solar water heater - Eco
SOLAR WATER HEATER
TABLE OF CONTENTS
10
INTRODUCTION ...........................................................................................................4
1.1 Use of Manual......................................................................................................................... 4
1.2
General Description............................................................................................................. 4
1.3 Specifications of Solahart Systems ........................................................................................ 5
1.4 System Parts Identification List .................................................................................................. 6
1.5 Solahart Model Details ............................................................................................................... 8
2.0
PRE-INSTALLATION INSPECTION..............................................................................9
2.1
2.2
2.3
Site Inspection Equipment ...................................................................................................... 9
Review Local Codes ............................................................................................................... 9
Choose Solahart Location .................................................................................................... 10
2.3.1
2.3.2
2.3.3
2.4
2.5
Roof Survey .......................................................................................................................... 13
Roof Support Requirements ................................................................................................. 14
2.5.1
2.5.2
2.6
2.7
2.8
Water Quality ................................................................................................................................ 16
Water Pressure ............................................................................................................................. 16
Water Hammer.............................................................................................................................. 16
External Piping Insulation ............................................................................................................. 16
Plumbing Survey................................................................................................................... 17
Electrical Survey ................................................................................................................... 21
2.8.1
2.9
General Electrical Requirements .................................................................................................. 21
Customer Approval ............................................................................................................... 21
HAZARDS AND SAFETY PRECAUTIONS .................................................................22
PRE-INSTALLATION ..................................................................................................24
4.1
4.2
4.3
4.4
5.0
Permits.................................................................................................................................. 24
Work Force ........................................................................................................................... 24
Inventory ............................................................................................................................... 24
Required Tools, Equipment and Supplies ............................................................................ 24
INSTALLATION PROCEDURES.................................................................................25
5.1
Prepare the Roof .................................................................................................................. 25
5.1.1
5.1.2
5.2
Roof Reinforcement (if necessary) ............................................................................................... 25
Fragile/Ornamental Roof Material................................................................................................. 25
Supporting Structure installation........................................................................................... 26
5.2.1
5.2.2
5.2.3
5.3
Standard Installation ..................................................................................................................... 26
Metal / Sturdy Tile Installation....................................................................................................... 27
Frame Installation.......................................................................................................................... 29
Collector Installation ............................................................................................................. 31
5.3.1
5.3.2
5.4
Standard Installation ..................................................................................................................... 32
Frame Installation.......................................................................................................................... 33
Storage Tank Installation ...................................................................................................... 33
5.4.1
5.4.2
5.5
Standard Installation ..................................................................................................................... 34
Frame Installation.......................................................................................................................... 35
Installing Tank and Collector Connecting Pipework ............................................................. 35
5.5.1
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
Hartstat Installation (Optional) ...................................................................................................... 36
Plumbing Installation............................................................................................................. 37
Electrical Installation ............................................................................................................. 38
Install Roof - Jack Panel ....................................................................................................... 38
Connect Plumbing to Storage Tank (refer to Figure 5.13).................................................... 38
Fill and Test Potable Water Storage Tank (All Models)..................................................... 39
Test and Fill the Closed Circuit.......................................................................................... 39
5.11.1
5.11.2
6.0
Conventional Roof Modifications .................................................................................................. 14
Truss Frame Modifications............................................................................................................ 15
General Plumbing Requirements.......................................................................................... 16
2.6.1
2.6.2
2.6.3
2.6.4
3.0
4.0
Placement Requirements.............................................................................................................. 10
Area Requirements (refer to Figure 2.3):...................................................................................... 11
Pitch Requirements....................................................................................................................... 12
Closed Circuit Fluid ....................................................................................................................... 39
Test and Fill Procedure - Closed Circuit Installations without Hartstat Systems.......................... 40
Connect Storage Tank to Electrical Supply ....................................................................... 44
Complete Solahart Installation........................................................................................... 44
TROUBLESHOOTING ................................................................................................45
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7.0
MAINTENANCE ..........................................................................................................47
7.1
Periodic Maintenance ........................................................................................................... 47
7.1.1
7.1.2
7.1.3
7.2
Quarterly ....................................................................................................................................... 47
Annually ........................................................................................................................................ 47
Every 3 to 5 Years (10 years for Free Heat systems) .................................................................. 47
Maintenance Procedures...................................................................................................... 48
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
Draining Storage Tank .................................................................................................................. 48
Filling Storage Tank ...................................................................................................................... 49
Drain Closed Circuit ...................................................................................................................... 49
Thermostat Replacement.............................................................................................................. 49
Backup Heating Element Replacement ........................................................................................ 50
Anode Replacement ..................................................................................................................... 51
Temperature Pressure Relief (T/P) Valve Replacement .............................................................. 52
Collector Replacement.................................................................................................................. 53
Storage Tank Replacement .......................................................................................................... 53
APPENDIX A
APPENDIX B
FRAMES ...................................................................................................55
THIRD-PANEL PARTS LIST .....................................................................59
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10
INTRODUCTION
1.1
Use of Manual
This manual provides the manufacturers recommended procedures for Solahart Thermosiphon Series solar
water-heating systems. The procedures are essential for correct installation, troubleshooting and
maintenance.
Read each section of this manual thoroughly before beginning work on the system.
CAUTION
CHANGES TO THE DESIGN OR INTENDED USE OF THE SOLAHART SYSTEM WILL VOID THE MANUFACTURERS WARRANTY.
INSTALLATION, TROUBLESHOOTING, AND MAINTENANCE MUST BE PERFORMED BY A QUALIFIED TECHNICIAN.
1.2
General Description
The solar energy system described by this manual, when properly installed and maintained, meets the
minimum standards established by the Solar Rating and Certification Corporation (SRCC). This
certification does not imply endorsement or warranty of this product by the SRCC.
The solar energy system described by this manual, when properly installed and maintained, meets the
minimum standards established by the Florida Solar Energy Center, in accordance with Section
377.705, Florida Statutes. This certification does not imply endorsement or warranty of this product by
the Florida Solar Energy Center or the state of Florida.
The Solahart J, KF and Free Heat systems operate on the passive thermosiphon principle and are
revolutionary in their use of a ‘closed circuit’ to provide fail-safe freeze protection of the collector closed circuit.
The closed circuit consists of the solar absorbers, a single wall heat exchanger around the outside of the
storage tank, and plumbing attachments.
Radiant energy from the sun heats the special long-life fluid in the solar collectors. As the fluid is heated, it
rises into the tank heat exchanger and heats the potable water stored within.
The hot potable water is stored in a well-insulated steel storage tank, which is lined with two coats of
Primaglaze vitreous enamel for high temperature stability.
Flow of the closed circuit fluid, using the passive thermosiphon principle, is accomplished without pumps,
sensors or moving parts.
When installed in high radiation areas, high-performance KF and KF Free Heat systems may be fitted with an
optional Hartstat over-temperature protection system, to assist in limiting the maximum temperature of the
potable water in the tank.
Solahart L model systems also operate using the passive thermosiphon principle, without a closed circuit
system. Instead, potable water is circulated directly from the solar collectors into the storage tank, Solahart L
model systems are not suitable for locations that are prone to freeze conditions or where the air temperature
can fall below 41°F.
NOTE
FREEZE TOLERANCE LIMITS ARE BASED UPON AN ASSUMED SET OF ENVIRONMENTAL CONDITIONS.
Figure 1.1 Illustration of Typical System
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1.3
Specifications of Solahart Systems
STORAGE CYLINDER
Total Capacity (Nominal)
48 Gallons
80 Gallons
117 Gallons
Overall Size (L x W x H)
59” x 20” x 20”
90” x 20” x 20"
129” x 20” x 20”
15 – 145 psi
15 - 145 psi
15 – 145 psi
Weight Empty
143 lbs.
216 lbs.
324 lbs.
Weight Installed
540 lbs.
877 lbs.
1294 lbs.
Immersion Element (Booster)
2.4 kW 220/240 V
2.4 kW 220/240 V
4.8 kW 220/240 V
Nominal Temperature Setting
120 - 140°F
120 - 140°F
120 - 140°F
Nominal Working Pressure
Cylinder Material
Cylinder Lining
12 gauge low-carbon steel
2 coats specially developed “Primaglaze” high temp vitreous enamel
Insulation
Test Pressure
Pressure injected Polyurethane foam
300 psi
300 psi
300 psi
COLLECTORS (2)*
L Collector
J & KF Collectors
Overall Size (W x L)
82” x 76"
Nominal Area
43 sq. ft.
Case Material
23-gauge aluminium
Cover Material
Low iron tempered glass
Insulation material
Grey Polyester
Grey Polyester (KF uses FSB1 Fibre
Glass)
Absorber Material
20-gauge aluminium sheet / Copper
tube array
23 gauge low-carbon steel
Weight Empty
2 x 73 lbs.
2 x 93 lbs.
Weight Installed
2 x 79 lbs.
2 x 101 lbs.
N/A
Electric Welding
Test Pressure
22 psi
64 psi
Nominal Working Pressure
85 psi
12 psi
Plate-to-Plate Bonding
*Optional additional third collector available
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1.4 System Parts Identification List
NOTE: FOR REFERENCE ONLY. PARTS MAY VARY DEPENDING ON PARTS KITS PURCHASED.
Storage tank
Lag Screw (5/16” x 1 3/4”)
Solar collector
Tempering Valve
Collector Nut
3/4” Tee Adaptor
Collector Plug
3/4” T/P Valve
3/4” Tail Plug
3/4” Check Valve
3/4” Union
3/4” Cold Water Expansion Valve
3/4” Union Nut
PR6 jacket relief valve (including “O” ring)
18 mm Union Cone
Collector Union
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Fill Fitting
Collector Extrusion
Collector Down Pipe
Tank Clamp
Tank Strap
Collector Hot Pipe
Collector Strap
Collector Clamp
1.2 Gallon Hartgard
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Hartstat Valve
Hartstat Reservoir Clamp
Hartstat Reservoir
Hartstat Reservoir Clamp Bracket
1.5 Solahart Model Details
Solahart water heating systems are designated according to the system outlined below:
System Model
L - Open Circuit
J - Closed Circuit
KF - Closed Circuit High Performance
Free Heat – Closed Circuit High Performance with Extended Warranty
Tank Size
18 - 180 Litres/48 Gallons
30 - 300 Litres/80 Gallons
44 - 440 Litres/117 Gallons
ASG302KF
Auxilliary System Designation
ASG - Gas Boosted Auxilliary Tank
ASE - Electrically Boosted Auxilliary Tank
No Prefix - Stand-Alone Thermosyphon System
Number of Solar Collector Panels
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2.0
PRE-INSTALLATION INSPECTION
This section will guide you to gather the necessary information to install the system correctly. Use it together
with the Pre-Installation Checklist (supplied by local Solahart dealer) to identify all installation requirements.
The pre-installation inspection procedures include;
•
Review of local building codes for site requirements and specific guidelines for plumbing and electrical
installation,
•
Inspection of installation site,
•
Completion of the Pre-installation Checklist, including customer’s signature.
2.1
Site Inspection Equipment
•
Pre-Installation Inspection Checklist
•
Pencil or pen
•
Ladder
•
Tape measure
•
Flashlight
•
Water pressure gauge
•
Pitch gauge
•
Compass
2.2
Review Local Codes
2.2.1
Review local codes and record on checklist:
•
Area requirements
•
Plumbing requirements
•
Electrical requirements
•
Roof support stress load and modification requirements (including engineering review, if necessary).
2.2.2
Obtain building plans, if possible, to help locate bearing walls and determine truss strength.
2.2.3
Record extreme weather conditions on checklist;
•
Heavy-snowfall areas require roof-ridge mount (refer to Figure 2.1),
•
High-wind areas require an additional Bracing Kit,
•
Installation sites subject to winds of more than 50 m.p.h. require a specially engineered frame.
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Figure 2.1 Roof-Ridge Mounts
2.3
Choose Solahart Location
2.3.1
Placement Requirements
The system must face between 135 - 225° (Ideal direction is true South): (refer to Figure 2.2). Installations
outside this range require either an additional collector or frame.
Site must be shade-free year-round and clear of obstructions.
Figure 2.2 Solahart System Placement
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2.3.2
Area Requirements (refer to Figure 2.3):
No. of Collectors
Installation Area Required
2
8’x 8’
3
8' x 12’
Plumbing/Electrical stub-out;
•
1’ 6" left side for roof-ridge mount,
•
1’ 6" top or left side all others.
Maintenance area: 8’ on left side.
Code-required setbacks, heights, and distances from other structures, pipe vents and utilities.
Figure 2.3 Clearance Requirements
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2.3.3
Pitch Requirements
Correct operation requires a 15°- 45° pitch (slope). This can be done by using the roof slope itself or a frame
(refer to Figure 2.4).
Figure 2.4 Frame Installations
CAUTION
DO NOT INSTALL ON ROOF WITH PITCH BEYOND 45q.
Use pitch gauge and compass and complete the following steps. Record the results on the checklist.
•
Record pitch and compass bearing of proposed installation site.
•
Using Table 2.1, select number of collectors and correct installation type.
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Table 2.1 Roof Installations
Compass Bearing
Pitch
Mount
No. of Collectors
135° to 225°
15° - 45°
None
Base Model
135° to 225°
0° - 15°
Frame
Base Model
226° to 270°
15° - 45°
None
Base Model Plus 1
5° to 134°
270° to 315°
15° - 45°
Side Pitch
Base Model
0° to 44°
316° to 360°
15° - 35°
Reverse Pitch
Base Model
NOTES
1.
PITCH BEYOND 30° REQUIRES ADDITIONAL BRACING.
2.
A CRANE MAY BE NECESSARY IF INSTALLATION SITE IS ABOVE FIRST STORY OR NOT ACCESSIBLE FROM GROUND
(TREES, FENCES, GROUND SLOPE, ETC.).
2.4
Roof Survey
Record the following on checklist:
•
Type of roofing material (tile, shingle, tar & gravel, metal, etc.).
•
Condition of roof. Note repair requirements.
NOTE
ROOF IN POOR CONDITION MAY NEED REPLACEMENT BEFORE INSTALLATION.
•
Using Table 2.2, select the appropriate supporting structure.
Table 2.2 Installation Matrix
•
Roof Type
Installation Type
Supporting Structures
All types except sturdy tiles
and metal
Sturdy tiles or metal roof with
No obstruction of water flow
All types
All types
All types
With pitch (standard)
With pitch (metal / sturdy tile)
4 runners and
Collector Extrusion
Collector Extrusion only
Side pitch
Reverse pitch
Flat / shallow pitch
2 runners + Frame
2 runners + Frame
2 runners + Frame
Draw diagram (top view) of installation area. Mark location of system and stub-out (refer to Figure 2.5).
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Figure 2.5 Roof Site Plan Sample
2.5
Roof Support Requirements
The system weighs up to 1735 lbs (444 System) when installed and filled. It may not be necessary to provide
additional support but you must inspect the roof support system to determine if additional bracing is needed.
Record the following on the checklist.
CAUTION
IF THE FOLLOWING MODIFICATIONS DO NOT APPLY TO THE INSTALLATION SITE, AN ENGINEER MUST SPECIFY SUPPORT
MODIFICATIONS.
2.5.1
Conventional Roof Modifications
1.
Locate load bearing wall beneath installation site (refer to building plan if available) and indicate on
roof-site plan. If load-bearing wall is not available, indicate on checklist.
2.
Review Figure 2.6 and select correct supports.
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Figure 2.6 Conventional Roof Modifications
2.5.2
Truss Frame Modifications
1.
Determine correct truss frame modification using Figure 2.7 and Table 2.3.
Figure 2.7 Truss Frame Modifications
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Table 2.3 Allowable Spans for Fink and Queen Trusses
Allowable
2” x 4” Top Chord
2” x 6” Top Chord
24” O.C. Kickers
Bottom Chord
Pitch
Roof Material
21”
32”
X
2”x4” or 2”x6”
3:12¹
Tile
24”
36”
X
2”x4” or 2”x6”
3:12¹
Shake
25”
38”
X
2”x4” or 2”x6”
4:12²
Tile
28”
42“
X
2”x4” or 2”x6”
4:12²
Shake
28”
36”
X
2”x4” or 2”x6”
7:12³
Tile
30”
38”
X
2”x4” or 2”x6”
7:12³
Shake
¹
Pitch of 3:12 or less
²
Pitch of 4:12 to 6:12
³
Pitch of 7:12 or greater
Note
For spans > 36”, use double 2” x 6” kicker
2.6
General Plumbing Requirements
2.6.1
Water Quality
City water is a controlled water source and should not cause any difficulty with the system. Well water may
have elevated mineral content and require more frequent system maintenance.
2.6.2
Water Pressure
Water pressure range of 15 to 145 psi is required for correct operation.
Measure mains water pressure and record on checklist.
•
Pressures above 60 psi require installation of a Pressure Regulator on mains supply to site.
•
Pressures below 15 psi are too low to raise water to the Solahart system. Pressure must be raised to
15 psi before installation.
2.6.3
Water Hammer
Water hammer (loud knocking and vibration caused by air in water lines) may reduce efficiency of the system.
Test for water hammer by turning a faucet on and off or flushing a toilet. Record results on checklist.
2.6.4
External Piping Insulation
Where potable water piping is in an external location or attic space where the temperature can be as low as
19°F, it must be insulated with a minimum ¾” Armaflex (or similar) flexible elastomeric closed cell thermal
insulation. Where the temperature can fall to 12°F, the insulation thickness must be increased to 1 ½”.
It is also recommended that heat trace be installed on potable water piping in areas where the outside
temperature falls below 32°F for more than 4 hours with no hot water draw to protect against pipe freezing.
Insulation in external locations can deteriorate through UV radiation. To prevent this, a layer of outdoor UV
stable paint or other similar protective coating must be applied to the insulation.
NOTE
THE CLOSED CIRCUIT PIPING BETWEEN THE STORAGE TANK AND SOLAR COLLECTORS DOES NOT REQUIRE INSULATION.
WARNING
HEAT TRACE WILL NOT PROTECT AGAINST PIPE FREEZING IN THE EVENT OF POWER LOSS.
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2.7
Plumbing Survey
Choose installation type from the following;
1.
As a replacement for an existing water heater, refer to Figure 2.8 (Preferred).
2.
As the sole source of hot water for new construction or locations without a previous water heater, refer
to Figure 2.9.
3.
As a pre-heater to an existing water heater, refer to Figure 2.10.
NOTES
1.
USING THE SYSTEM AS PRE-HEATER TO AN ELECTRIC WATER HEATER IS LESS EFFICIENT THAN A STAND-ALONE
SYSTEM. (NON-PREFERRED). DO NOT PERFORM THIS INSTALLATION UNLESS SPECIFICALLY REQUESTED BY THE
CUSTOMER.
2.
ALL PLUMBING INSTALLATION MUST CONFORM TO LOCAL CODES.
3.
ALL PIPING MUST BE ADEQUATELY SUPPORTED; SUPPORTS MUST CONFORM TO LOCAL CODES.
4.
ALL PIPING MUST BE ADEQUATELY INSULATED; INSULATION MUST CONFORM TO LOCAL CODES.
4. ALL PIPING MUST BE SLOPED TO DRAIN.
CAUTION
PLUMBING MUST BE INSTALLED SO THAT THE PERFORMANCE OF ANY FIRE-RATED ASSEMBLY IS NOT REDUCED.
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Figure 2.8 Plumbing Schematic for Replacement of Existing Electric Water Heater (Preferred)
This method is also used for Auxiliary system connections where the electric or gas water heater remains and
the solar water heater serves as a pre-heater to it.
Typical for models J, KF & Free Heat
System Schematic
TP
Tank
Collector
Collector
Roof Level
Cold Supply
Drain Lines at
Ground Level
1
2
TWV2
1
Pre
Heat
TWV1
Ground Level
Drain Line at
Ground Level
2
Valve Settings;
Hot Outlet
Solar Only = (TWV1
M
– 1)+(TWV2 – 1)+(Pre Heat OFF)
Storage Only = (TWV1
– 2)+(TWV2 -2)+(Pre Heat OFF)
Solar Pre Heat = (TWV1 -1)+(TWV2 -2)+(Pre Heat ON)
Storage
Tank
M
TWV 1 = Two Way Valve -1Inlet Selector
= Mixing Valve
TWV 2 = Two Way Valve -1Outlet Selector
TP = Temperature & Pressure Relief Valve
Pre Heat = Solar Pre Heat Valve
Typical for Model L
System Schematic
TP
Tank
Collector
Collector
Roof Level
Drain Lines at
Ground Level
Cold Supply
1
2
TWV2
Pre
Heat
1
TWV1
Ground Level
Drain Line at
Ground Level
2
Valve Settings;
Hot Outlet
Solar Only = (TWV1
M
Storage Only = (TWV1
– 1)+(TWV2 – 1)+(Pre Heat OFF)
– 2)+(TWV2 -2)+(Pre Heat OFF)
Solar Pre Heat = (TWV1 -1)+(TWV2 -2)+(Pre Heat ON)
Storage
Tank
M
TWV 1 = Two Way Valve -1Inlet Selector
= Mixing Valve
TP = Temperature & Pressure Relief Valve
TWV 2 = Two Way Valve -1Outlet Selector
Pre Heat = Solar Pre Heat Valve
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Figure 2.9 Plumbing Schematic for Installation as Sole Source Heater
Typical for Models J, KF & Free Heat
System Schematic
TP
Tank
Collector
Collector
Roof Level
Roof Level
Ground Level
Ground Level
Cold Supply
M
Drain Lines at
Ground Level
Hot Outlet
M = Mixing Valve
TP = Temperature & Pressure Relief Valve
Typical for Models L
System Schematic
TP
Tank
Collector
Collector
Roof Level
Roof Level
Ground Level
Ground Level
M
Cold Supply
Drain Lines at
Ground Level
Hot Outlet
M = Mixing Valve
TP = Temperature & Pressure Relief Valve
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Figure 2.10 Plumbing Schematic for installation as Pre Heater
Typical for Models J, KF & Free Heat
System Schematic
TP
Tank
Collector
Collector
Roof Level
Cold Supply
Drain Lines at
Ground Level
1
2
1
Pre
Heat
TWV2
TWV1
Ground Level
Drain Line at
Ground Level
2
Valve Settings;
Hot Outlet
Solar Only = (TWV1 – 1)+(TWV2 – 1)+(Pre Heat OFF)
M
Storage Only = (TWV1 – 2)+(TWV2 -2)+(Pre Heat OFF)
Solar Pre Heat = (TWV1 -1)+(TWV2 -2)+(Pre Heat ON)
Storage
Tank
M
TWV 1 = Two Way Valve 1 - Inlet Selector
= Mixing Valve
TWV 2 = Two Way Valve 1 - Outlet Selector
TP = Temperature & Pressure Relief Valve
Pre Heat = Solar Pre Heat Valve
Typical for Model L
System Schematic
TP
Tank
Collector
Collector
Roof Level
Drain Lines at
Ground Level
Cold Supply
1
2
TWV2
Pre
Heat
1
TWV1
Ground Level
Drain Line at
Ground Level
2
Valve Settings;
Hot Outlet
Solar Only = (TWV1 – 1)+(TWV2 – 1)+(Pre Heat OFF)
M
Storage Only = (TWV1 – 2)+(TWV2 -2)+(Pre Heat OFF)
Solar Pre Heat = (TWV1 -1)+(TWV2 -2)+(Pre Heat ON)
Storage
Tank
M
TWV 1 = Two Way Valve 1 - Inlet Selector
= Mixing Valve
TP = Temperature & Pressure Relief Valve
TWV 2 = Two Way Valve 1 - Outlet Selector
Pre Heat = Solar Pre Heat Valve
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2.8
Electrical Survey
If the system is being used as a pre-heater to an existing water heater, electrical survey and installation may
not be required.
2.8.1
General Electrical Requirements
A 220 Volt, 25 Amp electrical breaker is required to activate the Backup Heating Element located near or as
part of the main circuit breaker/fuse panel.
In order to complete the Electrical Survey follow the procedure outlined below;
1.
Check availability of 220-volt, 25-amp breaker. Record on checklist.
2.
If breaker is not available, mark location for a separate breaker.
3.
Refer to Figure 2.12 for an electrical schematic for all new installations.
NOTE
ALL ELECTRICAL CONNECTIONS MUST CONFORM TO LOCAL CODES AND THE REQUIREMENTS AND CAUTIONS DETAILED IN
SECTIONS 3.0 AND 5.12.
Figure 2.11 Electrical Schematic for New Installation
2.9
Customer Approval
1.
Review checklist with customer and discuss all installation requirements and procedures.
2.
Have the customer sign the checklist.
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3.0
HAZARDS AND SAFETY PRECAUTIONS
IMPORTANT SAFETY INSTRUCTIONS
1.
WARNING – When using electrical appliances, basic safety precautions to reduce the risk of fire,
electric shock, or injury to persons should be followed, including:
2.
READ ALL INSTRUCTIONS BEFORE USING THIS WATER HEATER.
3.
The Water Heater must be grounded. Connect only to properly grounded outlet.
4.
Install or locate this water heater only in accordance with the provided installation instructions.
5.
Use this water heater only for its intended use as described in this manual.
6.
Do not use an extension cord set with this water heater. If no receptacle is available adjacent to the
water heater, contact a qualified electrician to have one properly installed.
7.
As with any appliance, close supervision is necessary when used by children.
8.
Do not operate this water heater if it has a damaged cord or plug, if it is not working properly, or if it
has been damaged or dropped.
9.
This water heater should be serviced only by qualified service personnel. Contact the nearest
authorised service facility for examination, repair or adjustment.
SAVE THESE INSTRUCTIONS
For safe installation and operation of the system, review the following hazards and follow all precautions.
WARNING - HAZARD:
Excessive Pressures and Temperatures
PRECAUTION:
To reduce the risk of excessive pressures and temperatures in this water heater, install temperature and
pressure protective equipment required by local codes but not less than a combination temperature and
pressure relief valve. The valve must be certified by a nationally recognised testing laboratory that maintains
periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief
Valves and Automatic Gas Shut Off Devices for Hot Water Supply Systems, ANSI Z21.22.
This valve must be marked with a maximum set pressure not to exceed the marked maximum working
pressure of the water heater. Install the valve into an opening marked for this purpose in the water heater, and
orient it or provide tubing so that any discharge from the valve will exit within 6 inches above, or at any
distance below the structural floor, and cannot contact any live electrical part. The discharge opening must not
be blocked or reduced in size under any circumstances.
WARNING - HAZARD:
Thermal Expansion
When a water heater is installed in a closed water supply system, such as one having a back-flow preventer in
the cold water supply, means shall be provided to control thermal expansion. Contact the water supplier or
local plumbing inspector for information regarding the control of this situation.
WARNING - HAZARD:
Electrical Shock
PRECAUTIONS:
1.
Disconnect all power sources before starting installation, maintenance or troubleshooting.
2.
Verify mains power is OFF.
3.
If power is needed later for maintenance, place highly visible tape or tags on all appropriate locations
to warn of LIVE electricity.
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WARNING - HAZARD:
Burns from Hot Water and Steam
PRECAUTIONS:
1.
Use extreme care when opening relief valves, charging closed circuit, and filling storage tank.
2.
The electrical booster thermostat has been factory set at 122°F (50°C) to reduce the risk of scald
injury. Adjusting the thermostat to a higher setting is not recommended. Hotter water increases the risk
of scald injury.
3.
Should the thermostat require adjustment to meet the customer demands this can be achieved by
rotating the adjustor on the thermostat to the desired temperature.
4.
Solar collectors can heat the water in the storage tank to temperatures that are higher than the
thermostat setting.
WARNING - HAZARD:
Burns from Collector Fluid or Downpipe and Hot Pipe
PRECAUTION:
Cover the solar collectors with an opaque (no light can penetrate) material and allow plumbing and fluid to cool
before attempting any maintenance.
WARNING - HAZARD:
Heights
PRECAUTIONS:
1.
Use extreme care to avoid falling while on a ladder or the roof.
2.
If a roof section does not appear to be solid under foot, do not subject it to any added weight until it is
adequately reinforced.
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4.0
PRE-INSTALLATION
Review the checklist for installation requirements. Complete the following before beginning installation.
4.1
Permits
Obtain required permits before installation.
4.2
Work Force
An 80 gall storage tank weighs up to 216lbs empty, requiring a crew of two or more to install.
4.3
Inventory
Review Section 4.4, Frames (Appendix A),Third Panel Parts Kits (Appendix B) and all optional supplies before
installation.
4.4
Required Tools, Equipment and Supplies
Basic Plumbing, Electrical and Carpentry Supplies
•
Metric wrench (36 mm open end
wrench)
•
Flashlight / electric lantern
•
•
Pipe vice / cutter / threader
12” pipe wrench
•
•
Multimeter
Two 12” adjustable (crescent)
•
•
Hacksaw
Wrenches
•
•
1/2” Electric drill with bit set
Water pressure gauge
•
•
Crowbar
Skill Saw with standard and
masonry blades
•
Copper tubing cutter
•
Crane, if required
•
Soldering kit
•
1” Wood-boring bit
•
Caulking gun
•
24” Spirit (bubble) level
•
Cable cutter / stripper
•
6” diagonal cutting and long nose
pliers
Consumable Supplies:
•
Masking/duct tape
•
I00' Grounded extension cord
•
Wood/sheet metal screws
•
Screwdriver Set (# 2 Philip’s, 1/4”
Slotted)
•
Dielectric pipe unions
•
Tape measure (I00 Foot)
•
Waterproof sealing compound
•
16-Ounce claw hammer
•
5/16” Lag Screws, 1 3/4”, 2”, 3”, 6”, as
required
•
Marking pen
•
Washers
•
Utility knife
•
Nails, 16g, or assorted, as required
•
3/8”-drive socket set
•
Silicone sealant
•
2 Extension ladders
•
2' x 4' x 8'4” redwood, treated-wood or
Unistrut runners, as required
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5.0
INSTALLATION PROCEDURES
This section contains instructions for correct installation of the system. Complete the procedures in the order
listed.
NOTE
INSTALLATION OF ROOF SUPPORTS, PLUMBING, AND ELECTRICAL MUST CONFORM TO LOCAL CODES.
Installation types are divided into the following:
Standard Installation:
System is mounted to wood or Unistrut runners directly to roof with no need for pitch or directional changes.
Metal / Sturdy Tile Installation:
System is mounted directly to roof with no need for pitch or directional changes.
Frame Installation (Side, Reverse, Shallow-Pitch and Flat-Roof Installation)
System is mounted on a variable pitch frame to provide pitch or a fixed pitch frame to provide directional
changes.
5.1
Prepare the Roof
5.1.1
Roof Reinforcement (if necessary)
1.
Refer to checklist for necessary roof modification.
NOTE
STORAGE TANK WILL BE PARALLEL TO RAFTERS OR TRUSSES FOR SIDE-PITCH MOUNT AND AT A RIGHT ANGLE FOR ALL
OTHER MOUNTS.
2.
Install supports.
5.1.2
Fragile/Ornamental Roof Material
The system may be installed directly on most roof types if the roof is in good condition with adequate drainage.
For other types of roofs, do the following:
1.
Clear area of roofing material from top of roof to lower edge of roof with 2’ clearance on each side
(refer to Figure 5.1). Set aside for reinstallation.
2.
Install waterproof material over cleared area.
3.
Fully seal and waterproof new material.
4.
Continue with Section 5.2, Supporting Structure Installation.
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Figure 5.1 Fragile Tile Site Preparation
5.2
Supporting Structure installation
Refer to the appropriate section listed below for installation procedures:
•
Standard Installation: Section 5.2.1.
•
Metal / Sturdy Tile Installation: Section 5.2.2.
•
Frame Installation: Section 5.2.3.
5.2.1
Standard Installation
1.
Mark supporting rafter/truss and bearing-wall locations on roof.
NOTE
SUPPORTING RAFTERS MAY BE EITHER 16” OR 24” ON CENTER. RUNNERS WILL NOT BE EQUALLY SPACED ON 16” ONCENTER RAFTERS (REFER TO FIGURE 5.2).
2.
Place four 2" x 4" x 8' 4” redwood, treated-wood or Unistrut runners parallel down roof slope over
marked rafters or trusses. For three-collector installations, two additional runners are necessary.
•
For standard installation, runners must be placed within 3’ of roof ridge (refer to Figure 2.3).
•
For roof-ridge mounts, place top of runners at roof ridge (refer to Figure 2.1).
NOTE
DOUBLE CHECK THE PLACEMENT OF RUNNERS OVER RAFTERS OR TRUSSES BEFORE DRILLING HOLES.
HINT
YOU MAY WANT TO PRE-DRILL RUNNERS WITH PILOT HOLES TO AVOID SPLITTING RUNNERS WITH LAG SCREWS.
3
Drill each runner in center and 6" from runner ends and attach to rafters or trusses with 5/6" x 6" lag
screws and washers.
4.
Flash and seal all roof penetrations.
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Figure 5.2 Wood Runner Installation Detail on 16 " and 24 " On-Center Rafters
5.
Position Collector Extrusion so that flat vertical edge is toward roof ridge (refer to Figure 5.3).
Figure 5.3 Collector Extrusion Detail for Standard Installation
CAUTION
EXTRUSION MUST SLOPE ½” PER COLLECTOR FROM HORIZONTAL (HOT PIPE SIDE TO BE HIGHER) FOR SYSTEM TO
WORK CORRECTLY.
6.
Level the Extrusion using a spirit level and shims (refer to Figure 5.3). After levelling, raise the hot pipe
side of the extrusion by ½” per collector to ensure correct operation of the system (eg. For a 2 collector
system, raise the hot pipe side of the extrusion by 1”).
7.
Mount the Extrusion to each runner using 5/16" x 2” lag screws or Unistrut bolts.
8.
Continue with Section 5.3, Collector Installation.
5.2.2
Metal / Sturdy Tile Installation
1.
Mark tank location on roof with front foot of tank located directly over reinforced roof area.
2.
Measure 82 inches down roof from front foot of tank to determine location for Collector Extrusion.
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3.
For Tiled roofs, remove tiles to allow for room to screw collector straps to rafters or trusses (refer to
Figure 5.4). If installing three collectors, remove tiles for third collector strap.
NOTE
BE SURE FLAT SIDE OF VERTICAL SUPPORT OF EXTRUSION FACES TOWARD COLLECTOR LOCATION, AND ’U’ SHAPE
OPENS TOWARD LOWER ROOF EDGE.
4.
If a third collector is being installed, use a Drive Cleat to attach the Collector Extrusion to the Extrusion
Extension (refer to Appendix B).
5.
Slide the Collector Extrusion on to the Collector Straps (refer to Figure 5.4). After levelling, adjust the
collector straps to raise the hot pipe side of the extrusion by ½” per collector to ensure correct
operation of the system (eg. For a 2 collector system, raise the hot pipe side of the extrusion by 1”).
Figure 5.4 Collector Extrusion and Strap Installation Detail - Tile Roof
CAUTION
1
STRAPS MUST BE ATTACHED DIRECTLY ONTO THE RAFTERS OR TRUSSES, NOT LESS THAN 39” APART
AND NOT MORE THAN 63" APART.
2
6.
EXTRUSION MUST SLOPE ½” PER COLLECTOR FROM HORIZONTAL (HOT PIPE SIDE TO BE HIGHER) FOR SYSTEM TO
WORK CORRECTLY.
Attach straps onto rafters or trusses with 5/16” x 6" lag screws (refer to Figure 5.5).
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Figure 5.5 Collector Extrusion and Strap Installation Detail-Metal Roof
7.
Replace tiles that have previously been removed.
NOTE
ENSURE THE WEATHERPROOF SEAL IS RESTORED.
8.
Flash and seal all roof penetrations.
9.
Continue with Section 5.3, Collector Installation.
5.2.3
Frame Installation
The frame is attached to two wood or Unistrut runners and installed over rafters or trusses, bearing wall or
reinforced roof area. Fixed pitch frame assemblies are used in reverse and side pitch installations, whereas
variable pitch frame assemblies are used for shallow pitch or flat roof installations.
CAUTION
FOR ALL FRAME INSTALLATIONS, TANK-END SUPPORT POINTS MUST BE LOCATED OVER LOAD-BEARING WALL OR A
REINFORCED ROOF AREA.
1.
Remove roofing if necessary where runners will be installed to provide solid base for the frame.
2.
Install two off 2" x 4" x 8'4” redwood, treated-wood or Unistrut runners;
•
Mark supporting rafter or truss locations,
•
Place tank-end of runners over load-bearing wall,
NOTE
IF RUNNERS BLOCK WATER FLOW, STRADDLE TWO CLOSEST RAFTERS.
•
Cut runners to straddle the two closest rafters diagonally,
•
Angle runners under support points to permit rainwater drainage,
•
Drill each runner in center and 6" from runner ends and screw to rafters or trusses
with 5/16" x 6" lag screws and washers,
•
Flash and seal all roof penetrations.
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3.
Move all pieces of Frame to roof and assemble (refer to Figure 5.6).
Figure 5.6 Frame Assembly
4.
Attach Frame to runners:
For shallow-pitch or flat roofs, screw frame directly to runners.
For side pitch or reverse pitch roofs;
•
Loosely screw collector end of frame to runners with 5/16" x 1 3/4" lag screws and washers,
•
Level frame and measure the required length for the tank-end pipe legs ( 5) (refer to Figure
5.7),
Figure 5.7 Pipe Leg Connection Detail
NOTE
ALLOW ROOM FOR ’U’ BRACKET PIPE-LEG CRADLE ON FRAME.
ROOFS WITH STEEP PITCH (ABOVE 20°) MAY REQUIRE SHORT PIPE LEGS AT COLLECTOR END OF FRAME FOR CLEARANCE
(REFER TO FIGURE 5.7).
•
Measure and cut un-drilled end of pipe legs to correct length,
•
Attach ’U’ brackets to runners with 5/16" X 1 3/4" lag screws and washers or Unistrut bolts
(refer to Figure 5.8),
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Figure 5.8 Lower Pipe Leg Installation
•
Insert un-drilled ends of pipe legs into frame,
•
Attach drilled end of pipe legs to ’U’ brackets using 2" screws (refer to Figure 5.8),
•
Screw pipe legs to frame with 2" screws through pipe legs and frame sleeves,
•
Continue with Section 5.3, Collector Installation.
5.3
Collector Installation
1.
Set Collectors in place, resting lower ends on Collector Extrusion or frame,
2.
Remove plugs from comers of Collectors,
3.
Connect Collectors with Collector Unions. Do not tighten fully (refer to Figure 5.9, Points A & B),
4.
Where applicable, connect the third collector using with Collector Unions,
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Figure 5.9 Collector Fitting Installation Detail
CAUTION
COLLECTORS MUST SLOPE ½” PER COLLECTOR FROM HORIZONTAL (HOT PIPE SIDE TO BE HIGHER) TO ENSURE
CORRECT OPERATION OF THE SYSTEM.
5.
Check that Collectors slope ½” per collector from horizontal (hot pipe side to be higher).
6.
Install the Collector Plug and the Collector Nut at Point C,
7.
Install collector Fill Assembly and Collector Nut at Point D,
8.
Attach collectors to support structure as shown in sections 5.3.1 and 5.3.2 below.
5.3.1
Standard Installation
Attach Collectors to Extrusion using 2 sets of Collector Clamps, Screws and Nuts, per collector (refer to Figure
5.10a).
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Figure 5.10a Collector Attachment Details: Standard and Metal or Sturdy Tile
5.3.2
Frame Installation
CAUTION
DO NOT DAMAGE INTERNAL COLLECTOR ABSORBER WITH SCREWS.
1.
Attach Collectors with 2 sheet metal screws per collector, through the angle iron upright into the
collector frame at the top and bottom of each collector (refer to Figure 5. 10b).
Figure 5.10b Collector Attachment Details: Frame Installation
2.
Tighten Collector Unions, parts and hardware securely.
3.
Continue with Section 5.4, Storage Tank Installation.
5.4
Storage Tank Installation
CAUTION
IF LIFTING TANK TO ROOF MANUALLY USE CORRECT LIFTING TECHNIQUES.
1.
Spread open Tank Clamps to allow room to clear tank foot, and attach to rear foot of tank.
2.
Place the Tank-to-Collector Spacers at the top of the collectors, to ensure correct spacing for
alignment of Downpipe and Hot Pipe (refer to Figure 5.11).
3.
Position tank centrally above the collectors, with the front foot of the tank resting up against the Tankto-Collector Spacers. Refer to Appendix B for a 3 collector installation.
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Figure 5.11 Collector Downpipe Alignment
NOTE
DO NOT TIGHTEN TANK IN PLACE AT THIS STAGE.
REFER SECTION 5.5.
CAUTION
IF PITCH IS 30q - 45q, ADDITIONAL TANK BRACING IS REQUIRED.
4.
Attach tank to supporting structure as detailed in sections 5.4.1 and 5.4.2 below;
5.4.1
Standard Installation
Drill holes in each runner, and screw the Tank Clamps directly to runner with 5/16" X 1 1/4" lag screws (refer
to Figure 5.12a).
Figure 5.12a Storage Tank Attachment Detail to Wood Runner
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Metal / Sturdy-Tile
1.
Attach the Tank Clamps to the stainless steel Tank Straps. The Tank Straps should run straight up
the roof perpendicular to the tank so that when they are fixed to the roof structure, they can support
tank without movement (i.e. the Tank Straps should not run up the roof at an angle).
2.
Remove the tiles to allow room to screw Tank Straps directly into the rafters or trusses.
3.
Position the Tank Clamps along the rear tank foot so that the Tank Straps align with the roof rafters or
trusses.
CAUTION
TANK STRAPS MUST BE SCREWED DIRECTLY INTO RAFTERS OR TRUSSES NOT LESS THAN 39" APART AND NOT MORE
THAN 63” APART.
4.
Attach the two Tank Straps directly to rafters or trusses with 5/16" x 1 1/4" lag screws (refer to Figure
5.12b).
Figure 5.12b Storage Tank Attachment Detail to Metal l Sturdy Tile
5.4.2
Frame Installation
Screw Tank Clamps directly to frame with 5/16" X 1 1/2" machine screws and washers.
5.5
Installing Tank and Collector Connecting Pipework
1.
Where there is a third collector, attach the 3-Panel Pipe Extensions to each end of the tank.
2.
Carefully align Collector Hot Pipe and Downpipe connections with tank.
3.
Connect Hot Pipe to lower-left side of tank (or Pipe Extension) and upper-left side of left-hand
collector. Do not fully tighten (refer to Figure 5.11).
NOTES
STORAGE TANK CONNECTION SHOULD ALWAYS BE HIGHER THAN COLLECTOR CONNECTION.
IF INSTALLING A HARTSTAT SYSTEM ON THE WATER HERATER, THEN THE HOT PIPE WILL BE A HARTSTAT HOT PIPE
ASSEMBLY, AS SUPPLIED WITH THE HARTSTAT KIT
4.
Connect Downpipe to lower-right side of tank (or Pipe Extension) and lower-right side of right-hand
Collector. Do not fully tighten (refer to Figure 5.11).
NOTES
IF INSTALLING A HARTSTAT SYSTEM ON THE WATER HEATER, THEN THE DOWNPIPE WILL BE A HARTSTAT DOWNPIPE, AS
SUPPLIED WITH THE HARTSTAT KIT
5.
Tighten the fasteners on the Tank Clamps and/or Tank Straps holding the tank in place.
6.
Tighten Hot Pipe and Downpipe connections.
7.
Install Tee Adaptor (refer to Figure 5.13).
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Figure 5.13 Storage Tank Plumbing Attachment Detail, Left Side
Model L
Models J, KF & Free Heat
NOTE
IF USING TEFLON TAPE TO SEAL T/P VALVE, MAKE SURE TAPE DOES NOT BLOCK WATER PASSAGE.
8.
Install T/P Valve into Tee Adaptor (refer to Figure 5.13).
9.
Install Tail Plug in right end of Tank (refer to Figure 5.14). Not used on L model systems.
5.5.1
Hartstat Installation (Optional)
The Hartstat hot pipe assembly and cold pipe should already be fitted to the system as instructed above.
Install the Hartstat reservoir system to the water heater in accordance with the installation instructions
provided with the Hartstat kit.
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Figure 5.14 Storage Tank Plumbing Attachment Detail, Right Side
5.6
Plumbing Installation
I.
Review checklist sketches for roof-jack location.
2.
Mark on the roof the exact location of roof-jack installation.
CAUTION
PLUMBING MUST BE INSTALLED SO THAT THE PERFORMANCE OF ANY FIRE-RATED ASSEMBLY IS NOT REDUCED.
NOTE
LOCATION OF ROOF JACK MAY VARY DEPENDING ON INSTALLATION TYPE.
3.
Install plumbing according to Figure 2.8, 2.9, or 2.10 and plumb lines to roof according to Key to StubOuts (refer to Figure 5.15).
4.
External Piping Insulation
•
Where potable water piping is in an external location or attic space where the temperature can be as
low as 19°F it must be insulated with a minimum ¾” Armaflex (or similar) flexible elastomeric closed
cell thermal insulation. Where the temperature can fall to 12°F the insulation thickness must be
increased to 1 ½”.
•
It is recommended that heat trace be installed on potable water piping in areas where the temperature
falls below 32°F for more than 4 hours with no hot water draw to protect against pipe freezing.
•
Insulation in external locations can deteriorate through UV radiation. To prevent this, a layer of outdoor
UV stable paint or other similar protective coating must be applied to the insulation.
NOTE
THE CLOSED CIRCUIT PIPING BETWEEN THE STORAGE TANK AND SOLAR COLLECTORS DOES NOT REQUIRE INSULATION.
WARNING
HEAT TRACE WILL NOT PROTECT AGAINST PIPE FREEZING IN THE EVENT OF POWER LOSS.
The following may be performed in any order necessary:
•
If water pressure exceeds 60 psi, install optional Pressure Regulator on main supply to building.
•
Install Safety Relief Line Connection to drain-line termination site within 6 inches of ground-level
drainage point capable of hot water disposal.
NOTE
1.
ALL PLUMBING INSTALLATION MUST CONFORM TO LOCAL CODE.
2.
ALL PIPING MUST BE ADEQUATELY SUPPORTED; SUPPORTS MUST CONFORM TO LOCAL CODE.
3.
ALL PIPING MUST BE ADEQUATELY INSULATED; INSULATION MUST CONFORM TO LOCAL CODE.
4.
ALL PIPING MUST SLOPE TO DRAIN.
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5.
Key to Stub - Outs
Figure 5.15 Stub-Out Attachment Detail
All plumbing and wiring Stub-Outs to be a minimum of 18" above roof frame.
(E)
Electrical Service (220V, 25-Amp required only if using auxiliary electrical backup In Tank)
(R)
3/4" Relief Line
(H)
Hot Supply to House
(C)
3/4" Cold Supply to Solahart
•
Install tempering valve between Solahart system and existing water heater tapping into cold water
supply line. If connecting to an existing conventional water heater, water from the Solahart system
must be tempered with cold water before entry into the existing water heater to avoid damaging it and
voiding its warranty.
•
Install hot and cold water shut-off valves next to the existing water heater in a convenient location.
5.7
Electrical Installation
NOTE
THIS SECTION DOES NOT APPLY IF INSTALLING SYSTEM AS PRE - HEATER TO EXISTING WATER HEATER.
1.
Refer to section 5.12 for electrical requirements.
CAUTION
DO NOT CONNECT ELECTRICITY TO MAINS CIRCUIT BREAKER AT THIS TIME.
2.
Install according to Figure 2.11 or 2.12, electrical schematics, and optional electrical connections on
the checklist.
5.8
Install Roof - Jack Panel
1.
Remove necessary roofing material,
2.
Place panel over plumbing and electrical stub-outs and install with nails or screws,
3.
Flash and seal all roof penetrations,
4.
Replace roofing material.
5.9
Connect Plumbing to Storage Tank (refer to Figure 5.13)
NOTES
1. ENSURE PLUMBING IS INSTALLED TO ALLOW REMOVAL OF STORAGE TANK END COVER FOR MAINTENANCE WORK.
2. PLUMBING CONNECTIONS ARE ¾” BSP (NOT NPT). ADAPTORS CONSISTING OF ¾” UNIONS, OLIVES AND COMPRESSION
NUTS ARE INCLUDED IN YOUR PARTS KIT.
1.
Connect cold water supply line to storage tank.
2.
Connect solar hot water line to Tee Adaptor.
3.
Connect drain line to T/P Valve.
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5.10
Fill and Test Potable Water Storage Tank (All Models)
CAUTION
1.
ON NEW CONSTRUCTION, DO NOT FILL STORAGE TANK AND/OR CHARGE THE CLOSED CIRCUIT SYSTEM UNTIL
WATER HEATER IS READY FOR USE. COVER COLLECTORS UNTIL SYSTEM IS FILLED AND CHARGED. PLACE TAG ON
SYSTEM IF NOT FILLED AND CHARGED.
2.
ON SOLAHART SYSTEMS MODEL J, KF & FREE HEAT, DO NOT FILL THE CLOSED CIRCUIT UNTIL THE
STORAGE TANK HAS BEEN FILLED AND PRESSURISED.
1.
Close all hot water outlet faucets except one in a safe location (a laundry tub is usually best).
2.
Open mains site water supply valve to water heater.
3.
As the water heater fills, air will be pushed from the open outlet faucet. When a continuous flow of
water is achieved the faucet should be closed which will pressurise the storage tank.
4.
Check tank and cold water lines for leaks and repair any found. For model L systems also check the
connections to and between the solar collectors.
5.
Ensure that the storage tank is completely free of air by opening the T/P Valve until it discharges a
steady stream of water. Then close the valve.
6.
For system model L the water heater is now operational. For closed circuit system models J, KF &
Free Heat, the system is now ready to Test and Fill the closed circuit as described in Section 5.11.
5.11
Test and Fill the Closed Circuit
Fill the closed circuit and test the closed circuit system connections for leaks as detailed below.
NOTE
FOR INSTRUCTIONS ON FILLING AND TESTING INSTALLATIONS FITTED WITH HARTSTAT SYSTEMS, REFER TO THE
INSTALLATION AND COMMISSIONING PROCEDURE CONTAINED IN THE HARTSTAT KIT.
5.11.1 Closed Circuit Fluid
The closed circuit of Solahart models J, KF & Free Heat must be filled ONLY with Solahart Hartgard solution
and potable water. Each system closed circuit is to be filled with one bottle of Hartgard and the balance
potable water. When mixed the approximate Hartgard concentration is 20%.
CAUTION
UNDER NO CIRCUMSTANCES CAN ANY FLUID OTHER THAN HARTGARD BE USED.
ALTERNATE FLUIDS COULD BE HAZARDOUS TO YOUR HEALTH.
5.11.1.1
Material Safety Data
Service Temperature Range
-40qF to 300qF
Viscosity
approx 0.00145 Ns/m
Freezing Point
-50°F
Boiling Point
212°F
Flash Point
218°F
Auto Ignition Temperature
> 750°F
Specific Heat
4190 J/kg/°C
Vapour Pressure
0.22 mm Hg @20°C
Fluid Colour
Light Blue
PH Mixed
7–9
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39
5.11.1.2
First Aid
•
Eye Contact:
Irrigate with water for 5 minutes
•
Skin Contact:
Wash with flowing water or shower
•
Inhalation:
No adverse effects
•
Ingestion:
No adverse effects
•
Advice to Doctor:
Treatment based on judgement of doctor in response to patient
reaction
5.11.1.3
Disposal of Fluid
Reprocess or burn in an approved incinerator in accordance with State/Local Government requirements.
5.11.2 Test and Fill Procedure - Closed Circuit Installations without Hartstat Systems
Remove the Fill Plug from the collector fill assembly.
Remove PR6 Jacket Relief Valve from the tank.
Connect a 1/2” hose and fill the closed circuit with water.
1
Continue filling until the water overflows
from the PR6 Jacket Relief Valve port
and air bubbles stop.
2
Fit the Test Block into the PR6 Port.
3
Fit the PR6 Jacket Relief Valve onto the Test Block.
4
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Now remove the hose from the Fill
Assembly and replace the Fill Plug.
Connect a bicycle pump to the Test Block
and pressurise the Closed Circuit to 80 kPa.
Check all connections for any evidence of leakage.
Ensure that the pressure remains
constant at 80 kPa for at least 10 minutes.
5
6
7
8
Rectify leakage if observed at any
of the connections and repeat steps 1 to 8.
9
Release the pressure from the closed circuit
by loosening the PR6 valve from the Test Block.
10
When the pressure is zero tighten the PR6 Jacket Relief Valve.
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Once again remove the Fill Plug
from the Fill Assembly and connect
11
the hose.
Remove the PR6 Jacket Relief Valve and siphon
the entire contents of the blue Hartgard
12
container with help of the hose.
Water will flow through the PR6 port
13
on the Test Block during this operation.
When the Hartgard container is completely
empty refit the PR6 valve onto the Test Block.
14
Remove the hose from the Fill Assembly.
Allow the fluid to flow until it stops.
(This checks the vacuum seal on the PR6 valve).
15
Once the flow stops, screw in the Fill Plug.
Pressurise the Closed Circuit to 80 kPa
as before with the help of the bicycle pump
16
and ensure there is no leak at the Fill Assembly.
Ensure that the pressure remains at 80 kPa
17
for at least 10 minutes, as before.
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Release the pressure from the closed circuit
by removing the PR6 Valve from the Test Block.
Remove the Test Block from the Tank.
18
19
Fit the PR6 Valve in its place on the tank
after ensuring that the “O” ring is in its seat.
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43
5.12
Connect Storage Tank to Electrical Supply
WARNING
TURN OFF ALL POWER TO AVOID INJURY.
CAUTION
TO REDUCE THE RISK OF ELECTRIC SHOCK OR FIRE:
•
•
•
USE ONLY ON A UTILITY SUPPLY HAVING A MAXIMUM 125 / 250 VOLT, THREE WIRE SYSTEM.
THE WATER HEATER MUST ALWAYS BE CONNECTED TO GROUND IN ACCORDANCE WITH THE LOCAL CODES.
CONNECT BRANCH CIRCUIT EQUIPMENT GROUNDING MEANS AND SYSTEM GROUNDING CONDUCTORS TO WATER
HEATER AT THE TERMINAL MARKED “G”.
•
USE ONLY COPPERS CONDUCTORS.
1.
Turn OFF all electrical supply to the residence.
2.
Remove left tank End Cover, thermostat and element covers, to expose electrical connections (refer to
Figure 5.16).
Figure 5.16 Detail of Electrical Connections
Neutral
Element x2
Active
Ground
3.
Connect tank electrical connections into the electrical stub-out location.
4.
Connect Solahart electrical circuit breaker/fuse box to mains supply line.
5.
Turn ON all electrical supply to the residence.
5.13
Complete Solahart Installation
1.
Insulate all plumbing lines. See Section 2.6.4 for details
2.
Replace tiles or other roofing to cover straps, etc, as necessary.
3.
Remove and dispose of packing materials and leave area clean and neat.
4.
Complete Service Technician contact details and Model details in the Owner’s Manual, then hand the
manual to the homeowner.
5.
Instruct homeowner regarding system operation and features.
6.
Complete Post-Installation Checklist.
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44
6.0
TROUBLESHOOTING
This section covers problems you my experience while installing or maintaining the Solahart system.
CAUTION
REVIEW SECTION 3.0, HAZARDS AND PRECAUTIONS, BEFORE PROCEEDING WITH ANY TROUBLESHOOTING.
SYMPTOM: Insufficient Hot Water
Possible Cause
Solar circuit breaker tripped / fuse blown
Safety Thermostat tripped/malfunction
Faulty Backup Heating Element
Hot water leak in household system
Blockage in water line
Pipes not properly connected during
installation
Tank blocked with sediment
Closed circuit charge low
Leak in closed circuit
Air bubbles in closed circuit
Ruptured tank jacket
Tank not level
Collectors not level
Collectors shaded during daylight hours
Tempering Valve malfunction
Corrective Action
Reset/replace as necessary
Replace as necessary according to Procedure 7.2.4
Replace Backup Heating Element
Locate and repair leak
Locate and correct blockages
Correct pipe connections according to installation
instructions
Flush tank to remove sediment
Recharge closed circuit
Locate and repair as necessary, recharge closed circuit
Recharge closed circuit
Replace tank
Level tank
Level collectors
Clear obstruction to sunlight on collectors
Repair/replace as necessary
SYMPTOM: Insufficient Hot Water in Morning or Following a Cloudy Day
Possible Cause
System circuit breaker tripped
Safety Thermostat switch tripped/malfunction
Faulty Backup Heating Element
SYMPTOM:
Corrective Action
Repair/replace as necessary
Replace as necessary according to Procedure 7.2.4
Replace according to Procedure 7.2.5
Excessive Cold Water Discharging from Drain Line
Possible Cause
No T/P Valve installed
Excessive pressure through T/P Valve
Faulty Cold Water Expansion Valve
Pressure build up from non-Solahart source
Corrective Action
Install T/P according to
Procedure 7.2.7
Repair/ replace as necessary
Repair/ replace as necessary
Repair plumbing as necessary
SYMPTOM: Hot Water discharging from Drain Line
Possible Cause
Faulty Safety Thermostat
Malfunctioning T/P valve
System oversized for customer requirements
Corrective Action
Repair/ replace as necessary
Press and release T/P valve handle to reseat valve Repair/
replace as necessary
Fit a Solahart Heat Dissipater Unit / Fit a Hartstat system for
closed circuit installations/ cover a solar collector / contact
Solahart Dealer
SYMPTOM: No Hot Water
Possible Cause
Hot Water Tempering Valve fouled
Pressure imbalance (over 5 psi)
Between hot and cold water lines
Fouled Pressure Regulator Valve
Cold water line blocked
Corrective Action
Repair/ replace as necessary
Locate and repair cause of imbalance
Repair/ replace as necessary
Repair as necessary
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SYMPTOM: Low Hot Water Pressure
Possible Cause
Fouled Pressure Limiting Valve / Strainer
Corrective Action
Repair/ replace as necessary
SYMPTOM: Water Too Hot
Possible Cause
Tempering Valve malfunction
Corrective Action
Repair/ replace as necessary
SYMPTOM: Severe Noise or Knocking When Water is Turned ON or OFF
Possible Cause
Pipes not solidly clamped down
Faulty washer(s) in outlet faucets
Other plumbing problem
Corrective Action
Repair as necessary
Repair as necessary
Repair as necessary
SYMPTOM: Gas Discharge from Hot Water Tap
Possible Cause
Result of system operating but water not being
used
Corroded Anode
Corrective Action
Run tap to allow gas to escape
Replace according to Procedure 7.2.6
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7.0
MAINTENANCE
This section covers scheduled inspections, maintenance and detailed procedures for disassembly and repair
of the Solahart system.
CAUTION
•
•
•
ONLY QUALIFIED PERSONNEL SHOULD PERFORM PERIODIC MAINTENANCE.
FOLLOW THE INSTRUCTIONS IN THIS SECTION AS CLOSELY AS POSSIBLE. IF YOU ARE UNSURE OF ANY
INSTRUCTIONS OR PROCEDURES, PLEASE CONTACT A SOLAHART DEALER.
USE OF ANY OTHER THAN SOLAHART REPLACEMENT PARTS MAY VOID THE MANUFACTURERS WARRANTY AND
MAY CAUSE SYSTEM MALFUNCTIONS.
•
7.1
REFER TO SECTION 3.0, HAZARDS AND PRECAUTIONS, BEFORE PROCEEDING WITH ANY MAINTENANCE.
Periodic Maintenance
To keep the Solahart system working efficiently, perform the following maintenance schedules:
7.1.1
Quarterly
CAUTION
COLLECTORS MUST BE COOL BEFORE WASHING.
1.
Clean collector glass periodically to remove accumulated dust and dirt.
2.
Trim trees near collectors.
7.1.2
Annually
Perform the regular quarterly and annual maintenance at the same time as this maintenance.
1.
Flush hot and cold water relief valves, lift valve handle - hold for 30 seconds - release to reset valve. If
water flow does not stop, life and release handle repeatedly until valve resets.
2.
If valve does not reset properly after a few tries, it must be removed and cleaned or replaced.
7.1.3
Every 3 to 5 Years (10 years for Free Heat systems)
Perform the regular quarterly and annual maintenance at the same time as this maintenance.
1.
Check all valves and electrical equipment.
2.
Replace Anode.
3.
Replace T/P Valve.
4.
Check fluid level in closed circuit. Replace fluid if necessary according to Section 5.10.
NOTE
NEVER REPLACE CLOSED CIRCUIT FLUID WITH USED FLUID. ALWAYS REPLACE WITH A NEW SOLUTION OF HARTGARD
AND POTABLE WATER.
5.
Install new Solahart logo if necessary.
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7.2
Maintenance Procedures
NUMBER
7.2.1
TITLE
7.2.1
Draining Storage Tank
7.2.2
Filling Storage Tank
7.2.3
Drain Closed Circuit
7.2.4
Thermostat Reset/Replacement
7.2.5
Backup Heating Element Replacement
7.2.6
Anode Replacement
7.2.7
Temperature Pressure Relief (T/P) Valve Replacement
7.2.8
Collector Replacement
7.2.9
Storage Tank Replacement
Draining Storage Tank
WARNING
TURN OFF ALL POWER.
1.
Cover collectors with opaque (light cannot penetrate) material.
CAUTION
BEFORE DRAINING STORAGE TANK ON CLOSED CIRCUIT MODELS, PRESSURE IN CLOSED CIRCUIT MUST BE RELIEVED OR
CIRCUIT MAY COLLAPSE. THIS ACTION IS NOT REQUIRED FOR L MODELS.
2.
Turn OFF Cold Water Shut-off Valve.
3.
Remove Jacket Relief Valve to relieve closed-circuit pressure in J, KF and Free Heat models only,
(refer to Figure 5.13).
4.
Relieve pressure in system by lifting T/P Valve handle for at least 30 seconds.
5.
To Empty the storage tank (all models):
Installations with Cold Water Expansion Valve:
Lift Cold Water Expansion Valve handle allowing the tank water to flow out of the tank until it is empty.
Installations without Cold Water Expansion Valve:
6
a)
Remove cold supply pipe from tank on roof.
b)
Attach a hose to tank inlet connection to direct flow from the tank to a safe location.
c)
Open a HOT faucet inside house to allow tank to drain.
To Empty the collectors (L models only)
1.
Empty storage tank as above.
2.
Remove plug from bottom right hand corner of the collector and allow the water to flow out.
The water volume is ½ US Gallon per collector.
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7.2.2
Filling Storage Tank
WARNING
TURN OFF ALL POWER.
1.
Place opaque (light cannot penetrate) coverings over collectors.
2.
Open at least one hot water faucet, preferably over a bathtub or large sink.
3.
Turn ON Cold Water Shut-off Valve.
4.
When water begins to flow through hot-water faucet without airbursts, turn faucet OFF. Bleed air from
all other hot water faucets.
5.
Lift T/P Valve handle for at least 30 seconds.
6.
Check for and repair any plumbing leaks.
7.
Replace Jacket Relief Valve using new “O” ring.
8.
Remove coverings from collectors.
9.
Turn ON power.
7.2.3
Drain Closed Circuit
WARNING
TURN OFF ALL POWER.
WARNING
TO AVOID THE RISK OF SCALDING, ENSURE THAT THE CLOSED CIRCUIT FLUID IS COLD BEFORE REMOVING THE
JACKET RELIEF VALVE.
NOTE
INSTALLATIONS FITTED WITH HARTSTAT SYSTEMS USE A 200KPA PR200 JACKET RELIEF VALVE IN PLACE OF THE 80KPA
PR6 VALVE.
1.
Place opaque (light cannot penetrate) coverings over collectors.
2.
Open at least one hot water faucet, preferably over a bathtub or large sink, and flush all hot water from
the system, replacing it with fresh cold water.
3.
Carefully unscrew and remove the Jacket Relief Valve from the tank, allowing the pressure in the
jacket system to normalize. Replace the Jacket Relief Valve.
4.
Remove the thumb screw from the fill fitting and connect one end of the ½” clear plastic tube (part of
the commissioning kit) to the fill assembly on the bottom left hand corner of the installation. Place the
other end of the tube into a clean plastic container, capable of holding all of the closed circuit fluid in
the system. There are 6.5 US Gal of fluid in the closed circuit of a 302 system.
5.
Place the container on the roof, such that the top of the container is below the bottom of the system.
Remove the Jacket Relief Valve, and allow all of the closed circuit fluid to flow into the container. Store
the container until after the repair, so that the fluid can be replaced back into the jacket.
NOTE
TO FILL AND TEST THE CLOSED CIRCUIT REFER TO SECTION 5.11.
7.2.4
Thermostat Replacement
WARNING
TURN OFF ALL POWER.
1.
Remove End Cover from left end of Storage Tank.
USA INSTALLATION MANUAL
49
2.
Remove yellow Thermostat Enclosure Cover.
3.
Disconnect electrical wires to Thermostat one at a time, noting proper connecting points for new
Thermostat.
4.
Install new Thermostat, connecting wires as noted.
5.
Replace yellow Thermostat Enclosure Cover.
6.
Replace End Cover.
7.
Turn ON power.
7.2.5
Backup Heating Element Replacement
WARNING
TURN OFF ALL POWER.
1.
Cover collectors with opaque (light cannot penetrate) material.
2.
Remove Jacket Relief Valve to relieve closed circuit pressure.
3.
Drain storage tank according to Procedure 7.2.1.
4.
Remove End Cover on left side of tank.
5.
Remove yellow Element Enclosure Cover.
6.
Disconnect wires from Heating Element.
Remove the four screws from the Element and remove the Element and seal (refer to Figure 7.1)
Figure 7.1 Heating Element Detail
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50
8.
Install new Element and new seal.
NOTE
IF THE NEW ELECTRICAL ELEMENT IS A SICKLE TYPE, THE SICKLE MUST BE INSTALLED IN THE HORIZONTAL POSITION.
THIS POSITION ENSURES THAT THE UPPER SECTION OF THE TANK CAN BE ELECTRICALLY BOOSTED AND THE LOWER
SECTION IS MAINTAINED FOR SOLAR INPUT.
9.
Refit the four element screws.
CAUTION
DO NOT OVER TIGHTEN THE FOUR ELEMENT SCREWS OR DAMAGE WILL OCCUR TO THE TANK AND SEAL. USE ONLY
LIGHT/MEDIUM SPANNER PRESSURE. THESE SCREWS MUST BE REFITTED CORRECTLY OR THE ELEMENT FLANGE
THREADS MAY BE DAMAGED.
10.
Re-connect Element wires.
11.
Replace yellow Element Enclosure Cover
12.
Replace tank End Cover.
13.
Refit Jacket Relief Valve.
14.
Fill Tank according to Procedure 7.2.2.
15.
Turn ON power.
16.
Uncover collectors.
17.
Check for leaks around element seal.
7.2.6
Anode Replacement
WARNING
TURN OFF ALL POWER.
1.
Drain Tank according to Procedure 7.2.1.
2.
Replacing Anode requires 8 feet of work area on left side of tank. If required area is not available:
•
Disconnect plumbing connections from Tank (refer to Figure 5.13 and 5.14).
•
Drain closed circuit according to Section 7.2.3.
•
Loosen Tank Clamps on rear feet of tank and move tank (refer to Figure 5.12a or b).
3.
Remove tank End Cover.
4.
Remove Anode by unscrewing counter-clockwise (refer to Figure 7.2).
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51
Figure 7.2 Anode Replacement Detail
5.
Insert replacement Anode.
6.
Tighten Anode, taking care not to strip threads.
NOTE
IF YOU MOVED TANK, REPLACE IN ORIGINAL POSITION, REATTACH TANK CLAMPS, DOWNPIPE AND HOT PIPE.
CHARGE CLOSED CIRCUIT ACCORDING TO SECTION 5.11.
7.
Refill tank according to Section 7.2.2.
8.
Check for leaks.
9.
Replace tank End Cover.
10.
Turn ON power.
7.2.7
Temperature Pressure Relief (T/P) Valve Replacement
1.
Turn OFF water to system at Cold Water Shut-off Valve.
2.
Remove Jacket Relief Valve to relieve closed-circuit pressure (refer to Figure 5.13).
3.
Relieve pressure in system by lifting T/P Valve handle for at least 30 seconds.
4.
Disconnect drain line and unscrew T/P Valve (refer to Figure 5.13).
WARNING
A SMALL AMOUNT OF HOT WATER MAY FLOW FROM THE TANK OUTLET SOCKET WHEN THE VALVE IS REMOVED. CARE
SHOULD BE TAKEN TO AVOID SCALDING.
5.
Install replacement T/P Valve and tighten into place.
6.
Reconnect drain line.
7.
Turn ON water and check for leaks.
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7.2.8
Collector Replacement
WARNING
TURN OFF ALL POWER.
1.
Cover ALL collectors with opaque (light cannot penetrate) material.
2.
Drain closed circuit according to Section 7.2.3 (not applicable for L Model Systems).
3.
For L Model Systems, turn OFF mains water supply and drain tank and collectors according to Section
7.2.1.
4.
Disconnect pipe work and remove mounting brackets on the damaged collector(s).
5.
Remove damaged collector (refer to Figures 5.9 and 5.10).
6.
Place new collector on supporting structure using bottom support extrusion as a guide.
7.
Position overhang to match existing collector.
CAUTION
USE ONLY MANUFACTURER-SUPPLIED HARTGARD.
8.
Remove plugs from ends of replacement collector.
9.
Connect Collector Unions between upper and lower inside collector ends.
10.
If the replacement collector is on the LHS of the collector bank reinstall Fill Assembly, Collector Nut,
and Hot Pipe (refer to Figure 5.9).
11.
If the replacement collector is on the RHS of the collector bank, reinstall Downpipe and Plug Assembly
(refer to Figure 5.14).
12.
If the replacement collector is the center collector (3-panel system), reinstall Collector Unions.
13.
Tighten Collector Unions and related parts.
14.
Level collectors.
15.
Attach collector to supporting structure.
16.
For L Model Systems, turn ON mains water supply and fill tank and collectors in accordance with
Section 7.2.2.
17.
Test and charge closed circuit according to Section 5.11.
18.
Turn ON power.
19.
Remove coverings from collectors.
20.
Check for leaks.
7.2.9
Storage Tank Replacement
WARNING
TURN OFF ALL POWER.
1.
Cover ALL collectors with opaque (light cannot penetrate) material.
2.
Drain closed circuit according to Section 7.2.3 (not applicable to L Model Systems).
3.
Drain tank according to procedure 7.2.1.
4.
Remove End Cover and yellow Thermostat and Element Enclosure Covers from left side of tank to
expose electrical connections.
USA INSTALLATION MANUAL
53
5.
Mark and disconnect tank electrical connections (refer to Figure 5.16).
6.
Mark and disconnect tank plumbing connections (refer to Figure 5.13 and 5.14).
7.
Loosen tank from supporting structure (refer to Figure 5.12a or b).
CAUTION
IF LIFTING TANK TO OR FROM THE ROOF MANUALLY, USE CORRECT LIFTING TECHNIQUES.
8.
Remove and discard old tank.
9.
Place new tank on roof, using care to avoid site damage.
10.
Move tank into location.
11.
Be sure Hot Pipe and Downpipe connections are properly aligned with the replacement tank.
12.
For three collector systems, attach 3-Panel Pipe Extensions to cold side of tank.
13.
Connect Hot Pipe to lower-left side of tank, or Pipe Extension for three panel systems (not applicable
to L Model Systems). DO NOT fully tighten connection.
14.
Connect Downpipe to the lower-right side of tank or Pipe Extension (not applicable to L Model
Systems). DO NOT fully tighten connection.
15.
For L Model Systems, connect Hot Pipe to tail socket on RHS of tank or Pipe Extension for three panel
systems. DO NOT fully tighten connection.
16.
For L Model Systems, connect Downpipe to cold inlet socket on LHS of tank or Pipe Extension. DO
NOT fully tighten connection.
17.
Level the tank.
18.
Secure tank to supporting structure.
19.
Tighten Hot Pipe and Downpipe connections to tank.
20.
Install Tee Adaptor (refer to Figure 5.13).
21.
Install T/P Valve (refer to Figure 5.13). Use Teflon tape to seal threads; avoid blocking water flow.
22.
Install PR6 Jacket Relief Valve and ’O’ ring (refer to Figure 5.13).
23.
Install Tail Plug (refer to Figure 5.14) or Heat Dissipater Unit (not applicable to L Model Systems).
24.
Connect cold water supply line (refer to Figure 5.15).
25.
Connect solar hot water line (refer to Figure 5.15).
26.
Connect drain line to T/P Valve (refer to Figure 5.15).
27.
Fill storage tank according to procedure 7.2.2.
28.
Charge and test closed circuit according to Section 5.11.
29.
Remove left End Cover and yellow Thermostat and Element Enclosure Covers from tank to expose
electrical connections.
30.
Connect tank electrical connections to electrical stub-out connections.
31.
Turn ON power and check for proper operation.
32.
Replace left End Cover and yellow Thermostat and Element Enclosure Covers on tank.
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APPENDIX A
FRAMES
Installations using 17.5q ‘A’ Frames
This ‘A’-Frame is for use in non-cyclone areas only. In areas susceptible to cyclones, hurricanes or very
high winds, a separate set of instructions and a cyclone frame mounting kit is required and available from your
Solahart dealer. The cyclone frame mounting kit is suitable for with pitch and low pitch installations only.
The Solahart ‘A’ Frame kit is for use where side pitch, against pitch and low or flat roof installations are
required. The ‘A’ Frame kit is provided with 17.5° angled side frames. Fixing nails, bolts, screws and flashing
material are not normally supplied by Solahart except by special arrangement. The weight of the assembled
frame is approx. 50kg. The installations described below are for Solahart 302 models, however, the same
procedure is applicable for all models.
‘A’ Frame Kit
The ‘A’ Frame kit consists of:
Part No.
33-0350
33-0354
33-0806
33-0808
33-0810
33-0825
33-0826
33-0842
33-0846
33-0874
33-1101
33-1824
33-1832
33-1839
33-1840
33-6807
Description
5/16" hex set screw
5/16" washer
5/16" nut
5/16" bolt (2" long)
Coach screws
Pipe leg
’U’ Bracket
Brace angle
Stainless steel straps
Tank clamp
17.5 Frame
Tank Collector Rail
Collector clamps
Collector Fixing Rail, Single Collector
Collector Fixing Rail, Two Collectors
Baseplate
Qty: 150/180
16
6
20
4
2
2
2
2
2
2
2
1
2
1
0
2
Qty: 220/300
18
6
22
4
2
2
2
2
2
2
2
1
4
0
1
2
Figure 1
The arrangement and location of the baseplate (Part No. 33-6807), pipe leg (Part No. 33-0825), ‘U’ Bracket
(Part No. 33-0826), and the length of the pipe leg will vary for different installation types.
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Side Pitch Installations (Tiled Roof)
Assemble the ‘A’ Frame kit and loosely bolt the baseplate to one side of the angle frame as per Figure 2. For
installations on a roof with a pitch of greater than 20°, a ‘U’ bracket and small pipe legs should be used on top
of the baseplate as shown in figure 3. Note that the baseplate is positioned towards the rear of the frame to
distribute the weight of the tank more evenly. Remove several roofing tiles to expose the outer wall. Fix the ‘U’
brackets to the top of the wall plate and secure with the coach screws supplied (refer to figure 4 for method).
Figure 2
Using the assembled stand in a level position, measure the required length for the pipe legs, allowing for the
inside length of the pipe leg cradle. Cut the two pipe legs the same length. Fit the pipe legs to the ‘U’bracket
using the 5/16” x 2” bolts. Insert the pipe legs to the assembled stand and fit the 5/16 x 2” bolts. Remove tiles
from above the baseplate to expose the rafters. Fix the two stainless steel straps (Part No. 33-0846) onto the
baseplate and fix the straps to the rafters as shown in figure 3. Replace the tiles. Replace the tiles to the lower
portion of the roof, then weather seal and overflash the penetrations through the roof (refer to figure 7).
Position the collectors centrally on the frame. Check that the collector is level across the frame using a spirit
level. Secure the collector in place using the collector clamps (Part No. 33-1842). Fit the tank and the fittings to
the frame as per the standard installation instructions. However, fit the aluminium tank clamps onto both rear
and front feet of the tank base.
Figure 3
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Against Pitch Installations (Tiled Roof)
Assemble the stand and then loosely bolt the baseplate to the frame in the position shown in figure 1. For
installations on a roof with a pitch of greater than 20°, a ‘U’ bracket and small pipe legs should be used on top
of the baseplate as shown in figure 3. The frame installation proceeds following the instructions for side pitch
installations, with the pipe legs located directly over a load-bearing wall. (See figure 4.)
Figure 4
Variations for Metal and Fibreboard Roofs
Fixing method is similar to that for a tiled roof, with the exception that two baseplates are used. The second
positioned over the building outer wall. These baseplates are fixed to the metal or fibreboard roof using coach
bolts through to the rafters (see figure 5). The holes for the bolts are sealed with mastic.
Figure 5
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57
Variations for Shallow Pitch or Flat Deck Roofs
On shallow pitch roofs (less than 8°) of metal or fibreboard materials, the frame may be installed without using
the pipe legs, provided that the inclination of the solar collector remains greater than 8° (see figure 6). On flat
roofs, the assembled frame may be installed without the baseplates. Provided the roof material is structurally
suited, the frame may be bolted directly to it.
Figure 6
Flashing and Roof Penetrations
Flashing of roof penetrations must meet the requirements of the local authorities. Suggested methods are
shown in figure 7.
Alternative:
Clamp flashing cone in place
with stainless steel hose clamp
and seal to pipe leg with
silicone mastic.
Pipe Leg
Overflashing Cone.
(Fixed to pipe leg)
Flashing
Sheet.
Figure 7
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APPENDIX B
THIRD-PANEL PARTS LIST
INSTALLATION DIAGRAM - MODELS 303J, 303KF,
303KF FREE HEAT, 303J FREE HEAT
INSTALLATION DIAGRAM - MODEL 303L
USA INSTALLATION MANUAL
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