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Itho Solar System
CombiSolar 150
Installation and service manual
Pre-heat drain back solar system with unvented hot water solar
cylinder for use with combination boilers
SOLAR Key Mark Certificated
Building Regulations Approved Certificate No. ETC16211
itho
Climate for life
Leave this manual with the User for safe keeping
Contents
1
2
3
4
5
6
7
Introduction.........................................2
Technical data....................................3
General information............................6
Installation..........................................12
Commissioning...................................16
System operation...............................18
Routine inspection..............................20
8
9
10
11
12
13
Component replacement....................20
Wiring diagram...................................23
Diagnostics and fault codes...............23
Checklist for unvented storage...........26
Parts list..............................................27
Inspection history...............................28
1 Introduction
The Itho CombiSolar 150 system is a pre-heat drain back solar collector system which includes a floor standing 150 litre
unvented cylinder to store water heated by the solar collector. It is recommended that the system is used in conjunction with a
Solar compatible combination boiler but other alternatives may be used if deemed suitable. Refer Fig. 3 and to Section 4.7.1.
The CombiSolar 150 system includes a 150 litre cylinder, at least one flat plate drain back solar collector (up to a maximum
of three), drain back unit and unvented kit. The 150 litre unvented cylinder is supplied with a pump, control box and
temperature sensors. The drain back unit is fitted with a heat exchanger and pump. A 3-way diverter valve is also supplied.
The unvented kit must be fitted in the mains water supply to the cylinder. The kit includes a cold fill manifold assembly (which
includes a pressure relief valve, pressure reducing valve, check valve and filter), expansion vessel, and a tundish. There is a
connection on the manifold that may be used as a balanced cold water supply.
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 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
Forced circulation hot water systems
BS 5546
Installation of hot water supplies for domestic purposes
BS 5918
Solar heating systems for domestic hot water
BS 6700
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 IP42, 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.
Proviso: WRAS Approval - Solar heating system components. Compliance with the relevant requirements of the Water Supply
(Water Fittings) Regulations 1999 has been assessed for this product only as a component of a heating system. If it is to be
installed as part of a system using solar energy or ground - or air - source heat pumps for pre-heating water which is to be used
as domestic hot water, the Water Fittings Regulations place a legal duty on the installer and user to ensure that the installation
and operation of the complete system prevents contamination of domestic hot water by Legionella bacteria, which can grow in
water stored at temperatures between 20° and 45°C. Where disinfection by heating is relied on to meet this obligation, information
on minimum conditions for thermal disinfection of Legionella bacteria can be found on the WRAS website - www.wras.co.uk
The Itho CombiSolar unvented hot water solar cylinder has been specifically designed to prevent the proliferation of
legionella bacteria in this hot water system, and disinfection by heating is not relied upon to meet this obligation.
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.
Itho CombiSolar 150 page 2
2 Technical data
2.1 DHW details
Solar cylinder
5.5 bar
Max. hot water working pressure
12 bar
Max. mains inlet pressure (inlet of pressure reducing valve)
Min. mains water pressure
0.1 bar
Mains inlet connection
15 mm
DHW outlet connection
15 mm
3-way diverter valve connections
15 mm
DHW cylinder capacity
152 L
Expansion vessel size (pre-charge press.)
12 L at 3.0 bar
Pressure reducing valve setting
3.0 bar
Temperature and pressure relief valve
90°C/7 bar
Pressure relief valve setting
6 bar
Flow rate
L/min
Max.18.0 Min. 1.0
gal/min Max. 4.0 Min. 0.22
70°C
Max. outlet water temp. (approx.)
1¼"
Immersion heater boss
Drain back unit (DBU)
DHW circuit:
Flow connection
Return connection
Max. working pressure
Collector circuit:
Flow connection
Return connection
Max. working pressure
Vessel size
Max. filled content
Heat transfer capacity
15 mm
15 mm
8 bar
15 mm
15 mm
6 bar
10.5 L
9.8 L
110 W/K
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
50°C - 36 minutes. Reheat time for 70% of store - 30 minutes
2.2 Solar collector details - per panel
Type:
Portrait
Landscape
Dimensions
Total surface area
m²
2.5
Aperture area
m²
2.3
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
44 Gross - 41 Nett
Profile of collector when fitted using flashing kit protrudes approximately 30 mm to 60 mm above the tiles
(depends upon type of tile used)
Hydraulics
Maximum pressure
bar
6
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
0.035
Cover frame
Material
Aluminium black powder coated
Temperature sensor
Type - NTC
Ohm
10 k
Connections
Pre-mounted flexible hoses
Return to DBU mm
15 mm
Flow from DBU mm
15 mm
Roof slope
20° Min (90° Max)
30° Min (90° Max)
Energy performance (system with 150L tank)
5.8 GJ/yr (1500 kWh/yr) (2 panels)
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
Maximum number of collectors
m²
3 x 2.3 m2 = 6.9 m²
Itho CombiSolar 150 page 3
2.3 Installation
Solar cylinder min. clearances for servicing Top
Bottom
Sides
Front
DBU min. clearances for servicing
Top
Bottom
Sides
Front
Lift weight - cylinder assembly
Lift weight - DBU
Weight full and operational - cylinder assembly
Weight full and operational - DBU
100 mm
325 mm
100 mm
450 mm
100 mm
10 mm
10 mm
450 mm
33 kg
9 kg
185 kg
18.8 kg
2.4 General
2.5 Electrical
Solar cylinder dimensions
Height
1330 mm
Dia.
710 mm
DBU dimensions
Height
572 mm
Width
430 mm
Depth
266 mm
Solar cylinder material
Stainless steel
DBU heat exchanger material
Stainless steel
Covers/Insulation material
EPS foam
Solar cylinder insulation thickness
100 mm
Standing energy loss of solar cylinder
0.96 kWh/24hr
0.27 W/litre
Heat coefficient of cylinder insulation
0.032 W/mK
Global warming potential
Zero
Ozone depletion potential
Zero
Insulation blowing agent
Steam (water)
Supply
External fuse
Power consumption
3-way valve
Max.
Min.
230/240 V ~ 50 Hz
3A
197 W
5W
Power consumption
Moisture protection
4W
IP44
2.6 Location
The DBU should be positioned as close as possible under the solar collector. The pipework between the collector and DBU can
be extended according to the tables in Fig. 7, maintaining a maximum vertical distance of 4 m using compression fittings only.
The pipework between the solar cylinder and DBU can be extended to a maximum of 12 m, maintaining a maximum vertical
distance of 6 m.
All pipework should be installed using the minimum of bends and restrictions possible and insulated using high temperature
lagging for the pipework between the collector and DBU.
All pipework between the solar collectors, drain back unit and cylinder (and all cylinder connections) MUST be copper
with compression fittings.
2.7 Electrical connections
N L 8 9
Note: This appliance must be earthed. Do not connect any other controls.
Brown wire
Blue wire
Brown wire
Blue wire
DBU pump
L
Live - Brown wire
Neutral - Blue wire
N
230/240V ~ 50Hz Fuse supply 3A
2 3 4 5 6 7
Control Box
PCB connections
21 22 23
Fig. 1
Earth
Connector blocks
Earth (Green/Yellow wire) from electrical supply and DBU pump
Open Therm connections to compatible Open Therm condensing boiler
Open Therm compatible room thermostat or remote display
Brown wire
White wire
Solar collector temperature sensor
L
Connector blocks
N
Brown wire
Blue wire
Black wire
Itho CombiSolar 150 page 4
3-way diverter valve
2.8 CombiSolar schematic
1
Solar cylinder
6
Combination boiler
10
5
4
Solar collector
Drain back unit
DHW heat exchanger
5
2
3
20
9
To boiler
To hot
water taps
7
8
Cold water
to DBU
Hot water
18
Cold water inlet
Hot water
from DBU
19
11
To solar cylinder
To items
6 & 13
13
12
14
17
16
15
1
Collector temperature sensor
2
Drain back unit pump
3
Drain back unit heat exchanger
4
Control box
5
Temperature sensors
6
Temperature and pressure relief valve
7
Solar cylinder pump
8
Limit thermostat
9
Drain point for cylinder
10 Immersion heater boss
11 Unvented kit
12 Cold fill manifold assembly
Mains cold water
13 Pressure relief valve (part of item 12)
14 Non-return valve (part of item 12)
15 Pressure reducing valve with filter (part of item 12)
16 Tundish
17 Expansion vessel
18 3-way diverter valve
19 Thermostatically controlled mixing valve (not supplied)
20 Thermostatically controlled mixing valve (not supplied)
Required when a solar compatible boiler is NOT used
Fig. 2
Itho CombiSolar 150 page 5
3 General information
3.1 Electricity supply
The CombiSolar 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 complete CombiSolar 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 CombiSolar system. Therefore, it is recommended that
the CombiSolar 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
Ensure the cold mains and hot water pipes do not have any dead legs of pipework.
The mains water supply must be first connected to the cold fill manifold detailed in Section 3.3 before the solar cylinder. No
valves must be fitted between the manifold and the cylinder. The incoming mains water pressure to the cylinder is regulated
to 3.0 bar by the pressure reducing valve in the manifold. 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.
Note:The hot water control thermostat on the combination boiler must always be set at maximum.
To ensure economic use, the pipe runs to the combination boiler and taps should be in 15 mm copper pipe and be as short
as possible. Wherever possible the pipework should be insulated to reduce heat loss.
Thoroughly flush out the mains water supply pipe before connecting it to the boiler and solar cylinder to avoid the danger of
dirt or foreign matter entering the system. Ensure the filter in the cold fill valve assembly is clear.
The temperature of the water in the solar cylinder is restricted to a maximum of 70°C. At this temperature the DBU pump is
switched off until the cylinder temperature is reduced.
To prevent high temperatures at the hot water taps, it is recommended that a thermostatically controlled mixing valve is fitted
after the boiler as shown in Fig. 3.
3.3 Unvented domestic hot water storage system
To comply with the Building Regulations for unvented hot water storage, it is required that the unvented kit detailed in Fig. 3
is 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 CombiSolar system in a separate package and must be fitted by a competent
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 600 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.
Sizing of copper discharge pipe 'D2' - refer also to Fig. 4A and 4B
Valve
outlet size
Minimum size of discharge
pipe 'D1' to tundish
Minimum size of discharge
pipe 'D2' from tundish
G½
15 mm
22 mm
28 mm
35 mm
Maximum resistance allowed, Resistance created
expressed as a length of straight
by each elbow
pipe (i.e. no elbows or bends)
or bend
up to 9 m
up to 18 m
up to 27 m
0.8 m
1.0 m
1.4 m
The discharge pipework from the tundish:
1. Shall fall continuously through its length.
2. Shall be of a heat resistant material, e.g. metal.
3. Shall not be fitted with any valves or taps.
4. Shall discharge to a safe visible position, e.g. into a gulley.
5. 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.
Itho CombiSolar 150 page 6
Thermostat sensor
Solar collector
Two required, up to a maximum of 3 allowed
(3 only when using portrait collectors)
Combination boiler
Temperature/pressure
relief valve
Drain back
unit
Thermostat
sensor
Drain back
unit pump
Hot tap
Heat
exchanger
Thermostatically
controlled
mixing valve
(if required)
Outlet water
temperature
60°C
Unvented
cylinder
Thermostat
sensor
Water temperature
less than 60°C
Cylinder
pump
Drain
point
3-way diverter valve
Thermostatically
controlled
mixing valve
Limit
thermostat
Water temperature
more than 60°C
Cold water
supply
Pressure
reducing Check
Filter valve
valve
Expansion
vessel
Pressure
relief valve
Cold fill manifold assembly
Tundish
Stop
valve
Unvented kit
Discharge
pipe
Mains water
supply
Fig. 3
Note: If the combination boiler is not Solar compatible, a
thermostatically controlled mixing valve MUST BE fitted in the
cold water inlet to the boiler to ensure the water entering the
boiler is less than 28°C.
Itho CombiSolar 150 page 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 pressure
relief valve
Pipe close to wall to
allow water to fan
out safely
300 mm
minimum
600 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
Type 'A'
air gap
Subtract the resistance for four 22 mm elbows of 0.8 m each = 3.2 m.
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.
End of pipe to be
clearly visible
Therefore the maximum permitted length equates to 18 - 4 = 14 m
As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory.
Fig. 4b
Itho CombiSolar 150 page 8
3.4 Solar cylinder description - Fig. 5
Positioning
The solar cylinder must be installed on a flat horizontal surface which is capable of supporting the weight of the cylinder
when full (185 kg).
The cylinder may be installed in any room or internal frost free 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.
Note: The bottom of the solar cylinder must be located within 6 metres in height from of the top of the drain back unit.
Dimensions
The dimensions of the cylinder and clearances required for servicing are shown in Fig. 5.
Water connections
700 Dia.
>100
>100
>100
56
189
1002
508
171
325
E
Cylinder Connections
F
35
A B C D
A
B
C
D
E
F
Water outlet to boiler
Cold water inlet
Return from DBU
Flow from cylinder to DBU
Cylinder sensor
Cylinder drain point
15 mm
15 mm
15 mm
15 mm
51
50
50
Fig. 5
The connections at the bottom of the cylinder are shown in Fig. 5.
Note: Use compression fittings only on the cylinder connections and copper pipe between the cylinder and drain back unit.
We also recommend a minimum of 1 metre of copper pipe from the cylinder for the water inlet and outlet connections.
Itho CombiSolar 150 page 9
3.5 Drain back unit (DBU) description - Fig. 6
Positioning
The DBU must be located within a height of 4 metres of the top of the solar collectors, see Fig. 8. The pipework from the collectors
to the DBU must always fall by a minimum of 40 mm per metre and must be insulated with high temperature pipe insulation.
Note: The DBU must be located within 6 metres in height from of the bottom of the solar cylinder.
Dimensions
The dimensions of the DBU and clearances required for servicing are shown in Fig. 6.
Water connections
All connections on the top of the DBU as shown in Fig. 6.
Water connections on top of DBU
Hot water out (15 mm)
Return from collector
Red (15 mm)
Connect to collector hose
with RED clip
Flow to collector
Blue (15 mm)
Connect to collector hose
with BLUE clip
55
130
185
266
Cold water in (15 mm)
140
245
280
10
100
430
10
340
572
290
450
10
300
Fig. 6
Note: 1. Use copper pipe and compression fittings only on the pipework between the DBU and solar collectors.
2. The tubing from the solar collectors must always slope down towards the drain back unit (at least 40 mm per metre).
3. There must not be any part of the tubing that will allow water to collect.
3.6 Solar collector description - 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
up to 60° from the horizontal, the annual solar energy supplied will be at least 90% of that obtained at the optimum collector
position (South at 30°).
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.
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 flashing kit (portrait or 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° for portrait and 30° for landscape. 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.
Itho CombiSolar 150 page 10
Collectors
Portrait
inclined
roof
Landscape
inclined
roof
Flat roof
2
X = 10m
X = 10m
X = 10m
X = 5m
-
-
3
Max. 5 metres
Please note: All maximum distances X are under the
condition that the connecting pipework between the
individual collectors does not exceed the 5 metres !
X
Two collectors required, up to a maximum of three allowed.
DBU
Max. 5 metres
X
DBU
Note: When fitted the collector must
be level, i.e. within 2 mm per metre
Pipe inlet
position
Pipe inlet
position
Min. 20° angle
Min. 30° angle
Portrait
Landscape
Fig. 7
b.
Positioning of a landscape collector onto a flat roof: Using the flat roof kit, 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.
Two collectors required,
up to a maximum of three allowed
Ensure that all external pipework
is insulated with high temperature insulation.
Minimum decline of
40 mm per metre required
Max. 4 m
Roof
The collector must always be able
to fully drain back, therefore the
lowest part of the collector must be
above pipes of the drain back unit.
Solar cylinder
Drain back unit (DBU)
Max.
6m
A
C
D
A
B
C
D
E
E
Preheated solar water to boiler
Cold water inlet
Warm solar heated water into the cylinder
Cool water to DBU
Cylinder drain point
B
Fig. 8
Itho CombiSolar 150 page 11
4 Installation
4.1 Unpacking
The CombiSolar 150 system is supplied in three boxes as follows:
Box 1 - Solar cylinder contents include:
Solar cylinder
Inlet pipework assembly
Temperature/pressure relief valve with discharge pipe
Cylinder pump
Cylinder stand
Control box
3-way diverter valve and fittings
Fitting instructions
Instructions
Data label
Box 2 - Drain back unit contents include:
Housing and drain back unit pump
Screw pack
Cable set for collector temperature sensor
Solar cylinder
and stand
Box 3 - Unvented kit contents include:
Cold fill manifold assembly
(includes - 3.0 bar pressure reducing valve/inlet filter and 6 bar pressure relief valve/check valve)
12 litre expansion vessel, pre charged to 3.0 bar
Fig. 9 - Box 1
Expansion vessel mounting bracket
Tundish
Fitting instructions
The following items are also required to complete the installation:
1.
Data Label
Solar collectors:
or Portrait.....................................................................................Part No. 602-0023
Landscape...............................................................................Part No. 602-0024
2.
Solar collector mounting kits:
a.
Pitched roof collector flashing kits - portrait 2 to 3 panels, landscape 2 panels.
Portrait left hand (PL)..............................................................Part No. 604-0101
Portrait right hand (PR)............................................................Part No. 604-0103
Portrait middle (PM).................................................................Part No. 604-0102
Landscape left hand (LL).........................................................Part No. 604-0105
Landscape right hand (LR)......................................................Part No. 604-0106
b.
Flat roof collector mounting kit, landscape only (2 off)............Part No. 604-0110
c.
On-Roof mounting kits for either Portrait or Landscape panels are available as
follows:
On-Roof basic kit.....................................................................Part No. 604-0111
On-Roof slate kit......................................................................Part No. 604-0112
On-Roof tile kit.........................................................................Part No. 604-0113
The basic kit is always required whether a slate or tile kit is selected.
Drain back unit
Fig. 10 - Box 2
3.
Combination boiler and flue.
Note: If the boiler is not Solar compatible, a thermostatically controlled mixing valve will be required.
4.
Thermostatically controlled mixing valve for hot water outlet.
5.
High temperature 15 mm pipe insulation (150°C plus).
6.
15 mm copper pipe and compression fittings with high temperature mounting brackets.
4.2 Location and clearances required
Refer to Section 3.4, 3.5 and 3.6 before locating the solar cylinder, drain back unit and solar collector.
4.3 Fit the collector and mounting structure (flashing kits or flat roof frame)
Refer to installation instructions supplied with the solar collector mounting kit to install the collector.
4.4 Fit the solar cylinder
The cylinder must be installed on a flat surface which is capable of supporting the weight of the full cylinder (see Sections
2.3 and 3.4).
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.
Itho CombiSolar 150 page 12
4.5 Fit the drain back unit (DBU) - Fig. 11
The DBU may be fitted at an angle of 55 to 90° in relation to the horizontal. If it is fitted vertically only the top two fixings need
be used, any other angle and all four fixings must be used. Drilling template, screws and plugs are supplied with the unit.
Using the template supplied will ensure the correct positioning of the fixing holes.
1.
Decide upon the position of the DBU, taking into account the clearances required around the unit, see Section 3.5,
Positioning and Fig. 6.
2.
Using the template supplied, mark the position of the fixings, then drill and plug the holes - ensure they are level.
If using only the top fixings, fit two of the screws supplied with the heads about 5 mm proud so that they will locate in
the keyhole slots on the fixing bracket.
3.
Remove the front cover of the DBU (it is a push fit).
4.
Offer the DBU into position and hang it on the two fixing holes.
If the four fixings are to be used, support the unit while fitting the bottom two screws.
5.
The DBU is pre-filled with the exact amount of water required.
6.
Connect the pipework from the collector to the DBU connections as detailed in Section 3.5, Fig. 6.
Note: All pipework from the collector
must always slope down towards the
drain back unit ( at least 40 mm per metre).
There must not be any part of the pipework
that will allow water to collect.
340
290
DBU centreline
Fixing holes
Use top two when fitted vertically
and all four when fitted at an angle
300
90°
Position of drain back unit
to be between 55° and 90°
55°
DBU
DBU
Fig. 11
4.6 Fit the unvented kit
1.
Unpack the box and check the contents.
2.
Locate the expansion vessel mounting bracket in a suitable position as close to the cylinder as possible and secure in
position with the screws and wall plugs provided. It may be vertical or horizontal.
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 3.0 bar. If it is not, adjust the pressure to give 3.0 bar. Check when
the system is not pressurised.
4.
Unscrew the plug from the cold fill manifold connection for the expansion vessel (see Fig. 12) and connect it to the
expansion vessel using the washer supplied.
The cold fill manifold can be installed either horizontally or vertically.
An inverted orientation may allow debris deposits onto the valve seating and cause the valve to malfunction.
Note: Ensure the arrow marking on the valve body is pointing in the direction of flow.
5.
Connect the mains water supply to the manifold inlet and complete the pipework. Thoroughly flush the water pipework.
Refer to Domestic hot water system, Sections 3.2 and 3.3.
Note: No isolation valve must be fitted between the manifold and the solar cylinder.
6.
Check the operation of the pressure relief valve (see Fig. 12) by turning the head anti-clockwise until it clicks. The click
is the valve lifting off its seat allowing water to escape from the system - check that this is actually happening.
Itho CombiSolar 150 page 13
Pressure reducing
valve (includes filter)
Pressure relief
valve
Mains inlet
Discharge
pipe
Expansion vessel
connection
Outlet to cylinder
Pressure gauge connection
Balanced cold water
(if required)
supply connection (if required)
Fig. 12 - Cold fill manifold
4.7 Fit the boiler
1.
It is recommended that the system is used in conjunction with a Solar compatible combination boiler. However, if it is not
Solar compatible, a thermostatically controlled mixing valve MUST BE fitted in the cold water inlet pipework.
Note: Solar compatible means the boiler is suitable for hot water above 28°C entering the cold water inlet.
Install the boiler as described in the instruction manual supplied with the boiler.
2.
Connect the outlet from the solar cylinder directly to the 3-way diverter valve and then on to the boiler cold water inlet
connection. See Figs 2 and 3.
Note: The diverter valve must be fitted within 1 metre of the
cylinder control box.
It is recommended that a thermostatic mixing valve is fitted in the
hot water outlet before the taps.
Note: Ensure the pipework is connected correctly to the diverter
valve. See Fig. 13.
3.
The boiler hot water thermostat must be set to its maximum
position. This will ensure that the hot water temperature from the
boiler will be approximately 60°C.
From solar cylinder
Note: The User must be informed that the boiler hot water
thermostat must remain at maximum.
4.8 Connect the pipework
To gas boiler
To hot water taps
via thermastatically
controlled mixing valve
Fig. 13
1.
Thoroughly flush out all the water pipework. Ensure that all the caps are removed from the connections.
Note: If soldering union bends, ensure that the bends are not connected to the valves etc., otherwise the internal seals
may be damaged.
Do not use soldered connections between the solar collector and DBU or at the cylinder connections.
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 instruction manual.
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.
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.
Itho CombiSolar 150 page 14
4.9 Electrical connections - See Figs. 14 and refer to Wiring diagram, Section 9
The cylinder sensors (item 1 in Fig. 14b), cylinder pump (iten 2 in Fig. 14b) and the limit thermostat (item 3 in Fig. 14b) are
supplied connected to the control box.
1.
Remove the screws securing the front of the control box - hinge the bottom cover down and the top cover up to provide
access to the terminals on the control board. Refer to Section 2.7 for details of all electrical connections required.
2.
Connect the drain back unit pump(item 7 in Fig. 14b) - The drain back unit pump is fitted with a cable. Route the
cable to the solar cylinder control box. 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 (7 in Fig 14a).
Connect the collector sensor (item 6 in Fig. 14b) - The sensor has a 7 metre cable. Plug the white sensor cable into the
blue connector sensor cable and route the cable to the solar cylinder control box. Connect the White and Brown wires to
terminals 2 and 3.
Ensure that the cable is secured in the cable clamp (6 in Fig. 14a).
3.
Note: When using two or more collectors, only one sensor is connected to the control box - Connect the sensor from
the collector in the more shaded position.
4.
Connect the 3-way diverter valve motor (item 4 in Fig. 14b) - The motor cable is 1.5 metre long. Connect the cable
via the cable clamp as follows:
The Black wire to terminal 21, the Blue wire to the neutral connector block N and the Brown wire to live connector block L.
Ensure that the cable is secured in the cable clamp (4 in Fig. 14a).
Note: Fit a wire to a connector block as follows - Lever up the coloured operating lever until it clicks into the open
position, insert the stripped end (9 - 10 mm) of the wire, and return the lever back to its closed position (flush with the
connector block housing).
5.
Connect the Mains Supply (item 5 in Fig. 14b) - Refer to Section 2.7.
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 (5 in Fig. 14a). Connect the new lead as follows:
Brown wire to live connector block L, Blue wire to neutral connector block N and Green/Yellow to the earth terminal.
To fit a wire to a connector block, see paragraph 4 above.
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.
DO NOT SWITCH ON the electrical supply at this stage.
6.
Make the following connections to the control box PCB, if applicable:
Connect terminals 4 and 5 to either an Open Therm room thermostat or Remote Display. Connect terminals 6 and 7 to
the Open Therm condensing boiler, i.e. if the boiler is suitable for Open Therm connections.
15
Red
14
White
1
Cylinder sensors
2
13
12
Cylinder pump
21 22 23 24 25 26
Collector sensor 6
PE
3-way diverter 4
valve
1
2 3 4 5 6 7
3
Overheat thermostat
N L 8 9 10 11
7
DBU pump
Mains supply 5
230 V 50 Hz
Fused 3 Amp
1
2
To earth screw on
cylinder pump manifold
3
Operating lever
N N N
L L L L L
Connector block
Earth terminal
4
5
7
6
Open Therm connections
4 and 5 Open Therm room thermostat or Remote Display
6 and 7 To Open Therm condensing boiler
Note: Do not connect any other external controls
Fig. 14a
Fig. 14b
Itho CombiSolar 150 page 15
5 Commissioning
5.1 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. 15) 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.
5.2 Drain back unit
The drain back unit is supplied pre-filled with the correct quantity of water
Pump vent
screw
5.3 Turn on the electrical supply
1.
2.
Check that all the wiring has been correctly installed and that all the terminal
connections are tight.
Fig. 15
Switch on the electrical supply and the display (see Fig. 16) 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 gain at the collector the cylinder pump and the drain back unit pump will run. The drain back unit
pump runs at full speed for 400 seconds to purge any air from the collector(s) then it modulates to its optimum speed for
the collector temperature.
5.4 Control box display - Fig. 16
The controls of the solar cylinder are able to indicate working modes in 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 10.2. If the button is not touched for 10 minutes or is
held in for 5 seconds, the last mode will become active.
Display
Push button
Fig. 16
Itho CombiSolar 150 page 16
Display shown
Display explained
The control of the solar system is operating (standard mode).
The control of the solar system is not operating. The solar system will not be heating up now. The
control can be switched on/off by pressing the button. The control shall then switch from 'oN' to 'oF'.
Note: Always leave the control at 'oN'.
System is at rest (no modes such as Pr, Cr, Ar or Sr, yet it is still in the 'oN' mode).
-Pre running
Any heat in the drain back unit is removed before the collector mode starts up.
Collector running
The solar cylinder operates and the collector is heated by solar energy.
After running
The drain back unit pump stops, but the system pump will operate to remove the last amount of heat
from the drain back unit, transferring it to the solar cylinder.
Stagnation running
When the solar cylinder is not operating the collector temperature can be very high, the system pump
will operate to cool down the drain back unit before starting the drain back unit pump.
Temperature of the domestic hot water in the cylinder
During normal operation the display will alternate to show the temperature (°C) of the domestic hot
water in the cylinder for 4 seconds, the operating mode (oN/oF) for 2 seconds and the system mode
(--, Pr, Cr, Ar, or Sr) also for 2 seconds.
Interruption code
with flashing dot in
right hand corner
of the display
An interruption code (71 to 84) may be displayed together with a flashing dot in the right hand corner
of the display. Refer to Section 10.1.
Complete the details of the boiler installation in the Checklist in Section 11.
5.5 User information
The User must be advised (and demonstrated if necessary) of the following important points:1.
How to turn the CombiSolar system on and off. It is recommended the system is always left on.
2.
Explain what information is shown in 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.
4.
Weekly cleaning of shower heads and emptying shower hoses after use.
5.
To avoid scalding - if a thermostatic blending valve is not fitted, take due care and attention, especially with children and
older people, when running a bath.
6.
Ensure the Checklist in Section 11 has been completed after the unit has been installed and commissioned.
7.
Leave the instruction manuals with the User for use on future calls and for recording details in the Inspection History
Section 13.
Itho CombiSolar 150 page 17
6 System operation
6.1 Working principal - Fig. 17
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 plate heat exchanger. Stored domestic
hot water is pumped from the bottom of the solar cylinder through the drain back unit plate heat exchanger 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 diverter valve. If the water from the cylinder is above 60°C the 3-way diverter 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.
Note: If the combination boiler is not solar compatible, a thermostatically controlled mixing valve MUST BE fitted in the cold
water inlet to the boiler.
Collector
sensor
Solar cylinder
Combination boiler
Upper
cylinder
sensor
Solar collector
Control box
Drain back unit
DHW heat exchanger
Lower
cylinder
sensor
Thermostatically
controlled mixing
valve for non Solar
compatible boiler
DBU heat
exchanger
Cold water
to DBU
System pump
To boiler
Hot water
To hot
water taps
Hot water
from DBU
3-way diverter valve
Thermostatically
controlled mixing valve
DBU pump
Cold water inlet
from cold water fill manifold
Fig. 17
6.2 Operation of the CombiSolar system - Fig. 17
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 400
seconds and then modulate between 30% 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 16% 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.
If a fault occurs, a fault code will be visible in the display. Refer to Section 10.1 for a list of fault codes and possible solutions.
Temperature display
During normal operation the display (Fig. 16) will alternate to show the temperature (°C) of the domestic hot water in the
cylinder for 4 seconds, the operating mode (oN/oF) for 2 seconds and the system mode (--, Pr, Cr, Ar, or Sr) also for 2
seconds, after which the sequence will be continually repeated.
Itho CombiSolar 150 page 18
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 diverter valve. If the water from the cylinder is above 60°C, the 3-way diverter valve diverts the flow directly to the
taps. If the temperature is less than 60°C the valve diverts the flow through the combination boiler for further heating and
then onto the taps. 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 (Fig. 17) is controlled by the PCB in the control box. The collector water is circulated in a closed
loop through the collector panel(s) 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.
Limit thermostat
In the unlikely event the temperature of the stored water in the solar cylinder reaches 90°C, the limit thermostat (see Fig. 3)
will operate and switch off the collector pump. If this happens the limit thermostat will need to be manually reset by pushing
its reset button.
Itho CombiSolar 150 page 19
7 Routine inspection
To ensure efficient operation of the CombiSolar 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 label for the cylinder is located on the side of the cylinder housing. The data label for the drain back unit is located
on the top of the front cover. Refer to Figs. 9 and 10.
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 prior to 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 drain valve (Fig. 2, item 9) 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 fitted to the cold fill manifold, see
Fig. 12 and 18 and Section 8.5.
5.
Check the operation of the pressure 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 label for the cylinder is located on the side of the cylinder housing. The data label for the drain back unit is located
on the top of the front cover. Refer to Figs. 9 and 10.
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 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.
8.2 Expansion vessel
Drain the cylinder as described in Section 8.1. Loosen the vessel clamp and unscrew the vessel from the cold fill
manifold assembly while holding the manifold with a spanner to prevent damaging the mains pipe. Reassemble in
reverse order with a new vessel and washer.
8.3 Temperature and pressure relief valve
Isolate the electrical supply before removing the casing. Drain the cylinder as described in Section 8.1. Remove the four
plastic pins securing the top cover and remove the cover. Remove the insulation around the valve to expose its connections.
Undo the 15 mm copper discharge pipe from the valve and undo the valve from the cylinder and remove. Unscrew the
adapter from the old valve and fit it to the new one using a suitable joint sealer. Reassemble in reverse order.
8.4 Cylinder manifold assembly
Drain the cylinder as described in Section 8.1. Disconnect the power cable from the pump and the earth lead from the
manifold assembly and unplug the limit 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.
Itho CombiSolar 150 page 20
8.5 Pressure reducing valve and cartridge filter
Drain the cylinder as described in Section 8.1. Unscrew the adjusting
screw to decompress the spring and carefully remove the plastic cover
using a suitable spanner. Extract the cartridge using long nosed pliers to
grip the head of the set screw then withdraw the filter. Clean the filter and
cartridge under clean running water.
If the filter or cartridge are damaged replace them.
Re-assemble in reverse order. Refill and check for leaks.
If it is necessary to recalibrate the pressure reducing valve use a suitable
Allen key to turn the adjusting screw in the centre of the plastic cover.
Rotate it anti-clockwise to reduce the pressure.
Adjusting screw
8.6 Cold fill manifold assembly
The manifold assembly includes the pressure reducing valve and the
pressure relief valve.
Drain the cylinder as described in Section 8.1. Unscrew the two mains pipe
connections and the discharge pipe connection, then unscrew the manifold
from the expansion vessel. Fit the new manifold in the reverse order using a
new washer. Open a hot tap to vent any air from the cylinder.
Note: The pressure reducing valve on a new manifold is set to 3.0 bar.
Cartridge
Filter
8.7 Cylinder pump
Drain the cylinder as described in Section 8.1. Remove the terminal cover on
the pump and remove the supply lead from the terminals. Unscrew the two
5 mm bolts and remove the pump head. Fit the new head and reassemble
in reverse order.
8.8 Cylinder temperature sensors
Isolate the electrical supply before removing the casing. Remove the four
plastic pins securing the top cover and remove the cover. Remove the
four plastic pins from the bottom cover to enable the centre cover to be
unwrapped from the insulation, the joint where the centre cover overlaps
is stuck with double sided tape and will need to be peeled apart.
Fig. 18
The sensors are located in two insulated pockets in the side of the
insulation behind two polystyrene plugs. Carefully cut the tape securing
the plugs and remove them, peel the sensors from the cylinder and feed them out through the bottom cover. Undo
the two screws on the control box cover to expose the PCB and unplug the sensor leads from their plugs, loosen the
gland nut and remove the wires. Feed the new sensor leads through the gland and plug them into their corresponding
coloured sockets and tighten the gland. Feed the sensors up through the bottom casing and fit them to the cylinder with
using the tape supplied making sure they are in the correct location. Reassemble in reverse order.
8.9 Control box PCB - refer to Section 9
Remove the screws securing the control cover and open 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.
8.10 Drain back unit pump - Fig. 19
Note: Care must be taken when carrying out repairs to the drain back unit as it reaches very high temperatures and can
emit steam from connections when being removed.
Isolate the electrical supply before removing the front cover of the unit (it is a push fit). Place a bucket under the drain
point (see Fig. 19) open the valve to drain (the unit contains just under 10 litres).
Disconnect the pump electrical lead and undo the two pump union nuts then withdraw the pump.
Fit a new pump and sealing washers and re-assemble in reverse order.
To fill the drain back unit
1. Unscrew the level point cap from the fitting in the flow pipe above the pump (Fig. 19).
2. Fill using standard domestic water via the level point with a funnel and hose.
3. Carefully fill the drain back unit until water overflows from the fitting in the pipe above the pump. This indicates the
correct fill level has been reached.
Note: Do not overfill.
4. Replace the level point cap to the fitting in the pipe above the pump and ensure the area around the pump is dry.
Itho CombiSolar 150 page 21
5. Switch on the electrical supply and 'start up' the
CombiSolar system as described in Section 5.3.
Fill/Overflow
point
6. Check for any leaks and replace the front cover.
Fill level
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.
8.11 Limit thermostat
Isolate the electric supply. The limit 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.
Pump vent screw
(in centre of pump)
8.12 Limit thermostat plug and lead
Isolate the electrical supply. Remove the screws
securing the control box 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.
Drain point
Fig. 19
8.13 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.
8.14 Drain back unit heat exchanger
Note: Care must be taken when carrying out repairs to the drain back unit as it reaches very high temperatures and can
emit steam from connections when being removed.
Isolate the electrical supply before removing the front cover of the unit (it is only a push fit). Place a bucket under the
drain point (see Fig. 18) open the valve to drain (the unit contains just under 10 litres).
Drain the water from the cylinder as described in Section 8.1. Undo the four pipe connections on the heat exchanger
and remove the heat exchanger (it may be necessary to cut the plastic retaining strap). Reassemble in reverse order
using new sealing washers and refill the drain back unit (refer to Section 8.10). Close cylinder drain valve and refill
cylinder and check for water tightness.
8.15 3-way diverter valve motor
Isolate the electrical supply. Remove the screws securing the control box cover and remove the cover. Disconnect the
diverter valve motor cable connections and remove the cable. Remove the motor from the diverter valve body.
Fit the new motor and reassemble in reverse order ensuring all electrical connections are made correctly. Refer to wiring
diagram in Section 9.
Itho CombiSolar 150 page 22
9 Wiring diagram
Upper Cylinder Sensor
Br - Brown
Bk - Black
Bl - Blue
W - White
G/Y - Green/Yellow
Lower Cylinder Sensor
Cylinder
Pump
88
RED
Br
W
15
Br
W
14
WHITE
Bl
Br
G/Y
Bl
13
Br
Br
12
21 22 23 24 25 26
Br
Limit
Thermostat
(manual reset)
Br
G/Y
DBU
Pump
G/Y
N L 8 9
23 4 5 6 7
1
W
Br
Bl
Br
Bl
Br
Br
G/Y
Bl
Collector Sensor
Bk
Br
Bl
Open Therm connections
4 and 5 Open Therm room thermostat or
Remote Display
6 and 7 To Open Therm condensing boiler
Note: Do not connect any other external
controls
Br
Bl
3-way Diverter
Valve
G/Y
Mains supply
230/240 V ~ 50 Hz
Fused at 3 A
N N N L L L L L
Connector Blocks
10 Diagnostics and fault codes
10.1 Fault codes
The solar system is fully controlled by the electronic control on the cylinder. Fault codes (71 to 84) will be shown in the
display (Fig. 15) together with a flashing dot in the right hand corner of the display. The following codes can be displayed.
Itho CombiSolar 150 page 23
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 10.3).
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 disappear 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 10.3).
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
Check water level in drain back unit.
Check limit 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 10.3).
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.
Collector temperature too high
Check the level of water in the drain back unit. Refer to filling procedure in Section 8.10.
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 10.3).
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.
Code 75
Codes 82, 83 and 84: These are communication faults between Open Therm compatible boiler and room thermostat.
Code 82
Check the electrical connections between the solar control and the boiler.
No communication with Open Check the boiler is operating correctly.
Therm boiler
Code 83
Check the electrical connections between the solar control and the boiler, and between the
boiler
and room thermostat.
No communication with Open
Therm room thermostat
Check the room thermostat is operating correctly.
Code 84
No communication with
Open Therm boiler and room
thermostat
Check the electrical connections between the solar control and the boiler, and between the
boiler and room thermostat.
Check the boiler and room thermostat are operating correctly.
Itho CombiSolar 150 page 24
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.
Display
Item being diagnosed
Value of item being diagnosed
Software version
S0
00 - 99
Frost protection
D0
Cb (Collector protection), 00 means collector protection is in off mode
Mode
D1
oF or oN
Collector temperature
D2
00 - 99 (°C). Above 99°C the value will flash, i.e. flashing 05 indicates 105°C
Upper cylinder temperature
D3
00 - 99 (°C)
Lower cylinder temperature
D4
00 - 99 (°C)
Aux heat source temperature
D5
-- or 00 - 99 (°C)
Drain back unit pump speed
D6
00 - 99 (%)
Cylinder pump speed
D7
00 - 99 (%)
Diverter valve
D8
-- or 0 = not fitted, 1 = Solar collector, 2 = Aux heat source
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)
0
32.15
35
6.53
70
1.75
5
26.31
40
5.33
75
1.48
10
19.86
45
4.37
80
1.26
15
15.89
50
3.60
85
1.07
20
12.49
55
2.99
90
0.92
25
10.00
60
2.49
95
0.79
30
8.06
65
2.09
100
0.68
Itho CombiSolar 150 page 25
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 relief valve and expansion valve fitted and discharge tested?
Yes
What is incoming static cold water pressure at the inlet to the pressure reducing valve?
Has strainer (if fitted) been cleaned of installation debris?
Yes
What is the pressure reducing valve setting (if fitted)?
No
bar
No
bar
Where is the pressure reducing valve situated?....................................................................................
Has the expansion vessel or internal air space been checked?
Yes
No
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING:
The hot water system complies with current Building Regulations
Yes
The appliance and associated equipment has been installed and commissioned
in accordance with the manufacturer's instructions
Yes
The operation of the appliance and system controls have been demonstrated to the customer
Yes
The manufacturer's literature has been left with the customer
Yes
COMMISSIONING ENGINEER'S NAME:
Print........................................................................
Sign.........................................................................
Date........................................................................
Itho CombiSolar 150 page 26
12 Parts list
5
10
8
3
12
11
4
Unvented kit
3
14
Collector
6
18
Solar cylinder
1
20
9
13
3-way diverter valve
15
2
Ref. Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Cylinder pump
PCB
Set of 2 cylinder temp. sensors & plug
Housing - cylinder
Top cover - cylinder
Bottom cover - cylinder
Manifold seal kit
Temp./press. relief valve - 90°C/7 bar
3-way diverter valve motor
Expansion vessel - 12 litre
Cold fill manifold assembly
Tundish
3-way diverter valve - body only
Collector temperature sensor kit
Drain back unit pump
Drain back unit heat exchanger
Drain back unit front cover
Limit thermostat
3-way diverter valve 15mm fittings kit
Manifold and pipework assembly
16
Drain back unit
Control box
Qty. Part No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
106-0499
106-1237
106-0497
106-0737
106-0736
106-0738
106-0495
106-1221
106-1235
106-1245
106-1223
106-1224
106-1234
106-0719
106-0985
106-1199
106-1225
106-1226
106-1236
106-1227
Ref. Description
-
Qty. Part No.
Collector temperature sensor lead
1
Plug and lead - overheat thermostat
1
Collector hoses & fittings - DBU to collector 2
HT pipe insulation pack - DBU to collector
1
10
Clips - cylinder to manifold
Foam seal - hose entry
1
Screw pack - DBU
1
Screw pack - flashing kit
1
Bolt/washer pack - collector to flashing kit
1
12 m collector temp sensor/pump ext. lead kit 1
Drain back unit pump lead
1
Floor standing frame assembly
1
1
Immersion boss plug and seal
Pressure reducing valve cartridge and filter 1
Note: Item 11 - Cold fill manifold assembly, includes a pressure reducing valve (3.0 bar) and a pressure relief valve (6 bar)
Itho CombiSolar 150 page 27
106-1228
106-1229
106-0801
106-0799
106-0668
106-0800
106-0812
106-0796
106-0797
106-0491
106-1230
106-0966
106-0882
106-1231
13 Inspection history
Details of CombiSolar installation
It is recommended your CombiSolar 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:............................................................... DBU Serial Number...................................................
Details of system inspection history
Date of Inspection
Details of Inspection
Engineer, Company, Tel. No.
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This manual has been carefully prepared but we reserve the right to alter the
specification at any time in the interest of product improvement. © Itho 2011.
Itho UK Ltd.
10 Faraday Court
T 0845 250 8090
First Avenue, Centrum 100
F 0845 250 8091
Burton on Trent
E [email protected]
Staffordshire DE14 2WX
I
www.itho.co.uk
itho
Climate for life
10/11/D271
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