SolarSmart 90 Installation and Servicing Instructions

SolarSmart 90 Installation and Servicing Instructions
Installation and Servicing
Instructions
Alpha SolarSmart 90
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 HELPLINETel: 0844 8718764
website:www.alpha-innovation.co.uk
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Building Regulations Approved
Certificate No. ETC11206
SOLAR Key Mark Certificated
THE NATIONAL FEDERATION OF
ROOFING CONTRACTORS LIMITED
Leave these instructions with the User
CONTENTS
1
2
3
4
5
6
Introduction ....................................... 2
Technical data ................................... 3
General information ........................... 6
Installation ......................................... 12
Commissioning ................................. 18
System operation .............................. 20
1
7
8
9
10
11
12
13
Routine inspection ............................. 22
Component replacement ................... 22
Wiring diagram .................................. 24
Diagnostics and fault codes ............... 25
Checklist for unvented storage ........... 26
Parts list ............................................ 27
Inspection history .............................. 28
INTRODUCTION
The Alpha SolarSmart 90 system is a pre-heat drain back solar collector system which includes a wall mounted 90 litre
unvented cylinder to store water heated by the solar collector. The system must be used in conjunction with an Alpha
combination boiler fitted with the Alpha Solar valve which is supplied with the system.
The SolarSmart 90 system consists of a 90 litre cylinder, a 2.5 m² flat plate drain back solar collector, drain back unit,
unvented kit and solar valve. The 90 litre unvented cylinder is fitted with a pump, control box and temperature sensors.
The drain back unit is fitted with a heat exchanger and pump.
The unvented kit must be fitted in the mains water supply to the cylinder. The kit includes a pressure reducing valve,
expansion vessel, expansion relief valve, check valve and a tundish. The solar valve must be fitted directly to the mains
water inlet of the Alpha combination boiler.
Note: In the northern hemisphere solar collectors should ideally face South. For more information see Section 3.6.
The solar collector is supplied in special packaging to protect it during transit. The four corners are protected with EPS
(polystyrene) caps and the exposed edges are protected with cardboard. The glass front and aluminium back panel are
exposed. The packaging is not intended to support the full lift weight of the collector.
When manually carrying the collector, always hold the exposed edges and not the packaging alone. The collector can
be lifted both horizontally and vertically.
The collector can only be carried using the lifting forks when on the original wooden pallet base.
IMPORTANT
This System has been approved to the Building Regulations for unvented hot water storage systems and the Local
Authority must be notified of the intention to install. Therefore the installation must be carried out by a person competent
to install unvented hot water systems.
The installation must be carried out in accordance with the following recommendations:All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L1
Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department
UK Water Regulations/Byelaws (Scotland)
Health & Safety Document No. 635 (The Electricity At Work Regulations 1989)
The installation should also be in accordance with the following British Standard Codes of Practice:BS 5449:1990
Forced circulation hot water systems
BS 5546:2000
Installation of hot water supplies for domestic purposes
BS 5918:1989
Solar heating systems for domestic hot water
BS 6700:2006
Design, installation, testing and maintenance of services supplying water
Failure to install this appliance correctly could lead to prosecution and will invalidate the guarantee. It is in your own
interest and that of safety to ensure that the law is complied with.
Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations.
This appliance meets the requirements of IPX4D, i.e. degree of protection against moisture.
Reference should be made to Criteria for gas fired combination boilers used as after heaters in solar thermal systems
and BRE Solar heating UK:1981.
Lightning Protection
Refer to BS6651 for lightning protection, however this does not give specific requirements for solar panels and
generally collectors mounted on non-metallic roof structures will not require lightning protection.
Advice should be sought if mounting on metallic roof structures or mounting in situations where the risk of strikes are high.
2
Alpha SolarSmart 90 - Contents/Introduction
2
2.1
TECHNICAL DATA
DHW SYSTEM
Solar Cylinder
Drain Back Unit (DBU)
Max. Hot Water Working Pressure
Max. Mains Inlet Pressure (inlet of pressure reducing valve)
5.5 bar
12 bar
DHW Circuit:
Flow Connection
15 mm
Min. Mains Water Pressure
Mains Inlet Connection
0.1 bar
15 mm
Return Connection
Max. Working Pressure
15 mm
8 bar
DHW Outlet Connection
DHW Cylinder Capacity
15 mm
91 L
Heat Exchanger Coil Content
Collector Circuit:
0.32 L
Flow Connection
Return Connection
15 mm
12 mm
Expansion Vessel Size (pre-charge press.)
Pressure Reducing Valve Setting
Temperature and Pressure Relief Valve
Expansion Relief Valve Setting
Flow Rate
L/min
gal/min
Max. Outlet Water Temp. (Approx.) °C
°F
8 L at 2.5 bar
2.5 bar
90°C/7 bar
6 bar
Max. Working Pressure
Vessel Size
6 bar
3.6 L
Max.18.0 Min. 1.0
Max. 4.0 Min. 0.22
Max. Filled Content
Heat Transfer Capacity
2.8 L
110 W/K
Max. 70 Min. 5
Max. 158 Min. 41
Note: Copper pipe MUST be used between the
cylinder, drain back unit and collector.
Reference to WRC-NSF Test Procedure 1.50.220 using a 30 kW boiler. Time to reheat water store by 55°C - 25
minutes. Reheat time for 70% of store - 18 minutes
2.2
SOLAR COLLECTOR SYSTEM
Type:
Portrait
Landscape
Dimensions
Total Surface Area
m²
2.5
Aperture Area
m²
2.26
Length x Width x Thickness
mm
2230 x 1120 x 92
1120 x 2230 x 92
Water Content
L
1.16
1.10
Lift Weight
kg
45 Gross - 44 Nett
Profile of collector when fitted using an Alpha flashing kit protrudes approximately 30 mm to 60 mm above the
tiles (depends upon type of tile used)
Hydraulics
Maximum Pressure
bar
8
Absorber
Aluminium Cover and Copper Pipe
(Length x Width x Depth)
mm
2140 x 1030 x 0.5
1030 x 2140 x 0.5
Spectral Selective Layer
Absorption Coefficient
%
95
Emission f
%
5
Glass
Transparent, Hardened - Thickness
mm
4
Collector Housing
Material
Aluminium Pressing
Insulation
Thickness
mm
50
Thermal conduction coefficient
W/mk
0.037
Cover Frame
Material
Aluminium Black Powder Coated
Temperature Sensor
Type - NTC
Ohm
10 k
Connections
Pre-mounted Flexible Hoses
Return to DBU
mm
12 mm
Flow from DBU mm
15 mm
Roof Slope
20° Min (90° Max)
30° Min (90° Max)
Energy Performance (System with 90L tank)
3.5 GJ/yr (972.2 kWh/yr)
Zero Loss Collector Efficiency (No)
80%
Collector Heat Loss Coefficient (a1)
W/m²k
3.175
Aperture to Gross Collector Area Ratio
0.9
Collector Pressure Drop
@80 l/h - 9 kPa
Max. Wind and Snow Load
Pitched roof
Same as Supporting Roof Structure
Flat roof
Wind Speed 27 m/s - Snow Load 1.9 kN/m2
Alpha SolarSmart 90 - Technical Data
3
2.3
INSTALLATION
Solar Cylinder Min. Clearances for Servicing
DBU Min. Clearances for Servicing
Top
100 mm
Bottom
Sides
300 mm
10 mm
Front
Top
450 mm
100 mm
Bottom
Side
100 mm
10 mm
Front
450 mm
22 kg
Lift Weight - Cylinder Assembly
Lift Weight DBU
Weight Full and Operational - Cylinder Assemby
6 kg
113 kg
Weight Full and Operational - DBU
8.8 kg
2.4
ELECTRICAL
2.5
Supply
External Fuse
Power Consumption
Solar Cylinder Dimensions
230/240 V ~ 50 Hz
Max.
Min.
GENERAL
3A
165 W
DBU Dimensions
5W
Height
Width
1110 mm
540 mm
Depth
Height
530 mm
460 mm
Width
Depth
365 mm
270 mm
Solar Cylinder - Material
DBU Heat Exchanger - Material
Covers/Insulation Material
Solar Cylinder Insulation Thickness
Standing Energy Loss of Solar Cylinder
Global Warming Potential
Ozone Depletion Potential
Insulation Blowing Agent
2.6
Stainless Steel
Copper
EPP Foam
50 mm
0.92 kWh/24hr
0.43 W/litre
Zero
Zero
Steam (Water)
LOCATION
Max. Height Between Top of Solar Collector and Bottom of DBU (see Note below)
3m
Max. Distance Between DBU and Bottom of Solar Cylinder
6m
Note: Whenever possible, always fit the DBU to the flexible hoses from the solar collector. If this is not possible, do not
use more than 2 m of 15 mm copper pipe (with compression fittings) for each of the flow and return between the DBU
and collector.
2.7
ELECTRICAL CONNECTIONS
Notes: This Appliance Must Be Earthed. Do Not Connect Any Other Controls.
Fig. 1
4
Alpha SolarSmart 90 - Technical Data
2.8
SOLAR SYSTEM SCHEMATIC
1
15
21
5
6
10
14
9
2
4
8
14
3
24
12
13
11
16
25
7
Cold water
inlet
1
Solar collector
13 Flow to tap
2
Drain back unit (DBU)
14 Temperature sensors
3
DBU pump
15 Insulation/casing
4
DBU heat exchanger
16 Bottom tray
5
Collector temperature sensor
17 Unvented kit
6
Solar cylinder
18 Tundish
7
Solar cylinder pump
19 Non-return valve
8
Filter
20 Expansion relief valve
9
Diffuser
21 Temperature and pressure relief valve
10 DHW outlet pipe
22 Expansion vessel
11 Solar valve
23 Pressure reducing valve with filter
12 Flow to boiler
24 Drain point for cylinder
25 Overheat thermostat
Fig. 2
Alpha SolarSmart 90 - Technical Data
5
3
3.1
GENERAL INFORMATION
ELECTRICAL SUPPLY
The Solar system requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A - The system must be earthed.
There must only be one common isolator, providing complete electrical isolation, for the Solar system.
This system has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less
than 0.75 mm² (24 x 0.2 mm) to BS 6500 Table 16. The system should be connected to a fused three pin plug and
unswitched shuttered socket outlet (both complying with BS 1363), or a fused double pole switch with a contact
separation of at least 3 mm in both poles.
Note: There is no electrical connections between the boiler and the Solar system. Therefore, it is recommended that the
Solar system electrical isolation is completely separate to the boiler and any external controls isolation.
All wiring must be in accordance with the current IEE Wiring Regulations (BS 7671).
3.2
DOMESTIC HOT WATER SYSTEM
The mains water supply must be first connected to the components detailed in Section 3.3 before the Solar cylinder. No
valves must be fitted between these components and the cylinder. The incoming mains water pressure to the cylinder is
regulated to 2.5 bar by the pressure reducing valve supplied in the unvented package. However, all taps and mixing
valves used with the hot water system must be suitable for operating at a pressure of up to 8 bar.
The Solar valve, supplied in the unvented package, must always be fitted directly to the cold water inlet of an Alpha
combination boiler.
Note: The hot water control thermostat on the combination boiler must always be turned to maximum.
To ensure economic use, the pipe runs to the Alpha combination boiler and taps should be in 15 mm copper pipe and be
as short as possible. Where possible the pipework should be insulated to reduce heat loss.
Before the mains water supply pipe is connected to the boiler, it should be thoroughly flushed out to avoid the danger of
dirt or foreign matter entering the boiler and the filter incorporated within the pressure reducing valve cleaned.
The stored water temperature is controlled to a maximum of 70°C.
To prevent high temperatures at the hot water taps, it is recommended that a thermostatically controlled mixing valve is fitted
after the boiler.
3.3
UNVENTED HOT WATER STORAGE SYSTEM
To comply with the Building Regulations for unvented hot water storage, it is required that the unvented kit components
detailed in Fig. 3 are fitted before the mains cold water inlet to the Solar cylinder. No isolating valves must be fitted
between these components and the cylinder.
All these components are supplied with the Solar system in a separate package and must be fitted by a competant
person in accordance with the instructions.
The installation is subject to Building Regulations approval and the Local Authority must be notified of the intention to install.
Discharge pipe - The discharge pipes from the temperature/pressure and expansion relief valves must be routed to the
tundish supplied and in 15 mm pipe. The discharge pipework from both relief valves may be joined together in the same
sized pipe, providing at least 22 mm pipework is connected downstream of the tundish.
Tundish - The tundish must be positioned within 500 mm of the appliance, so that it is visible to the User and away from
electrical devices. The minimum size of the discharge pipe downstream of the tundish is given in the following table.
The discharge pipework from the tundish:Sizing of copper discharge pipe 'D2' - refer also to Fig. 4A and 4B
Valve
outlet size
Minimum size of discharge
pipe 'D1' to tundish
G½
15 mm
1.
2.
3.
4.
5.
Maximum resistance allowed,
expressed as a length of straight
pipe (i.e. no elbows or bends)
Resistance created
by each elbow
or bend
22 mm
up to 9 m
0.8 m
28 mm
up to 18 m
1.0 m
35 mm
up to 27 m
1.4 m
Minimum size of discharge
pipe 'D2' from tundish
Shall fall continuously through its length.
Shall be of a heat resistant material, e.g. metal.
Shall not be fitted with any valves or taps.
Shall discharge to a safe visible position, e.g. into a gulley.
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.
6
Alpha SolarSmart 90 - General Information
Thermostat sensor
Solar collector
Combination boiler
Temperature/pressure
relief valve
Heat
exchanger
Drain back
unit pump
Thermostat
sensor
Hot tap
Unvented
cylinder
Outlet water
temperature
60°C
Water temperature
less than 60°C
Thermostat
sensor
Cylinder
pump
Drain
point
Thermostatically
controlled
mixing valve
Drain back
unit
Overheat
thermostat
Solar valve
Water temperature
more than 60°C
Cold water
supply
Expansion
vessel
Filter
Pressure
reducing
valve
Check
valve
Expansion
relief valve
Tundish
Unvented kit
Discharge
pipe
Stop
valve
Mains water
supply
Fig. 3
Alpha SolarSmart 90 - General Information
7
Given below are suggested methods of terminating the discharge pipe safely.
Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should be limited to not
more than 6 systems so that any installation can be traced reasonably easily. The single common discharge pipe should
be at least one pipe size larger than the largest individual discharge pipe to be connected.
If the system is installed where discharges from safety devices may not be apparent, i.e. in dwellings occupied by blind, infirm or disabled
people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.
a. Low level termination
Solar cylinder
temperature/pressure
relief valve
Metal discharge pipe (D1)
from relief valve to tundish
D1
Tundish
To expansion
relief valve
Pipe close to wall to
allow water to fan out
safely
300 mm
minimum
500 mm max.
D2
300 mm
minimum
100 mm max.
70 mm min.
Ground level
Gulley if
available
Metal discharge pipe (D2) from
tundish with continuous fall
Fig. 4a
b. High level termination
At high level, discharge onto a roof is acceptable providing the roof is capable of withstanding high temperatures and
there is a distance of 3 m from any plastic guttering systems that would collect such discharge.
Note: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rainwater goods may
be damaged by such discharges.
c. Termination into a hopper
D1
Worked example:Tundish
The example below is for a G½ temperature relief valve with a discharge pipe (D2)
having four elbows and a length of 7 m from the tundish to the point of discharge.
From the table on page 6:-
300 mm
minimum
Maximum resistance allowed for a straight length of 22 mm copper discharge pipe
(D2) from a G½ temperature relief valve is 9 m.
D2
Subtract the resistance for four 22 mm elbows of 0.8 m each = 3.2 m.
Type 'A'
air gap
Therefore the maximum permitted length equates to 9 - 3.2 = 5.8 m
5.8 m is less than the actual length of 7 m therefore calculate the next largest size.
Maximum resistance allowed for a straight length of 28 mm pipe (D2) from a G½
temperature relief valve equates to 18 m.
Subtract the resistance for four 28 mm elbows at 1.0 m each = 4 m.
Therefore the maximum permitted length equates to 18 - 4 = 14 m
End of pipe to be
clearly visible
As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory.
Fig. 4b
8
Alpha SolarSmart 90 - General Information
3.4
SOLAR CYLINDER INFORMATION - Figs. 5a and 5b
Positioning
The Solar cylinder must be installed on a flat vertical wall which is capable of supporting the weight of the cylinder when
full (113 kg).
The cylinder may be installed in any room or internal space, although particular attention is drawn to the requirements of
the current IEE Wiring (BS7671) Regulations, and in Scotland, the electrical provisions of the Building Regulations
applicable in Scotland, with respect to the installation of the cylinder in a room or internal space containing a bath or
shower. When the cylinder is installed in a room containing a bath or shower, it must not be possible for a person using
the bath or shower to touch any electrical switch or cylinder control utilising mains electricity.
The bottom of the Solar cylinder must be located within 6 metres of the top of the Solar collector and of the drain back
unit.
Dimensions
The dimensions of the cylinder and clearances required for servicing are shown in Fig. 5a.
100
Serial No. under cover
540
10
450
530
10
Front
Side
1110
187
Serial Number
300
Fig. 5a
Water connections
The connections at the bottom of the cylinder are shown in Fig. 5b.
Note: Use compression fittings only on the cylinder connections. Use a
minimum of 1 metre of copper pipe from the cylinder for the domestic
water inlet and outlet connections.
Cylinder Connections
A Water outlet to boiler
15 mm
B Cold water inlet
15 mm
C Return from DBU
15 mm
D Flow from cylinder to DBU 15 mm
Fig. 5b
Alpha SolarSmart 90 - General Information
9
3.5
DRAIN BACK UNIT (DBU) INFORMATION - Fig. 6
Positioning
The DBU must be located within a height of 3 metres of the top of the Solar collector, see Fig. 8. The pipework from the
collector to the DBU must always fall by a minimum of 40 mm per metre and must be insulated with high temperature
pipe insulation.
Dimensions
The dimensions of the DBU and clearances required for servicing are shown in Fig. 6.
Water connections
The connections at the top and bottom of the DBU are shown in Fig. 6.
50
55
68
Top
450
270
10
10
365
100
A
B
C
D
35
460
Front
Side
35
100
Serial No. inside DBU,
left above pump
50
55
DBU Connections
A Return from collector to DBU 22 mm
B Flow from DBU to collector
15 mm
C Flow from cylinder to DBU
15 mm
D Return from DBU to cylinder
15 mm
Bottom
198
Note: Use copper pipe and compression fittings only on the
pipework between the DBU and solar collector.
Fig. 6
10
Alpha SolarSmart 90 - General Information
3.6
SOLAR COLLECTOR INFORMATION - Fig. 7
The solar energy supplied by a system varies with the orientation and tilt of the collector, which will usually be
determined by the existing roof. However, the predicted variation is slight. For a collector facing anywhere between SE
and SW and tilted upto 60° from the horizontal, the annual solar energy supplied will be at least 90% of that obtained at
the optimum collector position.
It should be remembered that shading from trees, buildings etc., can produce a significant decrease in system
performance, and collectors should be positioned to minimise shading from the sun in the middle of the day.
The solar collector can be installed using one of the following methods:
a.
Integration of the collector into the tiles of a pitched roof: Using the Alpha Flashing Kit (Part No. 6.4000750 portrait or
Part No. 6.4000650 landscape), landscape or portrait 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 20° and the tiles used with the flashing kit must be suitable
to ensure that the installation is weatherproof. Full details of this type of installation are provided in the instructions
supplied with the kit.
Note: When fitted the collector must
be level, i.e. within 2 mm per metre
Min. 20°
angle
Min. 30°
angle
Portrait
Landscape
Fig. 7
b.
Positioning of a landscape collector onto a flat roof: Using the Alpha Flat Roof Kit (Part No. 6.4000800), the collector
is mounted on the framework supplied. The collector is fixed at an inclination of 30° and ballast is used to secure the frame
in the required position. Refer to Fig. 8 for details of location of the drain back unit in relation to the collector. Full details of
this type of installation are provided in the instructions supplied with the kit.
Note: When fitted the collector must
be level, i.e. within 2 mm per metre
Solar collector
Minimum decline of 40 mm per
metre required.
Maximum 3 metres
The collector must always be able
to fully drain back, therefore the
lowest part of the collector must
be above the pipes of the drain
back unit.
Ensure that all pipework is
insulated with high temperature
insulation.
Flat roof
Solar cylinder
Whenever possible, always fit the
DBU to the flexible hoses from the
solar collector. If this is not
possible, do not use more than 2 m
of 15 mm pipe for each of the flow
and return between the DBU and
collector.
Drain back unit
(DBU)
Fig. 8
Alpha SolarSmart 90 - General Information
11
4
4.1
INSTALLATION
UNPACKING
Top cover
The SolarSmart 90 system is supplied in three boxes as follows:
Clamping bracket
Box 1 - Solar cylinder
Top wall
mounting bracket
Contents:
Solar cylinder
Inlet pipework assembly
Temperature/pressure relief valve with discharge pipe
Casing and insulation
Cylinder pump
Control box
Top cover
Bottom cover
Wall mounting brackets
Screw pack
Fitting instructions
Solar
cylinder casing
Control box
Cylinder pump
Bottom wall
mounting bracket
Bottom cover
Bottom cover
fixing screw
and washer
Fig. 9
Box 2 - Drain back unit
Contents:
Mounting board
Drain back vessel
Housing and drain back unit pump (with 7 metre cable)
Screw pack
Cable set for collector temperature sensor
Pipe fittings for drain back unit/collector
Pipe insulation
Drain back
unit housing
Drain back
unit pump
Box 3 - Unvented kit and Solar valve
Contents:
2.5 bar pressure reducing valve
8 litre expansion vessel, pre charged to 2.5 bar
Expansion vessel mounting bracket
Tundish
6 bar expansion relief valve/check valve
Solar valve kit
Fitting instructions
Screws
Mounting board
Fig. 10
The following items are also required to complete the installation:
1.
Solar collector - Landscape or Portrait
2.
Solar collector mounting kit - a. Pitched roof collector flashing kit - landscape (Part No. 6.4000650)
or portrait (Part No. 6.4000750).
or
12
b. Flat roof collector mounting kit, landscape only (Part No. 6.4000800).
Alpha SolarSmart 90 - Installation
3.
Alpha combination boiler and flue.
4.
Thermostatic mixing valve.
5.
High temperature 15 mm pipe insulation (150°C plus).
4.2
LOCATION and CLEARANCE REQUIRED
Refer to Section 3.4, 3.5 and 3.6 before locating the solar cylinder, drain back unit and solar collector.
4.3
INSTALL THE COLLECTOR
Refer to installation instructions supplied with the Solar collector mounting kit to install the collector.
4.4
FIT THE SOLAR CYLINDER - Figs. 11a, 11b and 11c
The cylinder must be installed on a flat vertical wall
which is capable of supporting the weight of the full
cylinder (see Section 2.3). The cylinder should be
secured to the wall using the mounting brackets
supplied.
min. 280
10
Note: If the positions of all the fixing holes for the brackets
cannot be made into solid brickwork, then the use of two
rails, from the floor to the ceiling, is recommended (e.g.
Flamco rails) with the mounting brackets fixed to them.
1.
2.
ø 10 (6x)
Using the template supplied, mark the positions of the
fixing holes. Drill the holes approximately 60 mm deep
using a 10 mm dia. drill. All the holes must be into
solid brickwork.
Plug the holes and secure the top and bottom mounting
brackets to the wall, using the plugs and screws
supplied.
4.
Position the cylinder onto the bottom bracket ensuring
the sides of the bracket (B) are located into the grooves
in the cylinder (A), see Fig. 11b. Carefully slide the
cylinder towards the wall, making sure that the plastic
pins at the bottom of the cylinder are fully located over
the bottom bracket.
10
712
135
135
115
450
Note: Ensure that the cylinder is positioned squarely on
the bottom bracket before pushing it back towards the
wall.
5.
110
55 - 60
Decide on the position of the cylinder, taking into
consideration the clearances and the maximum
allowed distances from the drain back unit and
collector. Refer to Section 2.6.
3.
min. 280
110
Fig. 11a
Secure the top of the cylinder to the top mounting bracket using closing bracket as shown in Fig. 11c.
Rear view
Clamping bracket
Wall bracket
A
Solar cylinder
B
Fig. 11b
Fig. 11c
Alpha SolarSmart 90 - Installation
13
4.5
FIT THE DRAIN BACK UNIT (DBU) - Figs. 12a and 12b
The DBU may be installed to the inclined roof structure or on a flat vertical wall, which is capable of supporting the weight
of the full DBU (see Section 2.3). The DBU should be secured in position using the fixings supplied. If the strength of the surface
on which the unit is to be fitted is unknown, the wooden mounting board, supplied, should be used as shown in Fig. 12a.
To fit the DBU on an inclined roof - see Fig. 12a
1. With the help of Fig. 12a and Section 2.6, decide upon the position of the unit, taking into account the clearances required around
the unit and the distance between the break-through hole of the collector tubing and the DBU pipes that have to be connected.
Note: Whenever possible, always fit the DBU to the flexible hoses from the solar collector. If this is not possible, do not
use more than 2 m of 15 mm pipe for each of the flow and return between the DBU and collector.
2. If the DBU is used with an existing collector panel, loosely connect the collector tubing to the DBU pipes. This will help to
determine the position of the DBU to achieve the minimum 40 mm per metre downward slope of the collector tubing.
If the collector has not yet been fitted, ensure that there is 200 - 250 mm between the centre of the break-through hole and
the upper side of the DBU. See Fig. 12a.
3. Remove the front cover of the DBU (pull off away from the unit).
4. Secure the unit to the roof using the screws and washers supplied, then replace the front cover.
Note: The tubing from the solar collector
must always slope down towards the drain
back unit (at least 40 mm per metre).
There must not be any part of the tubing
that will allow water to collect.
Fig. 12a
To fit the DBU on wall - see Fig. 12b
With the help of Fig. 12b, decide upon the position of the unit,
taking into account the clearances required around the unit.
2. Remove the front cover of the DBU (pull off away from the
unit).
3. Mark the position of the three fixing holes. Drill the holes
approximately 40 mm deep using a 6 mm dia. drill.
4. Plug the holes and secure the unit to the wall, using the plugs
and screws supplied.
5. Replace the DBU front cover.
1.
Fig. 12b
14
Alpha SolarSmart 90 - Installation
4.6
FIT THE UNVENTED KIT - Fig. 13
1.
Unpack Box 3 and check the contents.
2.
Locate the expansion vessel mounting bracket in a suitable position as close to the solar cylinder as possible and secure
in postion using the srews and wall plugs supplied.
Note: Ensure there is enough space to fit/remove the cylinder bottom cover.
3.
Secure the expansion vessel to the mounting bracket using the metal band, nut, washers and bolt.
Note: Ensure the pressure in the expansion vessel is 2.5 bar. If it is not, adjust the pressure to give 2.5 bar.
4.
Connect the expansion relief valve to the expansion vessel as shown in Fig. 13.
Notes: a. The plug must be removed from the capped connection on the expansion vessel relief valve to enable
connection to the expansion vessel.
b. Mount the valve in either the horizontal or vertical orientation. An inverted orientation may allow debris deposits
onto the valve seating and cause the valve to malfunction.
c. Ensure the valve is mounted correctly, i.e. the arrow marking on the valve body is pointing in the direction of flow.
5.
Connect the mains water supply to the pressure reducing valve and thoroughly flush out the water pipework.
Refer to Domestic Hot Water System, Sections 3.2 and 3.3.
Fig. 13
4.7
FIT THE BOILER AND THE SOLAR VALVE
1.
Only an Alpha combination boiler may be
used with the SolarSmart 90 system. Install
the boiler as described in the instructions
supplied with the boiler.
2.
Connect the solar valve directly to the boiler
cold water inlet connection, then connect the
pipework to the solar valve as shown in Figs.
14 and 15.
Notes: a. If the valve is being fitted to an
existing boiler installation, the
mains water inlet must be re-routed
to the inlet of the solar cylinder's
unvented kit.
b. Ensure that the hot water outlets 'B'
and 'D' (Fig. 15) are connected
together after the leaving the boiler.
c. It is recommended that a
thermostatic mixing valve is fitted in
the hot water outlet before the taps.
Fig. 14
Alpha SolarSmart 90 - Installation
15
Filling loop
H
Filling loop
I
J
H
K
M
I
G
J
M
L
K
O
G
N
L
N
23
20
65
70
C
37
95
B
D
58
F
70
P
23
20
65
45
CD25, 28, 35C
A
B
C
D
E
F
-
70
37
95
C
A
E
B
D
58
F
70
45
A
E
CD25, 28, 35C with Premier Pack
Heating flow (22 mm)
Hot water outlet (15 mm)
Gas inlet (22 mm)
Hot water outlet from Solar valve (15 mm)
Heating return (22 mm)
Pressure refief valve outlet (15 mm)
G
H
I
J
K
L
-
Water inlet from Solar cylinder (15 mm)
Cold water inlet filter
Solar Valve
Heating return valve
Heating flow valve
Heating drain point
MN OP -
Condensate trap
Condensate discharge pipe
Cyclone drain point (if applicable)
Wall jig (if applicable)
½" Brass
plug
½" Brass
plug
H
H
I
J
I
M
J
K
M
G
K
L
G
O
L
N
N
23
20
65
70
C
37
95
B
D
58
F
70
E
P
23
20
45
65
A
70
C
37
95
B
CD25, 28X
58
D
70
F
E
45
A
CD25, 28X with Premier Pack
Notes: 1. Join together hot water outlets B and D to provide a single hot water supply immediately after boiler installation.
2. When connecting the Solar Valve to a CDX boiler the filling loop connection of the Solar Valve must be plugged with a ½"
brass plug.
3. When connecting the Solar Valve to a CDC boiler isolate the filling loop after filling the central heating system.
Fig. 15
3.
16
A self adhesive label is supplied in the
Solar Valve Kit. This label must be
located as shown in Fig. 16, over the
boiler hot water thermostat knob after it
has been set to its maximum position, i.e.
fully clockwise to position No. 9. This will
ensure that the hot water temperature
from the boiler will be approximately 60°C
and will prevent the knob from being
adjusted to a lower temperature.
Note: The User must be informed of the
purpose of this label, which must not be
removed.
Alpha SolarSmart 90 - Installation
OFF
0
A
1
1
3 RESET
C
4
7
SELECTOR
Fig. 16
3
9
8
D
1
2
2
B
6
3
4
8
5
THERMOSTAT
2
2
9
7
6
5
THERMOSTAT
IMPORTANT
This Combi boiler is fitted to an
Alpha Solar system and the hot
water thermostat MUST always be
set at maximum (No.9)
3
1
0
4
bar
4.8
1.
CONNECT THE PIPEWORK - Fig. 15
Thoroughly flush out all the water pipework.
Ensure that all the plastic caps are removed from all connections.
Note: If soldering union bends, ensure that the bends are not connected to the valves etc., otherwise the internal seals
may be damaged.
2.
Connect the pipework from the unvented kit to the solar cylinder.
Note: No valves must be fitted between the cylinder and the unvented kit.
3.
Connect the system pipework to the boiler and the discharge pipe to the heating system pressure relief valve.
Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler to a drain in such a manner
that it may be seen, but cannot cause injury to persons or property. Refer to the boiler instructions.
4.
Connect the discharge pipework to the temperature/pressure relief and expansion relief valves via the tundish supplied.
This pipework must be installed as recommended in Unvented Hot Water Storage System, Section 3.3.
5.
4.9
1.
Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water supply at this
stage.
ELECTRICAL CONNECTIONS - See Wiring Diagram Section 9
Gain acces to the electrical control box of the solar
cylinder by removing the screw and washer securing the
bottom cover and remove the cover. See Fig. 17.
Remove the screws securing the front of the control box
to provide access to the terminals on the control board.
Refer to Section 2.6 for details of all electrical
connections required.
2.
Connect the Drain Back Unit pump - The drain back
unit pump is fitted with a 7 metre cable. Route the cable
to the solar cylinder control box along the lower groove
in the cylinder insulation panel and pass it through the
cable clamp.
Connect the wires as follows:
Brown wire to terminal 9, Blue wire to terminal 8 and
.
Green/Yellow wire to
Ensure that the cable is secured in the cable clamp.
3.
Connect the Collector Sensor - The sensor has a 7
metre cable. Route the cable to the solar cylinder control
box along the lower groove in the cylinder insulation
panel and pass it through the cable clamp. Connect the
White and Brown wires to terminals 2 and 3.
Fig. 17
Ensure that the cable is secured in the cable clamp.
4.
Connect the Mains Supply - Refer to Sectioin 2.6.
Note: The solar cylinder has been fitted with a mains supply cable. However, if it is necessary to fit an alternative supply
cable refer to Section 3.1 and release the cable clamp. Connect the new lead as follows:
Brown wire to L, Blue wire to N and Green/Yellow to
.
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.
5.
Do not switch on the electrical supply at this stage.
Do not make any connections to terminals 4, 5, 6, or 7 and do not fit any other controls.
Alpha SolarSmart 90 - Installation
17
5
5.1
COMMISSIONING
FILL THE SOLAR CYLINDER
1.
Check that all the mains water connections are tight and any drain valves are closed.
2.
Open the mains water inlet valve. Thoroughly flush out the hot water system by turning on all the hot water taps and allow
the water to flow until no air is present, this will automatically vent the cylinder of air. Turn off each tap.
3.
It is important to vent the solar cylinder pump by unscrewing the centre cap from the pump head (see Fig. 18) until water
runs from it and then replace the cap.
4.
Isolate the mains inlet and drain the cylinder to remove any debris that may have collected in the cylinder. Refill and vent
the system as described above.
Fig. 18
5.2
DRAIN BACK UNIT
Collector
The drain back unit is pre-filled and should not
need any water added.
Note: The drain back unit is filled with domestic
water.
It is important to prime the drain back unit pump:unscrew the centre cap and rotate the spindle
using a small screwdriver. Replace the cap.
If the drain back unit requires to be filled, fill as
follows:
1.
Isolate the electrical supply to the
SolarSmart System.
2.
Remove the front cover from the drain back
unit (pulls off).
3.
Unscrew the plug located in the fill/overflow
point. See Fig. 19.
4.
Carefully fill the drain back unit with water
(use a flexible tube or funnel) until water
overflows from the fill/overflow point (see
Fig. 19). This indicates the correct fill level
has been reached.
5.
Replace the plug in the fill/overflow point.
6.
Switch on the electrical supply and 'start up'
the Solar system as described in Section 5.3.
7.
Check for any leaks and replace the front
cover.
Note: Do not overfill.
Fill/overflow
point
Correct filling level
for DBU
Heat
exchanger
DBU pump
Drain point
Cylinder
Fig. 19
18
Alpha SolarSmart 90 - Commissioning
5.3
TURN ON THE ELECTRICAL SUPPLY
1.
Check that all the wiring has be correctly installed and that all the terminal connections are tight.
2.
Switch on the electrical supply and the display (see Fig. 20) will show 'A1' and start to countdown from eighty to zero. During
this countdown the PCB does a self-diagnosis of all the sensors and pumps. If the collector temperature is between 10 and
130°C the drain back unit pump will run for a short period to run a test program, after which the system is ready for use.
3.
When all the self-diagnostic procedures have been completed, the display will flash between the solar cylinder
temperature and the operation mode.
4.
If there is enough solar light at the collector the cylinder pump will run, shortly followed by the drain back unit pump. The
drain back unit pump runs at full speed for 250 seconds to purge any air from the collector then it modulates to its
optimum speed for the collector temperature.
5.4
DISPLAY - Fig.20
The controls of the solar cylinder are able to indicate working modes on the display. The push button provides the means
to operate the cylinder. During normal operation the system can be turned on and off using the button. When the button is
held in for 5 seconds the diagnostic mode will be entered. Refer to Section 7. If the button is not touched for 5 seconds,
the last mode will become active.
Fig. 20
Display shown
Display explained
The indicates the operating mode of the solar system, on or off (on or oF).
If oF is shown the solar system is not operating, press the button to change from off to on.
Note: Always leave the system on
This is the temperature of the domestic hot water (°C) in the solar cylinder.
When the system is on and working, the display will alternate between the domestic hot
water temperature (for 4 seconds) and the operating mode (on or oF for 2 seconds).
This is the temperature of the domestic hot water (°C) in the solar cylinder.
The flashing dot in the right hand corner of the display shows that the drain back unit pump
and cylinder pump are running.
This is the temperature of the domestic hot water (°C) in the solar cylinder.
The flashing dot in the middle of the display shows that only the cylinder pump is running.
Flashing fault codes (71 to 84). Refer to Section 7 for a list of fault codes and possible
solutions.
Complete the details of the boiler installation in the Checklist in Section 12.
Alpha SolarSmart 90 - Commissioning
19
5.5
USER INFORMATION
The User must be advised (and demonstrated if necessary) of the following important points:1.
How to turn the Solar Smart system on and off. It is recommended the system is always left on.
2.
Explain what information is shown on the display and in the unusual case of a fault occurring, explain the fault codes that
may be shown.
3.
How important it is for the combination boiler hot water thermostat to be left at the maximum position (No. 9) and that it is
the purpose of the label (Fig. 16) to maintain this and that the label must not be removed.
4.
Show the User the position of the pressure relief valve discharge pipe.
5.
6.
Explain the importance of regular inspection to check the safe and efficient operation of the system.
Ensure the Checklist in Section 11 has been completed after the unit has been installed and commissioned.
7.
Leave these instructions with the User for use on future calls and for recording details in the Inspection History Section 13.
6
6.1
SYSTEM OPERATION
WORKING PRINCIPAL - Fig.21
The solar collector uses the energy of the natural light to heat the water being circulated around the collector. When the
heated water enters the drain back unit, heat is transfer into the stored water via a heat exchanger coil. Stored domestic
hot water is pumped from the bottom of the solar cylinder through the drain back unit heat exchanger coil where it is
heated and returned to the cylinder.
When a hot water tap is turned on mains water flows into the bottom of the solar cylinder and hot water flows out of the
top towards the solar valve at the boiler. If the water from the cylinder is above 60°C the solar valve diverts the flow
directly to the tap, if the temperature is less than 60°C the valve diverts the flow through the combination boiler. When the
flow is via the combination boiler the water temperature is maintained by the boiler. As the temperature of the water
entering the boiler is higher than the normal incoming mains water, less gas is required to heat the water to the set
temperature of above 60°C thereby saving energy costs.
Solar collector
Cylinder
temperature
sensor
Solar cylinder
Collector
sensor
Lower cylinder
temperature
sensor
Drain back unit
Drain back
unit pump
Cylinder
pump
Hot water to taps
Warm water to boiler
Solar valve
Mains cold water inlet
Fig. 21
20
Alpha SolarSmart 90 - System Operation
Heat exchanger
6.2
OPERATION OF THE SOLARSMART SYSTEM - Fig.21
Control
When the controls detect a collector sensor temperature that is at least 10°C higher than the lower cylinder sensor and
the solar cylinder temperature is less than 65°C, the drain back unit pump will start. The pump will run at full speed for
250 seconds and then modulate between 16 and 50% of full speed to circulate water around the collector. The speed of
the pump is dependent upon the difference in the temperature between the collector sensor and the lower cylinder
sensor.
At the same time that the drain back unit pump starts the cylinder pump will start at 10% of full speed to circulate the
cylinder water through the drain back unit heat exchanger. The drain back unit pump will stop when the temperature
difference between the collector sensor and the lower cylinder sensor falls to 3.5°C or the cylinder temperature reaches
70°C. The cylinder pump will continue to run for 120 seconds to collect any excess heat from the drain back unit then it
will also stop.
When both pumps are operating, a flashing dot will be visible in the right hand corner of the display (Fig. 20). If only the
cylinder pump is running, a flashing dot will be visible in the middle of the display.
If a fault occurs, a fault code will be visible in the display. Refer to Section 7 for a list of fault codes and possible
solutions.
Temperature display
The display (see Fig. 20) will display the solar cylinder temperature (10 - 70°C) for 4 seconds followed by the operating
mode (on or oF) for 2 seconds, after which the sequence will be continually repeated.
Domestic hot water circuit
When a hot tap is opened, cold mains water enters the solar cylinder at the bottom forcing hot water out from the top to
go to the solar valve where it either goes directly to the tap or to the boiler for further heating. The cylinder pump passes
the cool water from the bottom of the cylinder through the drain back unit heat exchanger and warm water back to the
centre of the cylinder.
Collector water circuit
The drain back unit pump (See Fig. 21) is controlled by the PCB. The collector water is circulated in a closed loop
through the collector panel where it is heated then passes through the heat exchanger in the drain back unit where heat
is transferred to the domestic water from the cylinder.
Frost protection
If the collector sensor registers a temperature less than 3°C, the temperature difference required to start the drain back
unit pump (normally 10°C) will be increased by 15° to 25°C. This will ensure that the unit will not operate in frosty
conditions (with the possibility of freezing). When the temperature rises above 3°C this temperature difference of 25°C
will remain for a further 24 hours when it returns to normal.
Pumps
If the electrical supply is on and the solar system has not operated for 24 hours, the pumps will operate automatically
every 24 hours, providing the collector temperature is above 10°C.
Overheat thermostat
In the unlikely event the temperature of the stored water in the Solar cylinder reaches 90°C, the overheat thermostat
(see Fig. 3) will operate and switch off the collector pump. If this happens the overheat thermostat will need to be
manually reset by pushing its reset button.
Alpha SolarSmart remote display unit - Part No. 6.4001100
The Alpha SolarSmart remote display unit is available as an optional accessory. This unit
allows the information and control available on the main Solar control panel to be in a place
that is more visible and accessible to the user. This is particularly useful if the solar system
is in the loft or garage.
Note: Two core cable is required to connect the display unit to the solar control box. The
Alpha SolarSmart display unit is only compatible with later versions of the SolarSmart
system. Compatibilty can be checked by looking at the PCB version label on the main
control PCB. Only version 28 (V28) onwards is compatible.
Alpha SolarSmart 90 - System Operation
21
7
ROUTINE INSPECTION
To ensure efficient operation of the SolarSmart system, it is recommended that it is inspected and checked (by a competent
person) as necessary at regular intervals.
Warning: Before removing any covers or working on the system, isolate the electrical supply.
The data badge for the cylinder is located on top of the front cylinder housing underneath the top cover. Refer to Fig. 5a
for location of serial number.
Always carry out electrical system checks, i.e. earth continuity, resistance to earth, short circuit and polarity with a
suitable meter, after any electrical work has been carried out on the system.
Check the operation of the system before and after any servicing or replacement of parts.
7.1
IMPORTANT NOTES FOR ROUTINE INSPECTION
1.
Run the system and check the operation.
2.
Ensure that all system connections and fittings are sound.
3.
Open the Solar cylinder's drain valve (Fig. 2, item 24) until the water from the bottom of the cylinder runs clear.
4.
Inspect and clean, if required, the filter and cartridge in the pressure reducing valve and cartridge in the expansion relief
valve fitted to the unvented kit.
5.
Check the operation of the expansion relief valve by turning the head anti-clockwise until it clicks. The click is the valve
lifting off its seat allowing water to escape to the discharge pipe - check that this is happening and that the valve is not
leaking after it has been operated,
6.
Check the charge in the domestic hot water expansion vessel and re-pressurise, if necessary.
Note: Only check the expansion vessel charge when the system pressure is zero.
7.
Record details of the inspection in the Inspection History Section 13.
8
COMPONENT REPLACEMENT
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.
The data badge for the cylinder is located on top of the front cylinder housing underneath the top cover. Refer to Fig. 5a
for location of serial number.
Always carry out electrical system checks, i.e. earth continuity, resistance to earth, short circuit and polarity with a
suitable meter, after any electrical work has been carried out on the system.
Check the operation of the system before and after any servicing or replacement of parts.
Refer to Section 12 for information on parts and their location.
8.1
REMOVE THE CASING
Isolate the electrical supply before removing the casing. Remove the pozi-head bolt securing the bottom cover and pull the
cover down to remove. When replacing the cover it must be offered up from beneath ensuring that the push button at the
front locates into the slot in the PCB cover.
Top cover - Lift upwards to remove.
Front casing - Once the top and bottom covers have been removed the front casing can be pulled straight forwards, this
will allow access to all components on the cylinder.
8.2
DRAIN THE CYLINDER
Isolate the mains water supply and open a hot tap to release the pressure in the cylinder. Attach a hose to the drain valve
located at the bottom of the cylinder and route the hose to a drain. Open the drain valve to drain the cylinder.
8.3
PRESSURE REDUCING VALVE
Isolate the mains water supply and open a hot tap to release the pressure in the cylinder. Undo the two compression nuts
and remove the valve. Fit the new valve, re-tighten the compression nuts and turn on the mains water supply. Open a hot
tap to vent any air from the cylinder.
8.4
EXPANSION RELIEF VALVE
Drain the cylinder as described in Section 8.2. Unscrew the two mains pipe connections and the discharge pipe
connection, then unscrew the valve from the expansion vessel. Fit the new valve in the reverse order using a new washer.
8.5
EXPANSION VESSEL
Drain the cylinder as described in Section 8.2. Loosen the vessel clamp and unscrew the vessel from the expansion relief
valve while holding the valve with a spanner to prevent damaging the mains pipe. Reassemble in reverse order with a new
vessel and washer.
22
Alpha SolarSmart 90 - Routine Inspection/Component Replacement
8.6
TEMPERATURE AND PRESSURE RELIEF VALVE
Drain the cylinder as described in Section 8.2. Loosen and remove the copper pipe from the valve and release the ¾" nut
and remove the valve from the cylinder. There is a ¾" to ½" adapter fitted to the valve, which must be removed and fitted
to the new valve and sealed with a thread sealer suitable for mains water. Reassemble in reverse order.
8.7
CYLINDER TEMPERATURE SENSORS
Remove the casing as described in Section 8.1. Remove the three screws securing the PCB cover and remove the cover.
Unplug the sensor plug from the PCB (refer to wiring diagram in Section 9) and remove the sensors and tape from the cylinder.
Fit the new sensors in position using the new tape provided and plug them into the PCB. Reassemble in reverse order.
8.8
PCB - refer to Section 9
Remove the casing as described in Section 8.1. Remove the screws securing the control cover and remove the cover.
Remove all terminal connections and remove all plug in connections. Pull back the two clips to the left of the PCB and pull
the PCB forwards to remove. Fit the new PCB and reassemble in reverse order.
8.9
CYLINDER PUMP
Drain the cylinder as described in Section 8.2. Remove the terminal cover on the pump and remove the supply lead from the
terminals. Unscrew the four 5 mm Allen bolts and remove the pump head. Fit the new head and reassemble in reverse order.
8.10 CYLINDER MANIFOLD ASSEMBLY
Drain the cylinder as described in Section 8.2. Disconnect the power cable from the pump and the earth lead from the
manifold assembly and unplug the overheat thermostat. Disconnect all pipe connection and remove the two retaining
clips, one either side at the top of the manifold. It is now possible to pull down on the manifold and remove it from the
cylinder, taking care not to damage the plastic tubes connected to it.
With the manifold removed from the cylinder it is possible to replace or service the following parts; hot water outlet pipe,
mains inlet strainer/diffuser, hot inlet pipe, hot inlet diffuser and pump outlet pipe.
Re-assemble in reverse order.
8.11 DBU PUMP
Note: Care must be taken when carrying out repairs to the DBU as it reaches very high temperatures and can emit steam
from connections when being removed.
Isolate the mains electric supply and remove the front case of the drain back unit by simply pulling it forwards. Place a
bucket under the drain plug at the bottom of the unit and using a suitable spanner, unscrew the plug while holding the plug
housing with another spanner to prevent damaging the pipe. Remove the terminal cover on the pump and remove the
supply lead from the terminals. Undo the four 5 mm Allen bolts and remove the pump head. Fit the new pump head,
reconnect the supply lead and fit the terminal cover. Replace the drain plug and remove the filling plug located in the
pump flow pipe, using two spanners as before. Using a short piece of hose and a funnel, slowly fill the drain back unit with
water until it reaches the level of the filler plug. Replace the plug and front case.
8.12 OVERHEAT THERMOSTAT
Isolate the electric supply and remove the casing as described in Section 8.1. The overheat thermostat is located on a
pipe at the bottom of the cylinder. Pull the plug from the thermostat and unscrew the thermostat from the pipe.
Reassemble in reverse order.
8.13 OVERHEAT THERMOSTAT PLUG AND LEAD
Isolate the electric supply and remove the casing as described in Section 8.1. Remove the screws securing the PCB cover
and remove the cover. Unplug the thermostat lead from terminal 12 on the PCB and the earth lead from its spade
connection. Unplug the lead from the thermostat located on the return pipe at the bottom of the cylinder. Loosen the gland
securing the lead and remove the lead, then feed the new lead into the gland and reassemble in reverse order.
8.14 COLLECTOR TEMPERATURE SENSOR
The collector sensor is sealed into the collector during manufacture. If it fails, a replacement sensor kit is available which
comprises of a sensor with a lead and grommet attached and a clip for securing the sensor to the collector plate. The
Collector will have a pre-drilled hole on one side blanked by a rubber grommet, which, must be removed to fit the new
sensor. The sensor should be fitted to the clip and then inserted through the hole in the collector with the sensor at the
back of the plate and the clip hooked over the front, similar to a pen clipped in a pocket. Slide the grommet along the lead
and into the hole making a seal.
Route the lead neatly to the break through in the roof and plug it into its connecting lead.
Note: 1) If a landscape collector is used the position of the grommet will be located at the top left hand side and for
portrait collectors the grommet will be located at the top right hand side.
2) Access to the grommet may be possible from within the roof area by removing tiles from inside.
Alpha SolarSmart 90 - Component Replacement
23
8.15 DBU HEAT EXCHANGER
Note: Care must be taken when carrying out repairs to the DBU as it reaches very high temperatures and can emit steam
from connections when being removed.
Isolate the mains electric supply and remove the front case of the drain back unit by simply pulling it forwards. Place a
bucket under the drain plug at the bottom of the unit and using a suitable spanner, unscrew the plug while holding the plug
housing with another spanner to prevent damaging the pipe. Loosen the pump inlet connection and the collector flow and
return connections to the heat exchanger. Loosen the cylinder flow and return connections to the heat exchanger and
remove. Replace in reverse order.
Replace the drain plug and remove the filling plug located in the pump flow pipe, using two spanners as before. Using a
short piece of hose and a funnel, slowly fill the drain back unit with water until it reaches the level of the filler plug. Replace
the plug and front case.
9
WIRING DIAGRAM
Upper Cylinder Sensor
Br - Brown
Bl - Blue
W - White
G/Y - Green/Yellow
Lower Cylinder Sensor
Cylinder
Pump
88
Br
W
15
Br
W
14
Bl
Br
G/Y
Bl
13
Br
Br
12
Br
Overheat
Thermostat
(manual reset)
G/Y
W
Bl Br
DO NOT
Br USE
Solar Collector
Sensor
DBU
Pump
N L 8 9
23 4 5 6 7
1
Bl Br
Bl
G/Y
G/Y
Supply
230/240 V ~ 50 Hz Fused at 3 A
NOTE: Do not connect any other external controls
24
Alpha SolarSmart 90 - Wiring Diagram
Br
G/Y
10 DIAGNOSTICS AND FAULT CODES
10.1 FAULT CODES
The solar system is fully controlled by the electronic control on the cylinder. Fault codes will be displayed at the cylinder
by means of a flashing fault code (71 to 80). The following codes can be displayed.
Codes 71, 72 and 80 will stop the solar system working: The cause must be rectified before the system will
operate. When the cause has been rectified the system will start by itself.
Code 71
Temperature of the collector is below -40°C or above 250°C.
Collector sensor fault
Check the collector sensor: does it operate (check sensor resistance in table on next
page).
Sensor cable damaged or short circuited.
Sensor is faulty.
Code 72
Temperature of the cylinder is below 0°C or above 100°C.
Upper cylinder sensor fault
Check the upper cylinder sensor: does it operate (check sensor resistance in table on
next page).
Sensor cable damaged or short circuited.
Sensor is faulty.
Code 80
Temperature of the cylinder is below 0°C or above 100°C.
Lower cylinder sensor fault
Check the lower cylinder sensor: does it operate (check sensor resistance in Section
7.3).
Sensor cable damaged or short circuited.
Sensor is faulty.
Code 77 is the only code displayed that is not actually a fault: The code will disapear if the button is pressed.
Code 77
The control has not been operating for 30 days.
The system is not turned on
Check the collector sensor and the lower cylinder sensor, do they operate (check
sensor resistance in Section 7.3).
Codes 74 and 75 will lock the solar system: The cause must be rectified before the system will operate. When the
cause has been rectified the system control can be reset by pressing the button.
Code 74
No circulation in the
collector
Code 75
Collector temperature too
high
Check water level in drain back unit.
Check overheat thermostat - manually reset if required.
Check the difference in height between the drain back unit pump and the upper most
side of the collector. This can be a maximum of 3 metres.
Check that the pipework between the DBU and collector is no more than 2 m in length.
Check the collector sensor and the lower cylinder sensor, do they operate (check
sensor resistance in Section 7.3).
Check the collector tubes, are they blocked with dirt? Is the decline of the pipes within
the 40 mm per metre requirement.
Check the electrical connection and operation of the drain back unit pump and the
cylinder pump.
After 5 minutes the collector temperature is still too high (above 130°C) with the drain
back unit pump operating.
Check the level of water in the drain back unit. Refer to filling procedure in Section
5.2.
Check the difference in height between the drain back unit pump and the upper most
side of the collector. This can be a maximum of 3 metres.
Check the collector sensor and the lower cylinder sensor, do they operate (check
sensor resistance in Section 7.3).
Check the collector tubes, are they blocked with dirt? Is the decline of the pipes within
the 40 mm per metre requirement.
Check the electrical connection and operation of the drain back unit pump and the
cylinder pump.
Alpha SolarSmart 90 - Diagnostics and Fault Codes
25
10.2 DIAGNOSTIC MENU
To enter the diagnostic menu press the button (beneath the display) in for 5 seconds. Each following press of the button
will advance through the diagnostic sequence as shown in the following table.
The code for the item being diagnosed and its value will be alternately displayed.
When you reach the last item, pressing the button again will return you to the first item. If you press the button in for 5 seconds
or do not touch it for 10 minutes, the system will leave the diagnostic mode return to the normal operating display.
Item being diagnosed
Pre
V28 PCB
Display
V28 PCB
2010 >
Display
Value of item being diagnosed
Software version
50
50
00 - 99
Frost protection
D0
D0
Cb (Collector protection), 00 means collector protection is in off mode
Mode
D1
D1
oF or oN
Collector temperature
D2
D2
00 - 99 (°C). Above 99°C the value will flash, i.e. flashing 05 indicates 105°C
Upper cylinder temperature
D3
D3
00 - 99 (°C)
Aux heat source temperature
N/A
D5
-- or 00 - 99 (°C)
Lower cylinder temperature
D5
D4
00 - 99 (°C)
Not allocated
D6
-
Drain back unit pump speed
D7
D6
00 - 99 (%)
Cylinder pump speed
D8
D7
00 - 99 (%)
Diverter valve
N/A
D8
-- or 0 = not fitted, 1 = Solar collector, 2 = Aux heat source
E0 - E9
E0 - E9
Fault history
--
XX
XX = Fault code
10.3 COLLECTOR SENSOR - TEMPERATURE AND RESISTANCE DATA
°C
KΩ (Ohm)
°C
KΩ (Ohm)
°C
KΩ (Ohm)
°C
KΩ (Ohm)
°C
KΩ (Ohm)
°C
KΩ (Ohm)
0
32.15
35
6.53
70
1.75
20
12.49
55
2.99
90
0.92
5
26.31
40
5.33
75
1.48
25
10.00
60
2.49
95
0.79
10
19.86
45
4.37
80
1.26
30
8.06
65
2.09
100
0.68
15
15.89
50
3.60
85
1.07
11 CHECKLIST FOR UNVENTED STORAGE
Ensure the following is completed after the unit has been installed and commissioned:UNVENTED HOT WATER STORAGE SYSTEM
Are combined temperature/pressure releief valve and expansion valve fitted and discharge tested?
What is incoming static cold water pressure at the inlet to the pressure reducing valve?
Has strainer (if fitted) been cleaned of installation debris?
What is the pressure reducing valve setting (if fitted)?
Where is the pressure reducing valve situated? ................................................................................
Has the expansion vessel or internal air space been checked?
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING:
The hot water system complies with current Building Regulations
The appliance and associated equipment has been installed and commissioned
in accordance with the manufacturer's instructions
The operation of the appliance and system controls have been demonstrated to the customer
The manufacturer's literature has been left with the customer
Yes
No
Yes
No
bar
bar
Yes
No
Yes
Yes
Yes
Yes
COMMISSIONING ENG'S NAME:
Print ...................................................................... CORGI ID No. ..................................................
Sign ...................................................................... Date .................................................................
26
Alpha SolarSmart 90 - CheckList for Unvented Storage
12 PARTS LIST
8
5
10
11
3
12
4
9
7
Unvented kit
14
Solar cylinder
17
19
2
6
20
1
18
13
16
Drain back unit
15
Solar valve
Ref. Description
1
2
3
4
5
6
20
7
8
9
10
11
12
13
14
Cylinder pump
PCB
Set of two cylinder temp. sensors
Front housing - cylinder
Top cover - cylinder
Bottom cover and screw - cylinder
Manifold and pipework assembly
Manifold seal kit
Temp./press. relief valve - 90°C/7 bar
Pressure reducing valve - 2.5 bar
Expansion vessel - 8 litre
Expansion relief/check valve - 6 bar
Tundish
Solar valve
Collector temperature sensor kit
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Part No.
Ref.
4.1060499
4.1060723
4.1060497
4.1060725
4.1060724
4.1060726
4.1060727
4.1060495
1.8244
1.017936
6.4009031
6.0001020
1.018148
3.017409
4.1060719
15
16
17
18
19
-
Description
Qty.
1
Drain back unit pump
1
Drain back unit heat exchanger
1
Front and back housing - drain back unit
1
Overheat thermostat
1
DBU pipe from pump
1
Collector temperature sensor lead
1
Plug and lead - overheat thermostst
Collector hoses & fittings - DBU to collector 2
1
Cylinder mounting kit
1
HT pipe insulation pack - DBU to collector
10
Clips - cylinder to manifold
1
Foam seal - hose entry
1
Screw pack - DBU
1
Screw pack - flashing kit
1
Bolt/washer pack - collector to flashing kit
12 m collector temp sensor/pump extension 1
lead kit
1
Remote data display unit
Part No.
4.1060730
4.1060509
4.1060506
4.1060794
4.1060705
4.1060798
4.1060795
4.1060801
4.1060494
4.1060799
4.1060668
4.1060800
4.1060802
4.1060796
4.1060797
4.1060491
6.4001100
Alpha SolarSmart 90 - Short Parts List
27
13 INSPECTION HISTORY
DETAILS OF SOLARSMART INSTALLATION
It is recommended your SolarSmart system is inspected regularly and that you complete the inspection record below.
Note: Always use the manufacturer's specified spare parts when replacing any parts.
Date of Installation: ....................................................................
Name of Installer: .......................................................................
Address: ......................................................................................
....................................................................................................
....................................................................................................
Postcode: ....................................................................................
Telephone No: ............................................................................
Cylinder Serial Number: .............................................................
(see data label on top of cylinder underneath the cover or bottom of cylinder - refer to Fig. 5a for positions)
DETAILS OF SYSTEM INSPECTION HISTORY
Date of Inspection
Details of Inspection
Engineer, Company, Tel. No.
................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
.............................................................................................
.......................................
................................
................................
................................
................................
Alpha Therm Limited.
Nepicar House, London Road, Wrotham Heath,
Sevenoaks, Kent TN15 7RS
Tel: 0844 8718764
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 2010.
email: [email protected]
website:www.alpha-innovation.co.uk
Manual compiled and designed by Publications 2000 - Tel: (01670) 356211
0710/D253
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement