Alpha SolarSmart 100 User guide

Installation and Servicing
Instructions
Alpha SolarSmart 100
Pre-Heat Drain Back Solar System and Wall Mounted
Unvented Hot Water Solar Cylinder
for use with an Alpha Combination Boiler
Leave these instructions with the User
SOLAR Key Mark Certificated
These instructions have been carefully prepared but we reserve the right
to alter the specification at any time in the interest of product improvement.
© Alpha Therm Limited 2014.
Part No. 1.032744 ST15.000233
0314/D337
Alpha Therm Limited
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
For Technical help or for Service call ...
ALPHA HELPLINE Tel: [phone]
email: [e-mail]
website: www.alpha-innovation.co.uk
Also includes User's instructions at back

2
To comply with Building Regulations Part L1 (Part 6 in Scotland) the system should be installed in accordance with the
manufacturer’s instructions. Self-certification that the system has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Checklist at the back of these instructions
Code of Practice
For the installation, commissioning and servicing of domestic heating and hot water products.
Benchmark places responsibilities on both manufacturers and installers*. The purpose is to ensure that customers** are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with
the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building
Regulations. Installers are required to carry out work in accordance with the following:
Standards of Work
• Be competent and qualified to undertake the work required.
• Install, commission, service and use products in accordance with the manufacturer's instructions provided.
• Ensure that where there is responsibility for design work, the installation is correctly sized and fit for purpose.
• Meet the requirements of the appropriate Building Regulations. Where this involves notifiable work be a member of a
Competent Persons Scheme or confirm that the customer has notified Local Authority Control (LABC), prior to work
commencing.
• Complete all relevant sections of the Benchmark Check list/Service Record when carrying out commissioning or
servicing of a product or system.
• Ensure that the product or system is left in a safe condition and, where possible, in good working order.
• Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing
work.
• Refer to the manufacturer's helpline where assistance is needed.
• Report product faults and concerns to the manufacturer in a timely manner.
Customer Service
• Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request.
• Give a full and clear explanation/demonstration of the product or system and its operation to the customer.
• Hand over the manufacturer's instructions, including the Benchmark Checklist, to the customer on completion of an
installation.
• Obtain the customer's signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of
manufacturer's instructions.
• Advise the customer that regular product servicing is needed, in line with manufacturers' recommendations, to ensure
that safety and efficiency is maintained.
• Respond promptly to calls from a customer following completion of their work, providing advice and assistance by
phone and, if necessary, visiting the customer.
• Rectify any installation problems at no cost to the customer during the installer's guarantee period.
* The use of the word "installer" is not limited to installation itself and covers those carrying out installation, commissioning and/or servicing of heating and hot water
products, or the use of supporting products (such as water treatment or test equipment).
** Customer includes householders, landlords and tenants.
The Benchmark Scheme is managed and promoted by:
Heating and Hotwater Industry Council (HHIC)
Camden House, Warwick Rd
Kenilworth
CV8 1TH
Telephone: [phone]
E-mail: inf[email protected]
Website: www.hhic.org.uk
BENCHMARK SCHEME
Useful contact details; Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk
Alpha Heating Innovation;
General Sales Enquiries - 0844 871 8760
Technical Helpline - 0844 871 8764
Alpha SolarSmart 100 - Benchmark Scheme

3
Alpha SolarSmart 100 - Contents/Introduction
CONTENTS
1 Introduction ........................................3
2 Technical data ...................................4
3 General information ...........................7
4 Installation .........................................13
5 Commissioning ..................................18
6 System operation ..............................21
7 Routine inspection .............................22
8 Component replacement ...................23
9 Wiring diagram ..................................25
10 Diagnostics and fault codes...............26
11 Parts list .............................................28
Benchmark Checklist
Service Record
The Alpha SolarSmart 100 system is a pre-heat drain back solar collector system which includes an unvented 103 litre
cylinder to store water heated by the solar collector. It is recommended that the system is used in conjunction with an Alpha
combination boiler fitted with the Alpha solar inlet sensor which is supplied with the system. The cylinder is fitted with a
pump, control unit, expansion vessel, safety valves and temperature sensors. A universal drain back unit (DBU) with pump,
stainless steel heat exchanger and vessel for use with one or two collectors is also supplied.
The SolarSmart 100 should be used with one or two collectors.
A tundish and 2.5 bar pressure reducing valve are supplied with the cylinder, the pressure reducing valve must be installed in
the mains inlet to the cylinder. All hot water blending valves fitted to the system must take the cold supply after the pressure
reducing valve to maintain a balanced pressure.
The solar collectors should be ideally facing South and when using two collectors (portrait only) they must both face in the
same direction. 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 and the
exposed edges are protected. The glass front and 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 lifting forks when on the original wooden pallet base.
IMPORTANT
This is in accordance with 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.
These appliances meet the requirements of IP20, 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 Alpha SolarSmart unvented hot water cylinders have 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.
1 INTRODUCTION

4
2.51
2.4
40
10
95
5
4
Aluminium
40
0.035
Aluminium
1 k
22 mm
15° Min. (75° Max.)
0.96
Same as Supporting Roof Structure
Wind Speed 25 m/s - Snow Load 1.9 kN/m2
Landscape
1170 x 2150 x 83
2.3
1030 x 2140 x 0.5
80 %
3.606
Portrait
2150 x 1170 x 83
1.7
2140 x 1030 x 0.5
79 %
3.260
2.1 DHW SYSTEM
2 TECHNICAL DATA
Alpha SolarSmart 100 - Technical Data
5.5 bar
12 bar
0.1 bar
15 mm
15 mm
103 L
8 L at 2.5 bar
2.5 bar
90°C/7 bar
6 bar
50 mm EPP
70° C
¾" BSP for 22 mm
1¼" BSP
Solar Cylinder
Max. Hot Water Working Pressure
Max. Mains Inlet Pressure (inlet of pressure reducing valve)
Min. Mains Water Pressure
Mains Inlet and DHW Outlet Connections
DBU Flow and Return Connections
DHW Cylinder Capacity
Expansion Vessel Size (pre-charge press.)
Pressure Reducing Valve Setting
Temperature and Pressure Relief Valve
Pressure Relief Valve Setting
Cylinder Case/Insulation
Max. Outlet Water Temp. (Approx.)
Tundish Connection
Immersion Heater Boss (Alpha immersion kit only)
15 mm
15 mm
6 bar
0.32 L
15 mm
22 mm
6 bar
10 L
8.8 L
50 mm EPP
Drain Back Unit (DBU)
DHW Circuit:
Flow Connection
Return Connection
Max. Working Pressure
Heat Exchanger Content
Collector Circuit:
Flow Connection
Return Connection
Max. Working Pressure
Vessel Size
Max. Filled Content
Case/Insulation
2.2 SOLAR COLLECTOR SYSTEM
Type:
Dimensions
Total Surface Area m²
Aperture Area m²
Length x Width x Thickness mm
Water Content L
Lift Weight kg
Hydraulics
Maximum Pressure bar
Absorber
Aluminium Cover and Copper Pipe
(Length x Width x Depth) mm
Spectral Selective Layer
Absorption Coefficient %
Emission f %
Glass
Transparent, Hardened - Thickness mm
Collector Housing and Frame
Material
Insulation - Mineral Wool
Thickness mm
Thermal conduction coefficient W/mk
Cover Frame
Material
Temperature Sensor
Type - PTC Ohm
Connections
Pipe connections mm
Roof Slope
Zero Loss Collector Efficiency (No)
Collector Heat Loss Coefficient (a1) W/m²k
Aperture to Gross Collector Area Ratio
Max. Wind and Snow Load
Pitched roof
Flat roof
Reference to WRC-NSF Test Procedure 1.50.220 using a 30 kW boiler. Time to reheat water store by
55°C - 25 minutes. Reheat time for 70% of store - 18 minutes
Note: Copper or Stainless Steel pipe MUST
be used between the cylinder, drain back
unit and collector. Solder connections
MUST NOT be used on the circuit between
the drain back unit and the collector

5
Alpha SolarSmart 100 - Technical Data
2.5 GENERAL2.4 ELECTRICAL
Supply
External Fuse
Power Consumption Max./Min.
230/240 V ~ 50 Hz
3 A
130 W / 5 W
Solar Cylinder Min. Clearances for Servicing Top
Bottom
Sides
Front
DBU Min. Clearances for Servicing Top
Bottom
Side
Front
Lift Weight - Cylinder Assembly
Lift Weight DBU
Weight Full and Operational - Cylinder Assembly
Weight Full and Operational - DBU
2.3 INSTALLATION
100 mm
300 mm
10 mm
450 mm
100 mm
100 mm
10 mm
450 mm
36 kg
10 kg
140 kg
19 kg
2.6 LOCATION
1013 mm
596 mm
567 mm
573 mm
400 mm
245 mm
Stainless Steel
Stainless Steel
EPP Foam
50 mm
1.62 kWh/24hr
0.65 W/litre
Zero
Zero
Steam (Water)
Solar Cylinder Dimensions Height
Width
Depth
DBU Dimensions Height
Width
Depth
Solar Cylinder - Material
DBU Heat Exchanger - Material
Covers/Insulation Material
Solar Cylinder Insulation Thickness
Standing Energy Loss of Solar Cylinder
Global Warming Potential
Ozone Depletion Potential
Insulation Blowing Agent
The collector installation must be carried out using the kits and connections supplied by Alpha. A maximum of two collectors
can be connected together using the additional collector connection kit.
The DBU should be positioned as close as possible under the solar collector. To enable the system to drain back correctly,
the top of the DBU must be below the bottom of the collectors with a continuous fall to the DBU connections. The pipework
between the collector and DBU can be extended according to the table in Fig. 6, maintaining a maximum vertical distance of
4 m using stainless steel or copper pipe and no soldered joints.
The pipework between the solar cylinder and DBU can be extended to a maximum of 10m, 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.

6
2.7 SOLARSMART 100 SYSTEM SCHEMATIC
Alpha SolarSmart 100 - Technical Data
Fig. 1
1 Solar collector
2 Collector temperature sensor
3 Drain back unit (DBU)
4 DBU pump
5 DBU heat exchanger
6 Solar cylinder
7 Control unit
8 Temperature sensors
9 Solar cylinder pump
10 Temperature and pressure relief valve
11 Expansion vessel
12 Immersion heater boss (use Alpha immersion kit only)
13 Drain point for cylinder
14 Pressure relief valve
15 Inlet filter
16 Pressure reducing valve
17 Tundish
18 Isolation valve
19 Boiler inlet sensor
Cold water inlet
Hot water
from DBU
Cold water
to DBU
Alpha InTec boiler
2
1
6
4
3
5
10
11
13
17
18
16
19
14
12
15
8
8
7
9
Warm water
to boiler inlet
Cold water supply if using
thermostatic mixing valve
Hot water
to taps
Thermostic
mixing valve
(recommended but
not supplied)

7
3.1 ELECTRICAL SUPPLY
The Solar system requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A - The system must be earthed.
There must only be one common isolator, providing complete electrical isolation, for the Solar system.
This system has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not
less than 0.75 mm² (24 x 0.2 mm) to BS 6500 Table 16. The system should be connected to a fused three pin plug and
unswitched shuttered socket outlet (both complying with BS 1363), or a fused double pole switch with a contact separation of
at least 3 mm in both poles.
Note: There is no electrical connections between the boiler and the Solar system. Therefore, it is recommended that the
Solar system electrical isolation is completely separate to the boiler and any external controls isolation.
All wiring must be in accordance with the current IEE Wiring Regulations (BS 7671).
3.2 DOMESTIC HOT WATER SYSTEM
Ensure that the cold mains and hot water pipes do not have any dead legs of pipework.
The mains water supply must be first connected to cold fill isolation valve and pressure reducing valve supplied with the
system. The incoming mains water pressure to the cylinder is then regulated to 2.5 bar by the pressure reducing valve.
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,
any cold connections to mixing and thermostatic type taps and showers must be taken from the solar cold feed after the pressure
reducing valve to balance the pressure and prevent any back feeding into the solar system.
The boiler inlet sensor supplied with the solar system should be connected to the boiler control panel (low voltage terminals
8 and 9) and the sensor clipped to the boiler inlet pipe to measure the temperature of the incoming solar water and give
better control of the outlet temperature and boiler efficiency.
Note: The hot water control thermostat on the combination boiler must always be turned to maximum.
To ensure economic use, the pipe runs to the combination boiler and taps should be in 15 mm copper pipe and be as short
as possible. Where possible the pipework should be insulated to reduce heat loss.
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. 1.
If required for electrical backup heating, an optional immersion heater kit is available, Part No. 3.023153.
3.3 UNVENTED HOT WATER STORAGE SYSTEM
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 are pre-formed and
factory fitted to the cylinder.
Tundish - The tundish supplied must be connected underneath the cylinder, as shown in Fig. 1, 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.
3 GENERAL INFORMATION
Alpha SolarSmart 100 - General Information
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.
Resistance created
by each elbow
or bend
0.8 m
1.0 m
1.4 m
Maximum resistance allowed,
expressed as a length of straight
pipe (i.e. no elbows or bends)
up to 9 m
up to 18 m
up to 27 m
Minimum size of discharge
pipe 'D2' from tundish
22 mm
28 mm
35 mm
Minimum size of discharge
pipe 'D1' to tundish
15 mm
Valve
outlet size
G½
Sizing of copper discharge pipe 'D2' - refer also to Fig. 2 and 3

8Alpha SolarSmart 100 - General Information
Fig. 3
c. Termination into a hopper
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.
b. High level termination
D1
D2
300 mm
minimum
Tundish
Type 'A'
air gap
End of pipe to be
clearly visible
300 mm
minimum
100 mm max.
70 mm min.
Gulley if
available
Pipe close to wall to
allow water to fan
out safely
Ground level
D2
D1
a. Low level termination
Worked example:-
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 7:-
Maximum resistance allowed for a straight length of 22 mm copper discharge pipe
(D2) from a G½ temperature relief valve is 9 m.
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.
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.
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.
Fig. 2

9
Alpha SolarSmart 100 - General Information
3.4 SOLAR CYLINDER DESCRIPTION - Figs. 4
Positioning
The SolarSmart 100 cylinder must be installed on a flat vertical wall which is capable of supporting the weight of the cylinder
when full (140 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 utilizing mains electricity.
The bottom of the solar cylinder must be located within 6 metres vertically of the top of the drain back unit.
Dimensions
The dimensions of the cylinder and clearances required for servicing are shown in Fig. 4.
Fig. 4
Cylinder Connections
A Water outlet to boiler 15 mm
B Cold water inlet 15 mm
C Return from DBU 15 mm
D Flow from cylinder to DBU 15 mm
Water connections
The connections at the bottom of the cylinder are shown in Fig. 4.
Note: Use compression fittings only on the cylinder connections. Use a minimum of 1 metre of copper pipe from the cylinder
for the domestic water inlet and outlet connections.
As it is a requirement that the discharge pipe must fall at least
300 mm directly from the tundish we recommend that it is
moved towards the rear wall using a suitable length of 15 mm
pipe and a ½" to 15 mm adaptor.
1013
A B CD
280.5 165.5
50
65
50 50
10 10
596
1145
20
563
280
4
Tundish
(as supplied)
100
300
450

10 Alpha SolarSmart 100 - General Information
3.5 DRAIN BACK UNIT (DBU) INFORMATION - Fig. 5
Positioning
The DBU must be located below the solar collector bottom edge by no more than 4 m vertically to enable the pump to
circulate the water around the collector. The pipework from the collector to the DBU must fall continuously by a minimum of
40 mm per metre to allow the water to drain back into the DBU.
The pipework must be insulated with high temperature insulation.
Dimensions
The dimensions of the DBU and clearances required for servicing are shown in Fig. 5.
Fig. 5
DBU Connections
A Return from collector to DBU 22 mm
B Flow from DBU to collector 15 mm
C Flow from cylinder to DBU 15 mm
D Return to cylinder from DBU 15 mm
AB
CD
110 150 140
110 150 140
10 10
573
125
20
245
450
100
100
Water connections
The connections at the top and bottom of the DBU are shown in Fig. 5.
Note: Use copper pipe and compression fittings only on the pipework between the DBU and solar collector.

11
Alpha SolarSmart 100 - General Information
3.6 SOLAR COLLECTOR INFORMATION
The solar collectors are certified and are in compliance with the Solar Keymark Standard. They can be mounted on all roof
types with the use of the appropriate fixing kits available.
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 between 15° and 75° 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.
One solar collector is required, upto a maximum of two collectors can be installed using one of the following methods:
a. Integration of the collector into the tiles of a pitched roof.
Using the Alpha In Roof Flashing kit (portrait or landscape) 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 15° and the tiles used with the flashing kit must
be suitable to ensure that the installation is weatherproof. Full details of this type of installation are provided in the
instructions supplied with the kit.
Note: When using two panels only a portrait flashing kit is available. If two landscape panels are used then use two
individual flashing kits or two On Tile kits.
Fig. 7 - Portrait
Fig. 6
DBU
X
Portrait Portrait
Landscape Landscape
Flexible
connectors
For one collector X max. = 12 m
For two collectors X max. = 8 m
Min. 15° angle
Note: When fitted the collector must
be level, i.e. within 2 mm per metre
Pipe inlet position
Pipe outlet position
Sensor pocket

12 Alpha SolarSmart 100 - General Information
Fig. 9
Fig. 8 - Landscape
b. Collector mounted on a pitched roof.
Using the Alpha On Tile Kit portrait or landscape collectors can be mounted on a pitched roof as shown in Fig. 8. The
roof must have an inclination of more than 15°. Full details of this type of installation are provided in the instructions
supplied with the kit.
Full details of this type of installation are provided in the instructions supplied with the kit.
The collector temperature sensor supplied must be fitted into the sensor pocket on the collector (see Figs. 7, 8 and 9) and
the cable fed through the roof with the collector pipes.
The system should be filled and commissioned within one week of installation, to prevent heat build-up in the collector which
may damage the collector.
c. Positioning of a landscape collector onto a flat roof.
Using the Alpha Flat Roof Kit, the collector is mounted on the framework supplied. The collector is fixed at an inclination of
30° and ballast or fixings must be used to secure the frame in the required position. Refer to Fig. 9 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.
Full details of this type of installation are provided in the instructions supplied with the kit.
A Preheated solar water to boiler
B Cold water inlet via isolating and pressure reducing valves
C Cool water to DBU
D Warm solar heated water into the cylinder
E Cylinder drain point
Solar cylinder
Max. 4 m
CD
Drain back unit (DBU)
Roof
Minimum decline of
40 mm per metre required
Ensure that all external pipework
is insulated with high temperature insulation.
The collector must always be able
to fully drain back, therefore the
lowest part of the collector must be
above the pipes of the drain back unit.
Only one collector required,
up to a maximum of two allowed
Max. 6 m
Sensor pocket
A
E
B
Min. 15° angle
Note: When fitted the collector must
be level, i.e. within 2 mm per metre
Pipe inlet position
Pipe outlet position
Sensor pocket

13
4.1 UNPACKING
The SolarSmart 100 system is supplied in two boxes as follows:
Alpha SolarSmart 100 - Installation
4 INSTALLATION
Fig. 10 - Box 1
The following items are also required to complete the installation:
1. Solar portrait collector............................................................................................................. Part No. 3.023011.
2. Solar landscape collector ....................................................................................................... Part No. 3.023012.
3. Portrait connection kit (sensor, flexible connection pipes and fittings) .................................... Part No. 3.023150.
4. Landscape connection kit (sensor, flexible connection pipes and fittings) .............................. Part No. 3.023151.
5. Twin collector connecting kit (fittings to connect two collectors together) ............................... Part No. 3.023152.
6. Solar collector In Roof Flashing kits :-
a. Single collector (portrait) ................................................................................................... Part No. 3.023230.
b. Twin collectors (portrait only) ............................................................................................ Part No. 3.023231.
c. Single collector (landscape) .............................................................................................. Part No. 3.023232.
7. Solar collector On Tiles kits :-
a. Single collector (portrait or landscape) ............................................................................. Part No. 3.023223.
b. Twin collectors (portrait or landscape) .............................................................................. Part No. 3.023241.
8. Solar collect On Slates kits :-
a. Single collector (portrait or landscape) ............................................................................. Part No. 3.023224.
b. Twin collectors (portrait or landscape) ............................................................................. Part No. 3.023243.
9. Single Flat Roof Frame kit (landscape only) ........................................................................... Part No. 3.023229.
10. Alpha combination boiler, flue and thermostat control.
11. Thermostatic mixing valve.
12. High temperature 15 mm pipe insulation (150°C plus).
13. Pipe securing clips - it is important that all pipework is supported and a fall maintained between the collector and drain
back unit.
Fig. 11 - Box 2
Solar cylinder
Mounting bracket
Control panel
Case fixing
screws
Data label
Box 1 - Solar cylinder
Contents: Solar cylinder with case and control panel
Wall mounting bracket and Screw pack
Wall template
Pressure reducing and Isolation valves
Boiler inlet sensor
Fitting instructions and Overstick label
Extension cable for collector sensor
Tundish and connection pipes
Box 2 - Drain back unit
Contents: Drain back unit
Screw pack
Wall template
Drain back
unit
Screws
Data label

14 Alpha SolarSmart 100 - Installation
4.2 LOCATION and CLEARANCE REQUIRED
Refer to Section 3.4, 3.5 and 3.6 before locating the solar cylinder, drain back unit and solar collector.
4.3 INSTALL THE COLLECTOR
Refer to installation instructions supplied with the Solar collector mounting kit to install the collector.
4.4 FIT THE SOLAR CYLINDER - Fig. 12
The cylinder must be installed on a flat vertical wall which is capable of supporting the weight of the full cylinder (see Section
2.3). The cylinder should be secured to the wall using the mounting bracket and fixings supplied.
Note: The cylinder contains an electrical pump and
consideration to noise transmission through walls and
pipes should be considered when positioning the cylinder.
1. 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 Sections 2.3 and 2.6.
2. Position the template supplied in the required position,
ensuring it is level, (note that the template includes
the minimum clearances required) and mark the
positions of the fixing holes. Drill the holes to suit the
fixing supplied or alternative fixings suitable for the
mounting surface/wall.
3. Secure the mounting bracket to the wall, using the
plugs and screws supplied.
4. Remove the two screws (top of the control panel)
as shown in Fig. 10 securing the cylinder case and
carefully pull off the case.
5. Lift the cylinder and carefully hang it onto the
mounting bracket as shown in Fig. 13
6. Adjust the cylinder on the mounting bracket until
the bottom fixing holes are lined up then secure the
cylinder to the wall with the two screws supplied as
shown in Fig. 14.
Fig. 13 Fig. 14
Bottom fixing holes and screws
Fig. 12
Template
Outline of
cylinder case
MOUNTING BRACKET
FIXING HOLES
TOP OF CASING
MINIMUM TOP CLEARANCE 100 mm
MINIMUM SIDE
CLEARANCE 10 mm
MINIMUM SIDE
CLEARANCE 10 mm
FIXING HOLES
BOTTOM OF CASING
SOLARSMART 100 CYLINDER
70
790.5
10
336
158
616
365
132.5 50 50 50 82.5 93
300
10
1400
1013
100
145 145 ==
FOR USE WITH 103 LITRES WALL HUNG UNVENTED SOLAR CYLINDER
WATER OUTLET
TO BOILER
15 mm
COLD WATER
INLET
15 mm
RETURN
FROM DBU
15 mm
FLOW TO
DBU
15 mm
MINIMUM BOTTOM
CLEARANCE 300 mm

15
4.5 FIT THE DRAIN BACK UNIT (DBU) - Figs. 15, 16, 17 or 18
The DBU must be fitted vertically, the unit can secured using two fixings and its built-in wall bracket, as shown in Fig. 16
or four screws directly into the wall as shown in Fig. 17. Screws and plugs are supplied with the unit. Using the template
supplied will ensure the correct positioning of the fixing holes.
1. Decide on the position of the DBU, taking into
consideration the clearances and the maximum allowed
distances from the drain back unit and collector. Refer to
Fig. 5.
2. Position the template supplied in the required position,
ensuring it is level, (note that the template includes the
minimum clearances required) and mark the positions
of the fixing holes. Drill the holes to suit the fixing
supplied or alternative fixings suitable for the mounting
surface/wall.
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 (see
Fig. 16).
3. Remove the front cover of the DBU (it is a push fit).
Offer the DBU into position and hang it on the two fixing
holes.
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.
Alpha SolarSmart 100 - Installation
Template
Outline of
cylinder case
SOLARSMART 100
DRAIN BACK UNIT
FIXING HOLES
FIXING HOLES
SCREW POSITIONS WHEN
USING HANGING SLOTS
MINIMUM SIDE
CLEARANCE 10 mm
MINIMUM SIDE
CLEARANCE 10 mm
400 245
573
150150120
110 200 110
100
8
461
773
573
10 10
156
100
70
8015050
70280
420
Fig. 15
Fig. 17Fig. 16
Keyhole slots
Fixing holes
Fixing holes

16 Alpha SolarSmart 100 - Installation
4.6 FIT THE BOILER AND CONNECT THE PIPEWORK
1. An Alpha combination boiler should be used with the SolarSmart system. Install the boiler as described in the
instructions supplied with the boiler.
2. Connect the outlet from the solar cylinder directly to the boiler cold water inlet connection, as shown in Fig. 1.
If the boiler has a Seasonality valve fitted it must be fully opened (turn adjusting screw fully clockwise).
Notes: a. If the solar system is being fitted to an existing boiler installation, the mains water inlet must be re-routed to
the inlet of the solar cylinder.
b. It is recommended that a thermostatic mixing valve is fitted in the hot water outlet before the taps.
3. Clip the boiler inlet sensor (supplied with the cylinder) to the boiler inlet pipe as close to the boiler as possible. This
should be connected to the boiler low voltage terminals 8 and 9 (DHW inlet sensor), the polarity of the connections is
not important. Refer to the boiler wiring
diagram.
4. A self adhesive label is supplied with
the cylinder. This label must be located
adjacent to the domestic hot water
thermostat knob which must be set
to max. as shown in Fig. 18. This will
ensure that the hot water temperature
from the boiler will be approximately
60°C.
Note: The User must be informed of
the purpose of this label, which must
not be removed.
4.7 CONNECT THE PIPEWORK
Refer to Figs. 1 and 19 and the wall templates when connecting the pipework.
1. Thoroughly flush out all the water pipework.
Ensure that all the plastic caps are removed from all connections.
Note: If soldering union bends, ensure that the bends are not connected to the valves etc., otherwise the internal seals
may be damaged, (soldered connections cannot be used between the solar collector and DBU, or direct to the cylinder
connections).
2. Connect the system pipework to the boiler and the pressure reducing and isolation valves, supplied, in the mains cold
water inlet to the cylinder. See Figs. 1 and 19.
Do not forget that all pressure relief valve
discharge pipes must be routed clear of
the boiler and cylinder to a drain in such a
manner that they may be seen, but cannot
cause injury to persons or property. Refer to
Section 3.3 and the boiler instructions. Refer
to Fig. 4 when connecting to the cylinder
tundish.
This pipework must be installed as
recommended in Unvented Hot Water
Storage System, see Section 3.3.
4. Check that the pressure in the cylinder
expansion vessel (see Fig. 20) is 2.5 bar. If
it is not, adjust the pressure to give 2.5 bar.
Check when the system is not pressurised
(drained).
5. Connect the mains water supply and
complete the pipework. Thoroughly flush
the water pipework. Refer to Domestic Hot
Water System, Sections 3.2 and 3.3.
6. 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.
bar
04
3
22.5
3.5
1.5
0.5
1
CORRECT PRESSURE
WHEN COLD
RESET
INFO
RESET
BOOST
bar
°C
x100rpm
IMPORTANT
MUST
This Combi boiler is fitted to an
Alpha Solar system and the domestic
hot water thermostat always be
set at maximum
Fig. 18
Fig. 19
Water outlet
to boiler
15 mm
Cold water
inlet
15 mm
Return from
DBU
15 mm
Flow to
DBU
15 mm
Compression fittings only
Cold water
inlet filter
Tundish outlet

17
Alpha SolarSmart 100 - Installation
4.9 ELECTRICAL CONNECTIONS - See Wiring Diagram Section 9
1. If the case is not already removed, remove the two screws
(top of the control panel) securing the cylinder case and
carefully pull off the case.
The cylinder sensors and cylinder pump are already
connected.
2. Remove the two screws securing the terminal block cover to
the left of the control unit as shown in Fig. 20.
3. Connect the Drain Back Unit pump - The drain back unit pump
is fitted with a 1.9 m cable. Route the cable to the solar cylinder
control unit through the hole in the bottom of the cylinder case
(as indicated in Fig. 20) and pass it through a cable clamp.
The DBU cable can be extended if required using standard
mains 3-core flex.
Connect the Brown wire to terminal 12, Blue wire to terminal
13 and Green/Yellow wire to on the terminal block.
Ensure that the cable is secured in the cable clamp.
4. Connect the Collector Sensor - The sensor is supplied with
a 3 m cable, a 9 m extension cable is also supplied with the
cylinder.
Route the cable to the solar cylinder control box through the
hole in the bottom of the cylinder case (as indicated in Fig.
20) and pass it through a cable clamp.
Connect the White and Red wires to terminals 45 and 46 (the
polarity is not important) on the terminal block.
Ensure that the cable is secured in the cable clamp.
5. Connect the Mains Supply
The solar cylinder has been fitted with a 2.5 m mains supply
cable. However, if it is necessary to fit an alternative supply
cable refer to Section 3.1 and release the cable clamp.
Connect the new lead as follows:
Brown wire to 2, Blue wire to 1 and Green/Yellow to the earth
point using a suitable spade connector.
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.
6. Fitting the optional Alpha immersion heater
Remove the blanking plug and washer as shown in Fig. 21.
Insert the element and secure in position using a new sealing
washer.
Pass the immersion heater cable through a cable clamp and
connect the wires, Brown to terminal 69, Blue to terminal 70
and Green/Yellow to on the terminal block.
Ensure that the cable is secured in the cable clamp.
7. Replace the connector block cover but do not switch on the
electrical supply at this stage.
Immersion heater
and washer
Terminal block
and cable clamps
Fig. 21
Fig. 20
Terminal block
cover
Fixing screws
Immersion heater
plug
Pump vent screw
(under cap)
Pressure relief
valve
Pressure relief
valve
Expansion
vessel test
point (under cap)
Mains supply cable and
case entry for other leads

18
When commissioning the system, ensure the Benchmark Checklist at the back of these instructions is completed.
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 and solar pump.
Vent the cylinder using the vent point in the drain back unit as shown in Fig. 22. Vent the cylinder pump by unscrewing
the centre cap (see Fig. 20) and rotate the spindle using a small screwdriver until water runs from it and then replace
the cap. Ensure the area around the pump is dry.
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. Check the operation of the two pressure relief valves (see Fig. 20) 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.
5.2 FILL THE DRAIN BACK UNIT
1. Unscrew the level point cap from the fitting in the flow pipe
above the pump (Fig. 22).
2. Fill using standard domestic water with a funnel and hose via
the 22 mm collector return connection until the water spills
from the fill level point.
3. Carefully fill the drain back unit until water overflows from the
fill level point 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.
5. Check that all the wiring has been correctly installed and that
all the terminal connections are tight.
Switch on the electrical supply and press the On/Off button on
the control panel (see Fig. 23) to start the system.
6. Check for any leaks and replace the front cover.
7. Complete the details of the installation in the Benchmark
Checklist at the back of these instructions.
5.3 CONTROL UNIT DISPLAY - Fig. 23
The Solar cylinder is fitted with a control unit with integrated display panel and push button controls. The display indicates the
working modes of the system with symbols to indicate the working components of the complete system.
When first switched on, the display will show all the symbols as shown in Fig. 23 for 2 seconds then the system schematic
is displayed and the countdown from 70 seconds to 0 will start (see Fig. 24). During this countdown the unit 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.
When all the self-diagnostic procedures have been completed the system will start normal operation.
After the 70 second countdown the normal operating display will appear with a schematic diagram of the system and
showing two temperatures. The top value indicating the temperature at the collector sensor (S3) and the bottom value
indicating the upper cylinder sensor temperature (S1) as shown in Fig. 25.
The system can be turned on and off using the On/Off button, however we recommend that the system is left in the on
position permanently and it will control itself depending on the solar energy available and the cylinder temperature.
If there is enough solar light at the collector the cylinder pump will run, shortly followed by the drain back unit pump.
Alpha SolarSmart 100 - Commissioning
5 COMMISSIONING
Fig. 22
Filling point (22mm return connection)
Fill level
Pump
Drain point
(collector circuit)
Vent point
(cylinder circuit)
Level point cap

19
Alpha SolarSmart 100 - Commissioning
Fig. 23
S
1
S 2 3 S
S
1
S 2
3 S
Control panel
buttons
Display
On/Off
button
5.4 CONTROL PANEL BUTTONS AND DISPLAY SYMBOLS
S
1
S 2 3 S
On/Off Switches the system on and off
Increase Not used in this instance
Decrease Not used in this instance
Info Sensor temperature info:
Keep it pressed in for 1 sec. displays sensor S2 and S3,
press in once more to display sensors S1 and S3
(S3 is always the upper temperature on the display)
Button Description
Description
Function
Function
Symbol
State Decription
DBU pump
Cylinder pump
Warning
Sun
Degrees celsius
Digits
Temperature sensors
Solar cylinder
Solar collector
On
Flashing
DBU pump in standby state
DBU pump operational
On
Flashing
Cylinder pump in standby state
Cylinder pump operational
Flashing Fault code will be displayed
Flashing Solar system operational
On Unit of temperature
On Display temperature, parameters values
and fault codes
On Active sensors
On Cylinder state correct
On Solar collector state correct

20 Alpha SolarSmart 100 - Commissioning
5.5 USER INFORMATION
The User must be advised (and demonstrated if necessary) of the following important points:-
1. How to turn the SolarSmart system on and off. It is recommended the system is always left on.
2. Explain what information is shown on the display and in the unusual case of a fault occurring, explain the fault codes
that may be shown (see Section 10).
3. Show the User the position of the tundish discharge pipes
4. How important it is for the combination boiler hot water thermostat to be left at the maximum position (No. 9) and that it
is the purpose of the label (Fig. 18) to maintain this and that the label must not be removed.
5. Weekly cleaning of shower heads and emptying shower hoses after use.
6. To avoid scalding; if thermostatic blending valves are not fitted, take due care and attention, especially with children and
older people, when running a bath.
7. Ensure the Checklist at the back of these instructions has been completed after the unit has been installed and
commissioned.
8. Leave these instructions with the User for use on future calls and for recording details in the Service Record at the back of
these instructions.
Fig. 24 Fig. 25
S
1
S 2
3 S
S
1
3 S