight and day electricity supply the timer switch should Be operated by a continuous power supply on its own circuit from the switchboard with the booster heating unit operated by the Off Peak power supply A double pole isolating switch is required to be installed at the switchboard to simultaneously isolate both circuits Or Be of a type whic...

Page 24: ...r outlet Tee before the water heater is operated except where the storage tank is vented to atmosphere through an open pipe Before fitting the relief valve make sure the probe has not been bent To fit the relief valve Seal the thread with an approved thread sealant such as Teflon tape never hemp Make sure tape does not hang over the end of the thread Hand tighten the valve into the hot water outle...

Page 25: ...ce The termination point of a drain line must comply with the requirements of AS NZS 3500 4 In locations where water pipes are prone to freezing drain lines must be insulated must not exceed 300 mm in length and are to discharge into a tundish through an air gap of between 75 mm and 150 mm If a drain line discharges into a tundish the drain line from the tundish must be not less than DN20 The drai...

Page 26: ...efer to local plumbing codes e g AS NZS 3500 4 for the requirement for insulation of external pipe work Solahart recommends That all hot water pipe work from the water heater should have closed cell insulation of minimum 13 mm thickness Thicker insulation may be required on external pipes to comply with the energy efficiency requirements of AS NZS 3500 4 in certain regions Insulation should be sui...

Page 27: ...outs at the rear of the Pipe Shroud Cover The pipe work should also be positioned with any roof penetrations behind the solar storage tank to maintain the aesthetics of the installation The pipe work including the TPR valve drain line shall not obstruct the hexagonal electrical cover The pipe work is to be installed to allow the fitting of the Pipe Shroud Cover without any distortion The TPR valve...

Page 28: ...ly use the screws provided Note The Pipe Shroud Cover when fitted must be flush with the jacket end of the solar storage tank There is to be no distortion of the cover due to poorly installed pipe work Correct the pipe work if the cover does not fit correctly To Turn Off The Water Heater If it is necessary to turn off the water heater on completion of the installation such as on a building site or...

Page 29: ...the flashing under the row above Now using a lifting device lift the collectors onto the roof and place them carefully into the collector rail Remove the red transit plugs from the collector sockets Join the collectors together using the collector connector assemblies Part No 337121 or 203000 On systems that use conetite fittings ensure the fittings are fully inserted into the sockets before tight...

Page 30: ...valves are located away from freeze locations wherever possible Note that freezing of the valves can permanently damage the valves Take particular care at roof penetrations Install the TRIO Valve and Cold Relief Valve indoors e g in the laundry or in other locations not subject to freezing but NOT in the ceiling space If these valves are located external to the building they must be insulated with...

Page 31: ...e HartStat valve was to close and the closed circuit is only partially filled the solar performance can be severely reduced resulting in a no hot water complaint In addition excessive noise can be generated from the system leading to possible disturbance and irritation to the householders To avoid premature closure of the HartStat valve the following instructions MUST BE followed during the commis...

Page 32: ...m 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 If this is not practical for a specific installation then the installer should discuss the possible options with the home owner This should be done prior to installing the new system so that any leak or spillage during in...

Page 33: ...hould be no water spillage however if more than 0 5 litres of water is spilled repeat steps 1 5 When charging the system using a PR6 Valve pressurise the system until the PR6 Valve opens or until a pressure of 80kPa is read on the pressure gauge whichever happens first When charging the system using a PR200 Valve pressurise the system until the PR200 Valve opens or until a pressure of 170kPa is re...

Page 34: ...d circuit fluid Important There should be no water spillage however if more than 0 5 litres of fluid is spilled repeat steps 1 5 Connect a bicycle pump portable compressor to the Test Block and pressurise the closed circuit until a pressure of 80kPa or 170kPa as applicable is read on the pressure gauge or the PR6 or PR200 relief valve opens whichever occurs first Ensure there is no leak at the Fil...

Page 35: ... must be fitted at each pipe connection Join the collectors using the collector unions provided Part No 330695 screwed fitting 341390 conetite fitting Apply only medium pressure with a spanner to tighten Centralise the collectors on the rail Lock the collectors to the rail with the collector clamps 2 per collector Tighten using the nuts and bolts provided Fit either the copper blanking discs Part ...

Page 36: ...e with the end cap in position ensure There is suitable access to the flats on the solar hot pipe fitting nut to enable it to be fitted securely Scoring of the end cap by the tool does not occur when screwing in the fitting The connection does not leak Removing the End Cap The end cap can be removed from the jacket end if required to allow the fitting of the solar hot pipe If it is necessary to re...

Page 37: ...ared pipe ends and each end of the TRV The TRV is to be orientated with the copper element probe facing upward toward the tank The TRV has an arrow and the word FLOW stamped on the outside of the body The arrow is to point upwards in the direction of the tank If this pipe assembly is being retrospectively fitted to an existing system replace existing O Rings with the new ones to seal cold pipe to ...

Page 38: ... off after this valve prior to an open circuit system then a second non return valve must be installed between the cold water branch and the solar storage tank If a pressure limiting valve is installed on the cold water line to the solar water heater and the cold water line to a temperature limiting device branches off before this valve or from another cold water line in the premises then a pressu...

Page 39: ...l 40 40 40 40 40 40 40 40 40 Weight kg 458 464 464 515 521 506 508 497 493 full lbs 1010 1023 1023 1135 1149 1116 1120 1096 1087 Weight kg 154 160 160 196 202 191 193 178 384 empty lbs 340 353 353 432 445 421 426 392 397 Length m 2 49 2 49 2 49 2 49 2 49 2 63 2 63 2 49 2 49 in 98 0 98 0 98 0 98 0 98 0 103 5 103 5 98 0 98 0 Height m 0 51 0 51 0 51 0 51 0 51 0 51 0 51 0 51 0 51 in 20 1 20 1 20 1 20 ...

Page 40: ... 043 in 40 27 40 27 40 27 40 27 40 27 41 1 41 1 41 1 Working kPa 1400 1400 1400 200 1400 200 1400 1400 pressure psi 203 203 203 29 203 29 203 203 Test kPa 300 300 300 450 450 450 300 300 pressure psi 43 43 43 65 65 65 43 43 No of risers 7 6 13 35 7 35 7 13 Riser material Copper Copper Copper Steel Copper Steel Copper Copper Absorber material Aluminium Aluminium Copper Steel Aluminium Steel Copper ...

Page 41: ...435 4724 56 0 12050 5182 43 0 Athens 38 0 N 3305 2776 84 0 4545 3622 79 7 5784 4327 74 8 8263 5255 63 6 Model 181J 181J 181J 181J Demand 80 litres day 110 litres day 140 litres day 200 litres day Location Qd MJ a QL MJ a f sol Qd MJ a QL MJ a f sol Qd MJ a QL MJ a f sol Qd MJ a QL MJ a f sol Stockholm 59 6 N 4441 2096 47 2 6107 2614 42 8 7772 3023 38 9 11103 3486 31 4 Wurzburg 49 5 N 4257 2273 53 ...

Page 42: ...on Qd MJ a QL MJ a f sol Qd MJ a QL MJ a f sol Qd MJ a QL MJ a f sol Qd MJ a QL MJ a f sol Stockholm 59 6 N 7772 3334 42 9 9438 3671 38 9 11103 3697 33 3 13879 3706 26 7 Wurzburg 49 5 N 7450 3457 46 4 9047 3863 42 7 10643 3927 36 9 13304 3938 29 6 Davos 46 8 N 8435 4791 56 8 10243 5234 51 1 12050 5242 43 5 15063 5257 34 9 Athens 38 0 N 5784 4361 75 4 7024 4973 70 8 8263 5313 64 3 10329 5609 54 3 M...

Page 43: ...Valve Safety Valve Pressure Control Valve and Expansion Control Valve ECV unless the water supply pressure cannot exceed the rated pressure of this water heater or its safety value whichever is lowest Heat exchange jacket solar heater transfer fluid circuit pressure relief valve when operated with solar heating 80 kPa without Over Temperature Protection OTP to the heat exchanger jacket vent port 2...

Page 44: ...44 INSTALLATION DIAGRAMS MODELS 151J 181J 181LCSC 181BTC 151J 181J 181LCSC 181BTC J collector illustrated ...

Page 45: ...45 INSTALLATION DIAGRAMS MODELS 151L 181L 151L 181L ...

Page 46: ...46 INSTALLATION DIAGRAMS MODELS 302J 302LCSC 302BTC 303J 302J 302LCSC 302BTC 303J J collectors illustrated ...

Page 47: ...47 INSTALLATION DIAGRAMS MODELS 302L 303L 302L 303L ...

Page 48: ...48 CONNECTION DETAILS Closed Circuit Systems Water Connections All Potable water drain lines are BSP Open Circuit Systems Water Connections All Potable water drain lines are BSP ...

Page 49: ... Two collectors 1 x two collector rail Three collectors 1 x two and 1 x one collector rails 300 mm 12 1 4 or 2 3 1 6 or 2 5 1 5 long 3 short 400 mm 16 1 4 1 5 or 2 6 1 5 long 3 short 450 mm 18 1 4 2 5 2 5 long 4 short 500 mm 20 1 4 1 6 or 2 5 1 6 long 4 short 600 mm 24 2 3 1 5 or 2 6 1 5 long 3 short 900 mm 36 1 4 2 5 1 4 long 4 short collector rail one collector collector rail two collectors 3 No...

Page 50: ... the groove location 2 Noting the orientation of the collector tank strap s folded end slide the short end of the strap through the slot from the underside of the tank clamp 3 Push the strap end through the tank clamp and make sure it is correctly orientated as illustrated 4 Loosely pre assemble bolt washer and nut as shown Ensure the bolt head fits into the valley of the tile or roof sheet profil...

Page 51: ...CONNECTION DETAILS 51 With Pitch Tiled Roof Mounting ...

Page 52: ...re a minimum DN20 or 22mm pipe is used for the solar cold and solar hot pipe and the pipes have a continuous upwards slope towards the tank from the collectors 8 Protective plastic film removed from tank if fitted 9 Covers removed from collectors 10 Pipe conduit penetrations through the roof have been sealed correctly 11 Roof tiles put back into position 12 Roof flashing watertight 13 System check...

Page 53: ...ll assist in the transfer of any heat from high temperature closed circuit fluid in the heat exchanger and solar collectors to the water in the solar storage tank 3 Close the hot water tap 4 Attach one end of a hose to the valve drain port of the fill drain valve assembly and place the other end into a container of sufficient volume to hold the closed circuit fluid Refer to the table on page 31 fo...

Page 54: ...id in the heat exchanger and solar collectors to the water in the solar storage tank of a closed circuit system 3 Close the hot water tap 4 Turn off the water heater Refer to To Turn Off the Water Heater on page 28 5 Ensure all hot water taps are closed Closed circuit system 6 Attach a hose to the valve drain port of the fill drain valve assembly Place the end of the hose into a container Place an...

Page 55: ...aining and Flushing the Solar Collectors Open Circuit System 21 From the bottom end of the solar collectors unscrew and remove the end plug Connect a hose to the collector connection Let the other end of the hose go to a drain 22 From the top end of the solar collectors unscrew and remove the end plug This will let air into the collector and allow the water to drain through the hose 23 If flushing...

Page 56: ...of the procedure Draining and Flushing the Solar Storage Tank and Collectors commencing on page 54 2 Allow the cylinder to drain to a level below the anode fitting then lower the temperature pressure relief valve lever to close the valve It is very important the lever is raised and lowered gently 3 Remove the electrical cover 4 J L Tank Unscrew the anode nut located to the left of the electric ele...

Page 57: ...se circle Replace Complete Solar System Replace Solar Tank Replace Electric or Gas Replace Heat Pump New Building New Install on Existing Building not replacing a unit Other System Model No System Type Tank Model No Tank Serial No Collector Model No No of Collectors Collector Serial No s 1 2 3 4 Electric Booster please circle Electric continuous Off Peak 1 night Off Peak 2 night day Solar Preheat ...

Page 58: ...58 This page is intentionally blank ...

Page 59: ...59 This page is intentionally blank ...

Page 60: ...ional Sales 61 8 9351 4600 Facsimile International Sales 61 8 9351 4698 Email solahart solahart com au Web www solahart com Postal Address PO Box 7508 Silverwater New South Wales 2128 Australia Principal Tank Manufacturing Facility 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 Tel...

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