Hamilton Engineering SOLSTREAM DCH-1000 User manual

Hamilton Engineering Company, Inc.
34000 Autry Street, Livonia, MI 48150 | hamiltonengineering.com
Ph. 734.419.0200 | Toll Free 800.968.5530 | Fax [phone]
Keep this manual with
heater for future reference.
SOLSTREAM™Complete Thermal Exchange Gas Fired Water Heater
Installation, Operation, and Maintenance Manual
Certified to
U.S. patent 5,924,391
5

Hamilton Engineering Company, Inc.
34000 Autry Street, Livonia, MI 48150 | hamiltonengineering.com
Ph. 734.419.0200 | Toll Free 800.968.5530 | Fax [phone]
Safety......................................................................................1
The SOLSTREAM™System ............................................. 2
Typical System.............................................................2
Specifications ..............................................................4
Heater ..........................................................................4
Materials of Construction.........................................4
Operational Specifications .......................................4
Technical Specifications ..........................................4
Dimensions..............................................................5
Orientation...............................................................6
Transfer Pump Assembly ..............................................8
Materials of Construction.........................................8
Dimensions and Operational Specifications .............8
Orientation...............................................................8
Storage Tank ................................................................9
Materials of Construction.........................................9
General Specifications .............................................9
Specifications by Model...........................................9
Orientation.............................................................10
Assembly and Installation................................................11
Unpacking...................................................................11
Installing Large Heaters ..............................................11
Installing Small Heaters .............................................13
Installing Exhaust Ducting .........................................15
Installing Intake Air Ducting .......................................16
Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Connection .........................................................18
Electrical Panels ................................................................ 19
Control Panel..............................................................19
Disconnect Panel ...................................................... 20
Heater Label.............................................................. 20
Electrical Connections................................................21
Top Plate to Upper Canister........................................21
Upper to Lower Canister.............................................22
Transfer Pump ............................................................23
Storage Tank ..............................................................23
Main Power Connection............................................. 24
Operation.............................................................................25
Description of Operation ............................................25
Sequence of Operation...............................................26
Pre-Start-Up Checklist...............................................27
Commissioning...................................................................28
Inspecting Installation............................................... 28
Inspecting Water System.......................................... 28
Commissioning.......................................................... 28
Periodic Maintenance ......................................................30
Maintenance Schedule.............................................. 30
High Temperature Switch Check................................31
Troubleshooting ................................................................32
Troubleshooting Table ...............................................32
PLC I/Os .....................................................................33
Parts Lists............................................................................34
Top Plate ................................................................... 34
Water Train ................................................................35
Control Box ................................................................36
Disconnect Box ..........................................................37
Fuel Train ...................................................................38
Lower Canister...........................................................39
Storage Tank .............................................................40
Appendix: Modulating Burner........................................ 41
Descriptions of the major modulation
components ...............................................................41
Operation: ................................................................. 42
Limited Warranty and Remedy..................................... 44
Notes ....................................................................................45
Contents

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 1 of 49
Solstream™Installation, Operation, and Maintenance Manual
Safety
— injury or death and property damage are imminent
— injury or death and property damage are possible
— potential property damage, expensive repairs, and/or voiding the warranty may result
Icon Legend
If instructions are not followed:
�Read this manual.
�Improper installation or operation may cause a
fire or explosion resulting in property damage,
personal injury, or death. Hamilton Engineering
strongly recommends that a qualified installer be
used.
�Service must be performed by a qualified person.
�Improper installation, start-up, operation,
maintenance, or service may void the warranty.
�Hot water or metal may cause scald burns.
Skin exposure to 140° water or metal for
only five seconds may cause a second
degree burn.
�Do not attempt to use the heater if it has
been submerged in water. Contact a
qualified service technician to inspect it
and replace compromised parts.
�Applicable codes must be followed
and supersede any other instructions.
Generally applicable codes in the US
include:
·NEC
·NFPA #86
Warning: If the information in these instructions is not followed
exactly, a fire or explosion may result causing property damage,
personal injury, or death.
· Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
· What to do if you smell gas
–Do not try to light any appliance.
–Do not touch any electrical switch; do not use any phone in your building.
–Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
–If you cannot reach your gas supplier, call the fire department.
· Installation and service must be performed by a qualified installer, service
agency, or gas supplier.
Note: Operating with any safety device bypassed will void the warranty.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 2 of 49 Typical System
Solstream™Installation, Operation, and Maintenance Manual
The Solstream™System
Hamilton's Solstream™ water heaters:
�Are designed for industrial applications
�Use complete thermal exchange technology
�Come in sizes from 1 to 16 million Btu/hr
�Heat water up to 185°F maximum
Typical System
Heater Transfer
Pump
Storage Tank
Hamilton Engineering reserves the
right to make design or specification
changes without notification.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 3 of 49 Typical System
Solstream™Installation, Operation, and Maintenance Manual
Solstream™ water heaters are highly efficient, low maintenance systems.
�Complete thermal exchange technology means no fuel is used for warm-up
or idle time and no energy is lost through conversion or exchange.
�Without internal moving parts, there is very little to maintain.
�Water conditioning is not required.
Common options:
�Gravity drain (without a transfer pump)
�Standard (consistent incoming water temperature) or
modulating burner actuator
�Natural gas or propane fuel
�Remote or integral tank
Other available options include:
�Skid-packaged heaters
�Performance matched components
�Ultra-low NOx emissions
�Non-standard fuels
�Storage tank heating element
Peripheral components:
�Digital mixing valves
�Variable frequency drive pump
�Hose stations
Optional services:
�Turn-key installation
�Installation project management
�System assessment and optimization
�Energy conservation measures (ECM)
For further information, visit http://www.hamiltonengineering.com
or contact Hamilton Engineering.
Solstream™ systems are highly customizable at both a system
and component level. The information in this manual
generally uses a 5 million Btu/hr unit and is intended to
be typical. Illustrations are not intended to be complete or
correct in every detail. System-specific drawings, including
wiring schematics, are provided with each unit and should
be referred to when installing and operating your system.
Note: Hamilton provides separate IOMs for the burner, blower, and for optional
components. Consult the appropriate document for more information.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 4 of 49 Specifications — Heater
Solstream™Installation, Operation, and Maintenance Manual
Operational Specifications
Technical Specifications
Specifications
· Solstream™ water heaters are built to UL standard 795
· May be manufactured to comply with various other electrical or water quality standards
· Three-phase power is required; most available voltages may be accommodated
*Consult factory for additional information.
Materials of Construction
Heater
Component Material
Canister 304 SS (10 ga. ≤ DCH-9000; 3/16 > DCH-9000)
Canister gasket WARCO white (food grade buna rubber)
Flame tube 304 SS
Gas piping Malleable iron with standard yellow finish
Water piping Welded stainless steel (304)
Spray ring 304/316 SS
Pall ring 304 SS
Spec English Units SI Units
Gas supply pressure 2–6 psig (optimum 4–5.5 psig) 0.14–0.41 bar (optimum 0.28–0.38 bar)
Water supply pressure 30–100 psig with ± 5 psig variation 2.07–6.84 bar with ± 0.34 bar variation
Inlet water temperature 32 °F to 120 °F 0 °C to 49 °C
Outlet water temperature 185 °F 85 °C
Water temperature differential 10 °F to 140 °F 5.6 °C to 77.8 °C
NOx emission 30–60 ppm
Thermal efficiency 99.7%

D
A
E
B
C
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 5 of 49 Specifications — Heater
Solstream™Installation, Operation, and Maintenance Manual
Dimensions
*Connections may be NPT, flanged, or use a sanitary ferrule as required.
*DCH capacity ratings are subject to a +/- 5% total output variance based on supply conditions variables and combustion requirements. If actual
installation conditions differ from those listed in the product IOM then the 5% variance may be additionally impacted.
Solstream™ Dimensions and Weights
Model
Connections Dimensions Weight btu/hr kW1 2 A B C D E
in mm in mm in mm in mm in mm in mm in mm lb kg
DCH-1000 1 25 1 25 95 2413 71 1803 39 991 24 610 8 203 825 375 1,000,000 292
DCH-1500 1 25 1 25 97 2464 73 1854 41 1041 26 660 8 203 850 386 1,500,000 439
DCH-2000 1-1/2 40 1-1/2 40 100 2540 76 1930 44 1118 30 762 10-3/4 273 1500 680 2,000,000 585
DCH-3000 2 50 1-1/2 40 100 2540 76 1930 44 1118 36 914 12 305 1600 725 3,000,000 878
DCH-5000 2-1/2 65 2 50 127 3226 97 2464 65 1651 44 1118 16 406 2500 1136 5,000,000 1464
DCH-6000 3 80 2 50 132 3353 100 2540 70 1778 47 1194 18 457 2900 1316 6,000,000 1757
DCH-7000 3 80 2 50 139 3531 107 2718 77 1956 50 1270 18 457 3200 1455 7,000,000 2050
DCH-9000 3 80 2 50 169 4293 139 3531 107 2718 60 1524 20 508 5000 2273 9,000,000 2635
DCH-10000 3 80 2 50 181 4597 151 3835 119 3023 61 1549 20 508 5200 2405 10,000,000 2928
DCH-12000 4 100 3 80 181 4597 151 3835 119 3023 61 1549 22 559 5500 2495 12,000,000 3514
DCH-15000 4 100 3 80 192 4877 161 4089 129 3277 70 1778 24 610 7000 3175 15,000,000 4392

Control Panel
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 6 of 49 Specifications — Heater
Solstream™Installation, Operation, and Maintenance Manual
Orientation
Lower
Canister
Upper
Canister
Top Plate
Blower Exhaust vent
Burner
Water
pressure
switch
Water
inlet
High temp
shut-off
switch
Level
switches
Hot water outlet
Gas inlet (behind
pipe)
Drain plug
Burner actuator
UV scanner
Anchoring tab
Disconnect
panel
Water flow
volume
adjust valve
Water inlet
valve
See next page
for Fuel Train
components

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 7 of 49 Specifications — Heater
Solstream™Installation, Operation, and Maintenance Manual
Fuel Train Components
Low gas
pressure
switch
High gas
pressure
switch
Proof of
Closure (POC)
switch
Dual blocking
valves
Regulator
Regulated
pressure
display
Visual display of
valve state
(white = closed
red = open)

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 8 of 49 Specifications—TransferPumpAssembly
Solstream™Installation, Operation, and Maintenance Manual
Transfer Pump Assembly
Component Material
Piping 304 OR 316 stainless steel
Braided flex hose Stainless steel
Pump Stainless steel (TEFC motor)
Bypass valve Stainless steel motorized butterfly valve
Globe valve Stainless steel
Stand Carbon steel (painted)
Model
Maximum
Flow Rate
Inlet
Connection
Outlet
Connection
Flow
Control
Valve
Bypass
Valve
Pump
Power
GPM m3/hr in. mm in. mm in. mm in. mm HP kW
TP-50 50 11.4 1-1/2 40 1-1/2 40 1 25 1 25 2 1.49
TP-90 90 20.4 1-1/2 40 2 50 1-1/2 40 1-1/2 40 3 2.24
TP-135 135 30.7 2 50 2-1/2 65 2 50 1-1/2 40 5 3.73
TP-200 200 45.4 2-1/2 65 3 80 2 50 2 50 7-1/2 5.59
TP-275 275 62.5 2-1/2 65 4 100 2-1/2 65 2 50 10 7.46
TP-350 350 79.5 3 80 4 100 3 80 2 50 10 7.46
Materials of Construction
Dimensions and Operational Specifications
Orientation
Water outlet
Water inlet
Pump
Throttling valve Actuated valve
Bypass

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 9 of 49 Specifications — Storage Tank
Solstream™Installation, Operation, and Maintenance Manual
Storage Tank
Design standard ASTM D49097-00
Maximum pressure Atmospheric
Vacuum None
Maximum temperature 180°F (82.2 °C)
Specific gravity 1.2
Seismic code/design None
Wind load 0 mph/kph
Immersion heater port 4" NPT
Sight glass port 1" NPT
Insulation thickness 2" (50 mm)
Component Material
Structural layer Fiber-reinforced plastic
Structural and liner resin DerakaneTM 441-400
Exterior layer resin Isophthalic polyester
Tank finish Gel coat with UV inhibitor
Color Gray (AT071)
Tank fittings Fiber-reinforced plastic
Vent Fiber-reinforced plastic
Manhole and cover Fiber-reinforced plastic
Manhole cover bolts Stainless steel
Manhole gasket EPDM
Hold down and lifting lugs Powder-coated carbon steel
Materials of Construction
General Specifications

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 10 of 49 Specifications — Storage Tank
Solstream™Installation, Operation, and Maintenance Manual
Orientation
Water inlet
Screened vent
Manway
Outlet
Outlet for immersion
heater (4" NPT)
Lower sight glass
mount (1" NPT)
(optional tank
level sensor)
Float switch mount
for low water to pump
cutoff (if used)
Thermometer
mount
Float switch mount
for heater start
Upper sight
glass mount
(1" NPT)
Float switch mount
for heater stop
Recirculation
return

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 11 of 49 Unpacking | Installing Large Heaters
Solstream™ Installation, Operation, and Maintenance Manual
Assembly and Installation
Installing Large Heaters
Unpacking
Note:
· Obvious damage should be noted on delivery paperwork.
Hidden damage must be reported to carrier within ten days.
· Cleaning heater using local plant standard is recommended
prior to installation.
· Storage tanks are typically shipped directly from vendor.
Depending on heater size and mode of shipping, one of two
scenarios may apply.
Small heaters (approximately DCH-5000 and under) when
shipped with adequate height clearance in vehicle:
· Top plate and upper canister will be attached and upright.
· A fork lift will usually be adequate for moving. Use of a
strap or chain is recommended.
Large heaters:
· Top plate will be bolted to lower canister.
· Upper canister will be on its side with top covered.
· A crane or hoist of some kind will be needed for moving.
At least two, preferably four straps or chains will be
needed.
1Stand upper canister upright and position near final
heater location.
Note: Remove cover and, if necessary, rearrange
palls until they are approximately level and do not
interfere with spray nozzles.
2Wipe off flange and place gasket on it
with holes aligned.
3Remove cable ties from wiring and unbolt
top plate from lower canister.
Note: Long bolt in blower motor bracket
must be reinstalled in that hole.

1
2
3
4
5
6
7
8
10
9
13
14
16
15
12 11
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 12 of 49 Installing Large Heaters
Solstream™ Installation, Operation, and Maintenance Manual
Note: This pattern is for
heaters with 16 bolts.
24-bolt patterns should
be tightened similarly.
4Remove top plate from
lower canister.
6Install all bolts and start
nuts. Liberal use of an anti-
sieze compound is strongly
recommended.
7
Tighten all bolts using
pattern shown or similar.
8Attach canister sections
as for a small heater
below.
5Position top plate on
top of upper canister
with holes aligned.
Attach as shown
to keep plate
approximately level.
Orient so union in fuel line
can be connected.
Note: "Gas" and "fuel" are
used interchangeably in this
document.
Note: Top plates on largest
heaters have lifting lugs.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 13 of 49 Installing Small Heaters
Solstream™ Installation, Operation, and Maintenance Manual
Installing Small Heaters
1Place lower canister in final heater position:
· On level surface
· With adequate clearances
· With adequate support for operating
weight
· With outlet facing transfer pump location
· Not near flammable or combustible
materials
2Wipe flange and gasket to remove
any dirt or debris and place gasket on
flange of canister with holes aligned.
3Move upper canister
into position over lower
canister using lift lugs.
5Lower upper canister completely, insert all bolts,
and start nuts. Liberal application of an anti-sieze
compound is strongly recommended.
18" 48"
(sides and back) (front)
Wall
To transfer
pump
4Lower carefully until a few bolts can be inserted.
Tip: Using several tapered pry bars or long
screwdrivers will aid in aligning.
Note: Control panels are typically above
standpipe (see approval drawing for actual
orientation). If slight indexing is required to align
outlet, some rewiring may be necessary between
canister sections.
6Raise entire heater slightly above floor to
allow self-aligning.

1
2
3
4
5
6
7
8
10
9
13
14
16
15
12 11
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater Page 14 of 49 Installing Small Heaters
Solstream™ Installation, Operation, and Maintenance Manual
8Lower onto floor and tighten all bolts
using pattern shown or similar.
Note: Leakage is normal pending
stress relief. Tighten applicable bolts
as required when leaks appear.
9Hamilton Engineering recommends
anchoring heater in place.
7Snug all bolts using pattern
shown or similar.
10 Repeat tightening sequence after
several hours and after a few days
of operation or as leaks occur.

Solstream™Installation, Operation, and Maintenance Manual
Page 15 of 49 Installing Exhaust Ducting
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater
Installing Exhaust Ducting
Note:
· Roof installation preferred.
· Solstream™ heater is not naturally
drafting; exhaust is under slight pressure.
· Insulation is not required because exhaust
temperature is only a few degrees above
incoming water temperature.
Install horizontal exhaust
duct sloping upward to drain
condensate in duct (1/4" per
foot is recommended).
Condensate will drip
from end of horizontal
ducting. Install where
dripping will not be a
nuisance or ice a hazard.
Connect exhaust
ducting using either
CPVC or single wall,
welded stainless
steel. Snap-together
ducting is not
recommended.
Cover external
termination with rain
guard and bird screen.
Models DCH-1000 and
DCH-1500 require a rubber
sewer connection boot to
connect. All other models
have a flange (shown).
Joint should be sealed
with RTV (clear silicone).
Exterior opening
must be at least equal
to cross section of
exhaust duct.
Heater
stack
Roof
Wall
Provide independent
support for duct. Do not
rest weight on heater.
Duct must be same size
or larger than heater's
exhaust outlet.
Hamilton
Engineering
recommends no
bend sharper
than 45°
Bird screen
installation is
recommended.

Solstream™Installation, Operation, and Maintenance Manual
Page 16 of 49 Installing Intake Air Ducting
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater
Installing Intake Air Ducting
Using outside air is recommended, especially:
·When inside air is not dust free
·When inside air is under positive or negative pressure
Alternatively, filtration may be used.
Duct diameter must be at
least as large as intake
diameter on blower. 15%
diameter increase is
recommended every 10 feet
removed from heater.
Material can be:
·CPVC
·Galvanized sheet metal
·Single wall stainless steel
Note:
Do not use manifold connected to other appliances.
Do not run heater under negative air pressure.
Typical enclosure
in sheet metal box
with screen.
Provide
independent
support for duct.
Do not rest weight
on blower
inlet.
Roof
Wall
Top must be
solid metal.
Bird screen
required.
Flexible
connector
required.

Solstream™Installation, Operation, and Maintenance Manual
Page 17 of 49 Water Connections
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater
Water Connections
Transfer pump assembly
must be installed on level
surface and at or below
heater level to maintain
pump's prime.
Inlet water pipe must
be at least as large as
heater's water inlet piping.
Maximum recommended
water velocity is 9 ft/sec in
inlet piping.
Suction hose between
heater and transfer
pump must be flexible
to isolate vibration.
Line from transfer
pump must be
routed to top of
storage tank to
prevent backflow.
If large pressure
swings occur, install
pressure regulating
valve in inlet water line.
Lower canister
Storage tank
Note: Incoming water must not
contain any chloride compounds
above 100 ppm or salts. These
will destroy 304 stainless steel.
(Alternative metals are available.)
Warranty is void unless clean,
potable water is used.
Line from transfer
pipe must be at least
as large as transfer
pump pipe.
Check valve
recommended.

Solstream™Installation, Operation, and Maintenance Manual
Page 18 of 49 Fuel Connection
Hamilton Engineering Company, Inc.
LIT97000 | Solstream™Installation, Operation,
and Maintenance Manual Water Heater
Fuel Connection
Note: If codes require pressure test
of fuel line, close ball valve entering
fuel train to heater. Failure to do so
may damage fuel regulator.
1Connect union in line between top plate
and upper canister.
Note: Local codes may require routing
regulator vent outside.
2Connect gas supply (applicable codes
may govern connection type). Provide
adequate support.
Note: Do not put excess weight on
heater connection.
3With ball valve entering fuel train
closed, purge air from fuel line.