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Solahart DBV 270 SM Owner'S Manual Download Page 35

STORAGE TANK AND GAS BOOSTER ASSEMBLY 

35 

MOUNTING THE GAS BOOSTER TO THE STORAGE TANK 

The gas booster is required to be mounted on the solar storage tank. They are connected together with the 
supplied fittings. 
 
Use  thread  sealing  tape  or  approved  thread  sealant  on  all  fittings.  Numbers  in  parentheses  refer  to  items 
shown in the 

diagram on page 

36. 

 
To mount the gas booster to the storage tank: 

 

Fit  the  hot  connection  assembly (1)  to  the  solar  hot  water  outlet  of  the  storage  tank  and  orientate  the 
assembly vertically downwards. 

 

Fit  the  cold  connection  assembly (2)  to  the  cold  water  inlet  of  the  storage  tank  and  orientate  the 
assembly vertically upwards. 

 

Fit  the  ¾” M x ¾” F  elbow (8)  to  the  water  inlet  on  the  underside  of  the  gas  booster  and  orientate  the 
elbow pointing to the left (when viewed from the front) of the gas booster. 

Note:

 The elbow must be fitted prior to them mounting of the gas booster to the storage tank. Otherwise 

the upper front cover opening will interfere with the elbow. 

 

Fit the gas booster (3) to the mounting bracket on the storage tank by hooking the top bracket of the gas 
booster over the mounting bracket. 

 

Secure  the  gas  booster  to  the  bottom  left  of  the mounting  bracket  using  the  mounting  screw  and 
spring washer (12) provided. 

 

Place the washer (4) supplied inside of the fitting of the water connection plumbing assembly (5) which 
connects to the hot water outlet of the gas booster. 

 

Connect the water connection plumbing assembly (5), with the 550 mm long insulated flexible hose (7) 
attached, to the hot water outlet of the gas booster. 

Note:

 The water connection assembly components are supplied only hand tightened. Each component 

is to be firmly connected using thread sealing tape or approved thread sealant. 

 

Place  the  bracket  support (6)  over  the  temperature  limiting  device  outlet  of  the  water  connection 
plumbing assembly (5) and fix to the jacket of the storage tank to secure the water connection plumbing 
assembly in position, using the screws provided. 

 

Connect the free end of the flexible hose (7) attached to the water connection plumbing assembly (5) to 
the cold connection assembly (2) on the storage tank. 

Ensure the hose is not kinked. 

 

Connect one end of the 425 mm long insulated flexible hose (9) to the elbow fitting (8) on the inlet of the 
gas booster and the other end to the hot connection assembly (1) on the storage tank. 

Ensure the hose is not kinked. 

Notes:

 

 

If  the  flexible  hose  has  a  brass  extension  piece  at  one  end,  ensure  this  end  is  connected  to  the 
elbow fitting (8) at the inlet of the gas booster. 

 

Connect this end prior to connecting the other end to the hot connection assembly (2). 

 

Position the front pipe cover (10) underneath the gas booster and over the plumbing fittings. 

 

Secure in position with the four screws (11) provided. 

 

Summary of Contents for DBV 270 SM

Page 1: ...s Boosted SOLAR WATER HEATER OWNER S MANUAL AND WARRANTY INSTALLATION INFORMATION WARNING Plumber Be Aware Use copper pipe ONLY Plastic pipe MUST NOT be used It is a requirement of a solar water heater installation that all pipe work be in copper and not plastic due to the effects of high water temperatures Solahart Industries Pty Ltd ABN 45 064 945 848 ...

Page 2: ...orage tank and the solar collectors The insulation will offer corrosion protection to a metal roof against water runoff over the copper pipe assist in avoiding accidental contact with the solar pipe work as high temperature closed circuit fluid can flow from the solar collectors to the solar storage tank and also reduce pipe heat losses There MUST BE a continuous fall of a minimum 5 1 in 10 grade ...

Page 3: ...y be of interest About Your Water Heater 4 Regular Care 11 Water Supplies 13 Save A Service Call 16 Installation Solar Storage Tank 20 Installation Solar Collectors 29 Connections Plumbing 37 Connections Electrical 41 Auxiliary Pump 43 Commissioning 46 Draining The Water Heater 60 Warranty 65 Solahart Offices 68 ...

Page 4: ... through an insulated copper pipe to the solar collectors to be heated by the sun s energy and then back to the heat exchanger Heat transfers from the closed circuit fluid in the heat exchanger to the water stored in the solar storage tank This process continues while solar energy is available and until the water in the solar storage tank reaches a temperature of approximately 75 C The pump is the...

Page 5: ...let booster temperature setting of the gas booster cannot be adjusted by the householder The setting can only be adjusted by your nearest Solahart Dealer The factory preset outlet temperature setting of the gas booster is 60 C Note AS 3498 requires that a water heater provides the means to inhibit the growth of Legionella bacteria in potable water This water heater has an in series gas booster whi...

Page 6: ...bination temperature pressure relief valve These devices must not be tampered with or removed The water heater must not be operated unless each of these devices is fitted and is in working order If the power supply cord or plug to the solar storage tank is damaged it must be replaced by a qualified person in order to avoid a hazard The power supply cord and plug must be replaced with a genuine rep...

Page 7: ... fall of a minimum 5 1 in 10 grade in the pipe work from the solar collector to the solar storage tank with the full length of the solar hot and solar cold pipes insulated and the system charged with correctly mixed closed circuit fluid to offer protection against freeze damage The system has NO WARRANTY for freeze damage if there is not a continuous fall in the solar hot and solar cold pipes or t...

Page 8: ...l between each series only if there is a particular fault condition with the system The operational modes are Flashes Operational Modes solid green remains on Standby mode 2 x green Flooding solar circuit 3 x green Pump flow control 4 x green Pump flow established 5 x green Tank at maximum temperature no green remains off Call for service If the power supply to the water heater is on and the green...

Page 9: ...en drained Open the cold water isolation valve fully at the inlet to the water heater Open all of the hot water taps in the house don t forget the shower Air will be forced out of the taps Close each tap as water flows freely from it Open the gas isolation valve fully at the inlet to the water heater Plug in the solar storage tank and gas booster at their power outlets and switch on the electrical...

Page 10: ... can be delivered Refer also to Pipe Work and Insulation on page 7 and to Rain Water Tank on page 8 VICTORIAN CUSTOMERS Notice to Victorian Customers from the Victorian Plumbing Industry Commission This water heater must be installed by a licensed person as required by the Victorian Building Act 1993 Only a licensed person will give you a Compliance Certificate showing that the work complies with ...

Page 11: ... a water heater must only be carried out by a qualified person Phone your nearest Solahart Dealer Note The five year service and routine replacement of any components such as the anodes and relief valves 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 The major service includes the following actions Re...

Page 12: ...tralia Western Australia and scaling water areas an expansion control valve is fitted to the cold water line to the water heater The expansion control valve may discharge a small quantity of water from its drain line during the heating period instead of the temperature pressure relief valve on the water heater Operate the easing lever on the expansion control valve once every six months It is very...

Page 13: ...lahart 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 anode may shorten the life of the water heater cylinder The correct colour cod...

Page 14: ...gen which is highly flammable should be vented safely by opening a hot tap and allowing the water to flow There should be no smoking or naked flame near the tap whilst it is turned on Any hydrogen gas will be dissipated This is indicated by an unusual spurting of the water from the tap Once the water runs freely any hydrogen in the system will have been released SATURATION INDEX The saturation ind...

Page 15: ...Y OF WATER CHEMISTRY ADVICE AFFECTING WARRANTY 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 warranty will not cover any resultant faults on the components listed below Water Chemistry Component Tot...

Page 16: ... rest of the house Try lighting another gas appliance Has the gas line been purged of air after installation Refer to your plumber NO WATER FROM THE HOT TAP No flow of water from the hot tap may indicate a restriction in or failure of the cold water supply to the water heater Check for water flow at other taps and that the cold water isolation valve refer to page 37 is fully open WATER FLOW FLUCTU...

Page 17: ...to provide the required solar energy to meet the average family needs However in some circumstances it may be necessary to install an additional solar collector Are you using more hot water than you think Is one outlet especially the shower using more hot water than you think Very often it is not realised the amount of hot water used particularly when showering Carefully review the family s hot wa...

Page 18: ... the water heater The benefit is that energy is conserved as the discharged water is cooler PRESSURE RELIEF VALVE DISCHARGING A pressure relief valve is incorporated into the gas booster controls This valve protects the gas booster by allowing water to escape in the event of excessive pressure build up in the waterways Normal operation A small volume of water may discharge from the bottom of the g...

Page 19: ... faulty tap washers and have your plumber rectify any leaking pipe work Is the gas booster operating too frequently Refer to Gas Booster Operating Too Frequently on page 17 Has there been an increase in hot water usage An increase in hot water usage may result in an increase in booster operation Has your water heating tariff rate been increased by your gas retailer since your previous account COLL...

Page 20: ...tely qualified tradespeople or be suitably supervised for trades assistant duties Every care must be taken to protect and warn occupants of the building and the public from personal injury which may occur from falling tools roof materials fittings or any other hazards of a general nature Advise the occupants of any inconvenience which may occur due to disconnection of existing water and electrical...

Page 21: ...olar storage tank is suitable for outdoor installation only The solar storage tank should be installed close to the most frequently used outlet and its position chosen with safety and service in mind Make sure people particularly children will not touch the flue terminal The flue terminal and air inlet must be clear of obstructions and shrubbery Consideration must also be given to the position of ...

Page 22: ...l to the opening may be deemed to comply Check with the local regulator The water heater can be turned through 60 either to the left or to the right with the discharge from the flue terminal discharging along the wall SAFE TRAY Where damage to property can occur in the event of the water heater leaking the water heater must be installed in a safe tray Construction installation and draining of a sa...

Page 23: ...f the existing gutter so as to enable rain water runoff to flow under the false gutter installing a flashing from the underside of the roofing material with a continuous fall to over the outside lip of the gutter The flashing should extend wider than the collectors and pipe work and turned up at the ends so if there is leakage of closed circuit fluid it cannot enter the gutter If any of these solu...

Page 24: ... There is no statutory requirement to fit a supplementary temperature limiting device if this water heater is installed in other than an early childhood centre school nursing home or a facility for young aged sick or disabled people Where another temperature limiting device is installed adjacent to the water heater the cold water line to the temperature limiting device can be branched off the cold...

Page 25: ...d hot water flow and return system is required in a building a temperature limiting device can only be installed on a dead leg branching off the circulated hot water flow and return pipe or a dead leg installed from the tempered water outlet of this water heater If circulated tempered water were to be returned back to the water heater depending on the location of the return line connection on the ...

Page 26: ...er cylinder refer to Water Supplies on page 13 and the Anode Selection chart on page 13 The black anode is typically fitted as standard Total Dissolved Solids Anode colour code 0 40 mg L Green 40 150 mg L Green or Black 150 400 mg L Black 400 600 mg L Black or Blue 600 2500 mg L Blue 2500 mg L Blue no cylinder warranty If the water supply has a TDS greater than 150 mg L and a green anode has not b...

Page 27: ...as Booster Details Gas Booster Model Delivery 25 C rise litres min Hourly Gas Consumption MJ Min Gas Pressure kPa Test Point Gas Pressure kPa Max Gas Pressure kPa minimum maximum Natural 10143272 27 205 1 13 0 193 0 905 3 50 Propane 10143273 27 205 2 75 0 277 1 430 3 50 Model numbers 2 Natural 3 Propane Number 2 or 3 is included in the model number e g 10143272 to denote gas type Technical data is...

Page 28: ...INSTALLATION SOLAR STORAGE TANK 28 TYPICAL INSTALLATION OUTDOOR LOCATION ...

Page 29: ...an inclination of up to 45 Where the solar collectors are installed at inclinations greater than 45 a With Pitch frame is necessary Refer to your local Solar Distributor for details For an installation on a roof with a pitch less than 10 a Variable Pitch frame is required Refer to your local Solar Distributor for details For an installation of collectors on a pitched roof in a cyclonic or high win...

Page 30: ...etre of pipe length reduce the number of 90 bends by two Note One 90 elbow is equal to two 90 bends Notes It is important not to cross connect the solar cold and solar hot pipes to the incorrect connections at the solar collectors and at the solar storage tank The solar cold pipe connects to the bottom of the solar collectors and the solar hot pipe connects to the top of the solar collectors diago...

Page 31: ...sses There MUST BE a continuous fall of a minimum 5 1 in 10 grade in the pipe work between the solar collector and solar storage tank for efficient and effective drain back to occur The highest point of the solar cold pipe and solar hot pipe must be where they connect to the solar collector The system has NO WARRANTY for freeze damage if there is not a continuous fall in the solar hot and solar co...

Page 32: ...hrough heights greater than 9 m and solar gain will not be achieved For heights greater than 9 m an auxiliary pump kit PN 299914 must be installed above and within 1 m of the solar storage tank The installation of an auxiliary pump will enable a maximum height of 18 m to be achieved Refer to Auxiliary Pump on page 43 Note The top of the solar storage tank must be a minimum of 500 mm below the bott...

Page 33: ...e to be isolated from the solar storage tank for the duration of the pressure test J and KF Solar Collector Installations If water is used as the pressure testing medium and if the collector circuit is not to be connected to the solar storage tank and the system commissioned on the same day then any excess moisture needs to be blown out and the collector circuit and solar collectors dried using dr...

Page 34: ...crews in the same locating holes Remove the screws securing the bottom bracket at the rear of the gas booster reposition the bracket across to the right of the gas booster as viewed from the rear face and refit the screws in the locating holes REMOVE SCREWS ROTATE BRACKET 180 REFIT SCREWS CONTINUOUS FLOW GAS WATER HEATER 27L TOP BRACKET REPOSITIONING CONTINUOUS FLOW GAS WATER HEATER 27L BOTTOM BRA...

Page 35: ... inside of the fitting of the water connection plumbing assembly 5 which connects to the hot water outlet of the gas booster Connect the water connection plumbing assembly 5 with the 550 mm long insulated flexible hose 7 attached to the hot water outlet of the gas booster Note The water connection assembly components are supplied only hand tightened Each component is to be firmly connected using t...

Page 36: ...mm LG 10 FRONT JACKET COVER 11 SCREWS PHILIPS PANHEAD No 8x13 12 SCREW M6x16 AND WASHER ITEM DESCRIPTION 12 1 Components for Assembly of Storage Tank and Gas Booster 1 Hot connection assembly 2 Cold connection assembly 3 Gas booster water heater 4 Washer 24 OD x 16 ID x 1 5 thick 5 Water connection plumbing assembly 6 Bracket support 7 Flexible hose cold inlet connection 550 mm long 8 Elbow fittin...

Page 37: ...n R 20 WATER INLET AND OUTLETS All pipe work must be cleared of foreign matter before connection and purged before attempting to operate the water heater All olive compression fittings must use brass or copper olives Use thread sealing tape or approved thread sealant on all fittings An isolation valve and non return valve must be installed on the cold water line to the water heater An acceptable a...

Page 38: ...e never hemp Make sure the tape does not hang over the end of the thread Screw the valve into the correct opening refer to the installation diagram on page 28 leaving the valve outlet pointing downwards Do not use a wrench on the valve body use the spanner flats provided A copper drain line must be fitted to the temperature pressure relief valve refer to Relief Valve Drain on page 39 The valve mus...

Page 39: ...ere 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 drain line from a tundish must meet the same requirements as for a drain line from a relief valve Warning As th...

Page 40: ...ar cold and solar hot pipes to the solar storage tank Remove the compression nut and olive from the solar hot inlet fitting at the top of the solar storage tank Remove the rubber washer from the union and discard Remove the plastic cap from the solar cold outlet pipe end at the top of the solar storage tank Fit the compression union supplied to the solar cold outlet pipe end Connect the solar cold...

Page 41: ... stated in AS NZS 3000 2000 clause 6 3 3 3 2 b ELECTRICAL CONNECTION All electrical work and permanent wiring must be carried out by a qualified person and in accordance with the Wiring Rules AS NZS 3000 and all local codes and regulatory authority requirements Warning Temperature controllers must not be fitted to an in series gas booster as part of solar water heater system because water at a tem...

Page 42: ...lead to the water heater jacket to prevent possible damage TEMPERATURE SETTING The gas booster outlet temperature setting can be adjusted The adjustment procedure is detailed in the Owner s Guide and Installation Instructions supplied with the gas booster The factory preset outlet booster temperature setting is 60 C AUXILIARY PUMP The auxiliary pump if installed must be wired to the control board ...

Page 43: ...ECTIONS The auxiliary pump is to be installed on the solar cold pipe from the solar storage tank to the solar collectors Refer to the label on top of the storage tank to identify the solar cold pipe The solar cold pipe connection is located toward the outer edge of the top of the solar storage tank within 1 m of the top of the solar storage tank with the inlet and outlet in a vertical orientation ...

Page 44: ...AUXILIARY PUMP 44 Auxiliary Pump Installation Solar Drain Back Auxiliary Pump Typical Installation ...

Page 45: ...ary Pump Wiring Connection Jacket Penetration Warning The removal of the lower front cover will expose 240 V wiring Switch off the electrical supply at the isolating switch to the water heater before removing the lower front cover and if necessary disconnecting the ribbon cable from the solar control module Connect the active plug from the auxiliary pump to the terminals marked PUMP 2 on the contr...

Page 46: ...e power outlets to the storage tank and gas booster The power outlets must be switched on for the solar controls to operate and solar gain to be achieved and for the gas booster to operate and have its frost protection activated Open a hot tap The gas booster will operate automatically Check to ensure the flow from each connected hot tap is sufficient to operate the gas booster The minimum operati...

Page 47: ... a drain back test The following equipment is required a 1500 mm long x 12 mm diameter clear hose closed circuit fluid level hose one 1 hose clamp a suitable plug for one end of the hose suitable tape to affix the hose to the side of the solar storage tank a torch to illuminate the working area under the heat exchanger and storage tank cylinder a non permanent marker Closed Circuit Fluid The water...

Page 48: ...o as not to be scalded by either the closed circuit fluid or the vapour escaping from the solar circuit Pre Commissioning Notes Before commencing the solar circuit commissioning procedure check the solar cold and solar hot pipe work to ensure there is a continuous fall from the solar collectors to the solar storage tank of a minimum 5 1 in 10 grade the maximum recommended pipe length is not exceed...

Page 49: ...le The ribbon cable can be disconnected from the solar control module if it is necessary to remove the lower front cover completely from the work area in front of the solar storage tank 4 Ensure the isolation valve in the pipe work between the outlet of the heat exchanger and the solar pump located behind the lower front cover of the solar storage tank is fully open Attach Closed Circuit Fluid Lev...

Page 50: ... circuit is complete to reconnect the hot sensor lead otherwise when the electrical supply is switched on the solar pump will deactivate after one hour and the solar control unit will then enter a fault mode and no solar gain will be achieved 10 Switch on the electrical supply at the power outlet to the solar storage tank Warning Take care not to enter the area inside the solar storage tank behind...

Page 51: ...ep 4 there is no leakage from the solar circuit It is important to check all of the solar circuit pipe work including in the roof space and on the roof If leaking rectify any leaks in the solar circuit the height from the base of the storage tank to the top of the collectors has not exceeded the maximum allowable height the length of solar cold and solar hot pipe has not exceeded the maximum recom...

Page 52: ...drain back completely to this level then check there is a continuous fall of at least 5 1 in 10 grade in the solar pipe work from the solar collectors to the solar storage tank the solar collectors have an inclination of not less than 10 refer to Solar Collector Location on page 29 the connectors on the inlet and outlet of the collectors are orientated downwards to ensure complete drain back of th...

Page 53: ...elow the text marking it will be necessary to add water to the heat exchanger to top up the level of closed circuit fluid There is sufficient Hartgard concentrate in the solar circuit heat exchanger such that only water needs to be added to the system if it is required to top up the level of closed circuit fluid Note The dynamic level of the closed circuit fluid upon the completion of commissionin...

Page 54: ...ked on the side of the solar storage tank in step 8 It would be necessary to add one litre of water to the heat exchanger E g If the dynamic level is 180 mm above the text marking then place a mark at least 30 mm but no more than 180 mm below the static level marked on the side of the solar storage tank It would be necessary to drain between one litre and five litres of closed circuit fluid from t...

Page 55: ...nut 19 Drain closed circuit fluid from the heat exchanger if required To drain closed circuit fluid If not already removed disconnect the drain line and remove the spring clip from the solar circuit relief valve at the top of the solar storage tank and remove the valve refer to step 6 Warning The solar circuit may be under pressure Take care when removing the solar circuit relief valve as a sudden...

Page 56: ...e solar pipe work and collector unions for leaks whilst the pump is operating and the solar circuit is at its working pressure It is important to check all of the solar circuit pipe work including in the roof space and on the roof 25 If the procedure to check the solar pipe work for leaks is not complete before the pump has automatically turned off then switch off the electrical supply at the powe...

Page 57: ...rmless to the environment However it is good practice to recover any excess closed circuit fluid and remove from site for appropriate disposal Completing the Commissioning of the Solar Circuit 30 Reconnect the hot sensor lead to the connecting plug located on the tab in the upper front cover opening It is important to reconnect the hot sensor lead otherwise when the electrical supply is switched o...

Page 58: ...4 x red Top three tank thermistors open or short circuit 5 x green Tank at maximum temperature 5 x red Sensor strip plugged into incorrect port on printed circuit board PCB no green remains off Call for service 6 x red No heating fluid flow through collectors Notes Warning The removal of the lower front cover will expose 240 V wiring Switch off the electrical supply at the power outlet to the sola...

Page 59: ...ion of the Installation Instructions and Owner s Guide supplied with the gas booster BURNER GAS PRESSURE It is necessary to check the burner gas pressure at both the minimum and maximum operational settings It is necessary to have the electrical supply to the water heater switched on the hot water must be flowing and the burners on to check and if necessary adjust the operational gas pressures War...

Page 60: ... be turned on again SOLAR STORAGE TANK Warning Exercise care as water discharged from the solar storage tank may be of a very high temperature To drain the storage tank Turn off the water heater refer to To Turn Off The Water Heater on page 59 Close all hot water taps Operate the relief valve release lever do not let the lever snap back or you will damage the valve seat Operating the lever will re...

Page 61: ...a 12 mm diameter clear hose to the heat exchanger drain valve hose tail connection refer to step 5 of Attach Closed Circuit Fluid Level Hose on page 49 Disconnect the drain line from the solar circuit relief valve at the top of the solar storage tank Remove the spring clip from the solar circuit relief valve and remove the valve Warning The solar circuit may be under pressure Take care when removi...

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Page 65: ... responsibility In other words the cost of dismantling or removing cupboards doors or walls and the cost of any special equipment to bring the water heater to floor or ground level or 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...

Page 66: ...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 entitled to make a claim under this warranty if your water heater a Does not have its original serial numbers or rating labels b...

Page 67: ...Installation please circle New Solar to Solar Tank Replacement Other Work Delivery Details 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 Booster Type please circle Electric continuous Off Peak 1 night Off Peak 2 night day In Tank Gas Booster In Line Booster Solar Preheat only Booster Control please circle None Timer Manua...

Page 68: ... Email solahart solahart com au Web www solahart com Postal Address PO Box 95 Welshpool WA 6986 Australia International Offices Registered Office 1 Alan Street PO Box 6 Rydalmere New South Wales 2116 Australia www solahart com au Europe Phone International 31 492 579 696 Facsimile International 31 492 579 694 USA Australia Phone International 1 334 260 1586 For SERVICE Telephone 1800 638 011 or yo...

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