Solahart SOLAR WATER HEATERS User manual

OWNER’S MANUAL
Includes Installation Instructions
SOLAR WATER HEATERS
Solahart Industries Pty Ltd
ABN 45 064 945 848

CONTENTS
Here's How It Works................................................................................................................. 1
Facts You Should Know About Your Solahart Water Heater .................................................. 2
Operating Your Solar Water Heater ......................................................................................... 4
Maintenance ............................................................................................................................. 8
Installation Instructions - All Models ....................................................................................... 10
Installation Instructions –Closed Circuit Series...................................................................... 18
Installation Instructions –Open Circuit Series........................................................................ 24
Installer’s Checklist ................................................................................................................. 27
Servicing ................................................................................................................................. 27
Technical Specifications ......................................................................................................... 28
Annual Performance Calculations For Europe.................................................................................30
Installation Diagram Models 151J & 151KF .....................................................................................31
Installation Diagram Models 151L & 151L Free Heat ......................................................................32
Installation Diagram Models 181J, 181KF, 181J Free Heat & 181KF Free Heat.............................33
Installation Diagram Models 181L & 181L Free Heat ......................................................................34
Installation Diagram Models 182J, 182KF, 182J Free Heat & 182KF Free Heat.............................35
Installation Diagram Models 221J & 221KF .....................................................................................36
Installation Diagram Models 301J & 301KF .....................................................................................37
Installation Diagram Models 301L & 301L Free Heat ......................................................................38
Installation Diagram Models 302J, 302KF, 302J Free Heat & 302KF Free Heat.............................39
Installation Diagram Models 302L & 302L Free Heat ......................................................................40
Installation Diagram Models 303J, 303KF, 303J Free Heat & 303KF Free Heat.............................41
Installation Diagram Models 303L & 303L Free Heat ......................................................................42
Installation Diagram Models 443J, 443KF, 443J Free Heat & 443KF Free Heat.............................43
Installation Diagram Models 443L & 443L Free Heat ......................................................................44
Connection Details.................................................................................................................. 45
Solahart Thermosiphon Solar Water Heater Warranty .......................................................... 47
HOME OWNER: WE RECOMMEND THAT YOU READ PAGES 1 TO 9
The other pages are intended for the installer but may be of interest to you
33-1197 Revision F –Jan. 12

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 1
HERE'S HOW IT WORKS
Solahart thermosiphon solar water heaters are available in two series:
Closed Circuit Series –J, KF, LCSC & BTC models
Open Circuit Series –L & LCSD models
Both series transfer heat absorbed from the sun by the solar collectors to the water storage tank through the Natural
Thermosiphon Principle without the need for pumps or sensors.
The Solahart collectors absorb solar energy. The low-iron content solar glass allows more solar energy to pass through and
be retained than conventional glass.
In the Closed Circuit Series, heat is absorbed by the collector and
passed to the „Hartgard‟ heat transfer liquid inside the collector. As the
temperature of the „Hartgard‟ increases, the hot fluid rises up through
the collector by the Natural Thermosiphon Principle, into the heat
exchanger jacket around the potable water storage tank. Here, the heat
is transferred to the potable water, cooling the „Hartgard‟ fluid.
The cooler fluid is then forced back down into the collectors through
the displacement action of further hot fluid rising up into the heat
exchanger jacket.
Diagram of Closed Circuit Series
The cooler fluid that has been forced down is again heated
in the collectors and rises back up to pass the heat to the
potable water in the storage tank. This circulation repeats
until all water in the storage tank is heated.
Open Circuit Series Closed Circuit Series
For the Open Circuit Series, heat is collected directly by the potable
water circulating through the collector. As the potable water heats up, it
rises by the Natural Thermosiphon Principle, directly to the storage
tank. As the heated potable water travels through to the storage tank,
the cooler potable water returns to the collectors. This circulation
repeats until all water in the storage tank is heated.
Diagram of Open Circuit Series

2 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
FACTS YOU SHOULD KNOW ABOUT YOUR
SOLAHART WATER HEATER
WARNING: FOR CONTINUED SAFETY OF THIS APPLIANCE IT MUST BE INSTALLED, OPERATED AND
MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER‟S INSTRUCTIONS.
CAUTION: THIS WATER HEATER IS ONLY INTENDED TO BE OPERATED BY PERSONS WHO
HAVE THE EXPERIENCE OR THE KNOWLEDGE AND THE CAPABILITIES TO DO SO.
THIS WATER HEATER IS NOT INTENDED TO BE OPERATED BY PERSONS WITH REDUCED
PHYSICAL, SENSORY OR MENTAL CAPABILITIES I.E. THE INFIRM AND CHILDREN.
CHILDREN SHOULD BE SUPERVISED TO ENSURE THEY DO NOT INTERFERE WITH THE
WATER HEATER.
WARNING: THIS WATER HEATER USES 240 V AC POWER FOR THE ELECTRICALLY
OPERATED COMPONENTS. THE REMOVAL OF THE FRONT COVER WILL EXPOSE 240 V
WIRING. IT MUST ONLY BE REMOVED BY A QUALIFIED ELECTRICAL SERVICE PERSON.
CAUTION: CARE SHOULD BE TAKEN NOT TO TOUCH THE PIPE WORK CONNECTING THE
SOLAR STORAGE TANK AND THE SOLAR COLLECTORS. VERY HIGH TEMPERATURE HOT
WATER CAN BE GENERATED BY THE SOLAR COLLECTORS UNDER CERTAIN CONDITIONS
AND WILL FLOW THROUGH THE PIPE WORK FROM THE SOLAR COLLECTORS TO THE SOLAR
STORAGE TANK.
Water Heater Application
This water heater is designed for the purpose of heating potable water. Its use in an application other than this may shorten
its life.
Hot Hot Water!
Your Solahart water heater will generate hot water quickly and efficiently. Under normal family use, it will operate between
60ºC and 70ºC. However, the temperature can exceed this and under certain circumstances may be as high as 95ºC (see
recommendation below). This can occur during prolonged periods of direct sunlight (particularly in summer) or during long
periods of reduced water usage. Extreme care should be taken in these circumstances.
CAUTION: CHECK THE WATER TEMPERATURE BEFORE USE, SUCH AS WHEN ENTERING A
SHOWER OR FILLING A BATH OR BASIN, TO ENSURE IT IS SUITABLE FOR THE APPLICATION
AND WILL NOT CAUSE SCALD INJURY.
We recommend, and it may also be required by regulations, that an approved temperature limiting device be fitted into the
hot water pipe work to the bathroom and ensuite when this water heater is installed. This will keep the water temperature
below 50 C at the bathroom and ensuite. The risk of scald injury will be reduced and still allow hotter water to the kitchen
and laundry.
Precautions
The water heater must be maintained in accordance with the Owner‟s Manual. Refer to “Maintenance” on page 8 and to
“Anode Inspection and Replacement” on page 8.
If this water heater is to be used where an uninterrupted hot water supply is necessary for your application or business you
should ensure that you have back up redundancy within the hot water system design. This should ensure the continuity of
hot water supply in the event that this water heater were to become inoperable for any reason. We recommend you seek
advice from your plumber or specifier about your needs and building back up redundancy into your hot water supply
system.
Victorian Customers
Notice to Victorian Customers from the Victorian Plumbing Industry Commission. This water heater must be installed by a
licensed person as required by the Victorian Building Act 1993. Only a licensed person will give you a Compliance
Certificate, showing that the work complies with all the relevant Standards. Only a licensed person will have insurance
protecting their workmanship for 6 years. Make sure you use a licensed person to install this water heater and ask for your
Compliance Certificate.
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33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 3
Water Quality - Is It Suitable For The Solahart Water Heater?
Your Solahart water heater is suitable for use with water with a total dissolved solid content less than 1,000 ppm and for
which the total hardness does not exceed 200 ppm CaCO3. Water supplies having calcium hardness (CaCO3) and an
alkalinity in excess of 150 ppm should be treated by a softening process prior to use with this water heater to prevent
scaling and damage to the electric booster element.
A water analysis can be obtained from your water supply authority.
Period Of Reduced Usage Or Holidays
WARNING: IF THE WATER HEATER IS LEFT UNUSED FOR TWO WEEKS OR MORE,
FLAMMABLE HYDROGEN GAS MAY ACCUMULATE IN THE WATER CYLINDER.
To dissipate this gas safely, it is recommended that a sink hot tap be turned on for several minutes. Do not use a
dishwasher, clothes washer or other appliance for this purpose. During this procedure there must be no smoking, open
flames or any electrical appliance operating nearby. If hydrogen is discharged through the tap it will make an unusual sound
like air escaping.
‘Hartgard’ Solution –Freeze Protection
Solahart Closed Circuit Systems are protected against freezing or harsh water conditions by our exclusive „Hartgard‟ fluid.
„Hartgard‟ is a blue, non-toxic, propylene glycol fluid which, when mixed with water, provides the Heat Transfer Fluid
contained in the solar panels and the heat exchanger jacket around the tank. „Hartgard‟ is used to lower the freezing
temperature of the Heat Transfer Fluid and so provides protection against freezing (Note: for the correct % of Hartgard in
the Heat Transfer Fluid, refer to the section on Frost / Freeze Protection). „Hartgard‟ is a special food grade solution and is
the only solution permitted to be used in the closed circuit systems. Hartgard has been approved by the National Health and
Medical Research Council of Australia.
WARNING: SHOULD THE WATER FROM YOUR CLOSED CIRCUIT SERIES WATER HEATER
APPEAR BLUE, THEN THIS MAY INDICATE A LEAK OF „HARTGARD‟ FROM THE HEAT
EXCHANGE JACKET INTO THE POTABLE WATER.
Although ‘Hartgard‟ is of food-grade quality and not hazardous to health, the blue colour in the water does indicate a fault
and your Solahart dealer should be contacted to inspect the system.
Over-Temperature Protection System
The Closed Circuit Series solar water heaters have a means of controlling the maximum temperature of the water in the
storage tank. These systems may be installed with a „HartStat‟ valve located between the hot outlet of the collectors and the
inlet to the tank heat exchanger. This valve closes when the tank has reached a sufficiently high temperature, thereby
preventing further heat transfer to the tank, and thus limiting its temperature.
The Open Circuit Series systems may be installed with a „TRV‟ located between the cold inlet of the tank and the cold inlet
of the collectors. This valve restricts the flow through the collectors when the tank has reached a sufficiently high
temperature.
PR6 / PR200 Jacket Pressure Relief Valve
The Closed Circuit Series tank‟s heat exchange jacket has a pressure relief valve located in the vent pipe of the jacket. This
relief valve is to prevent over-pressurisation of the closed circuit either due to incorrect filling or abnormal operating
conditions. During the water heater's first summer season, fluid will discharge from the relief valve until the ideal closed
circuit fluid volume is established. Discharges from the valve after this time could indicate the water heater is not operating
efficiently. Under these circumstances contact your nearest Solahart dealer immediately. Do not attempt to service the water
heater yourself.
When operating in daylight, the heat exchange circuit will be pressurised and will contain a mixture of superheated water
and steam. Do not remove the PR6 / PR200 valve during operation as there may be a very high SCALDING risk present.
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4 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
OPERATING YOUR SOLAR WATER HEATER
Primary heating of your hot water will be from solar energy. The solar heating requires no operation by the user.
Supplementary water heating (“boosting”) is also provided. Dependent upon the system that you have purchased, this will
be either:
In-tank electric or gas boosting
In-series gas boosting
Note: Australian Standard AS 3498 requires that a water heater provides the means to inhibit the growth of Legionella
bacteria in potable water.
With in-tank boosting, this water heater can satisfy this AS 3498 requirement provided the booster is either
permanently switch on or switched on by timer control for a sufficient period each day, and the electric booster
thermostat setting is 60°C or higher. Refer to the tables commencing on page 5 for recommended boosting periods.
If this water heater is installed with an in-series continuous flow gas booster, then this requirement of AS 3498 can be
satisfied provided the booster is permanently switch on, its preset outlet temperature setting is 70°C or higher and a
remote temperature controller is not used.
If this water heater is installed with an in-series storage booster, then this requirement of AS 3498 can be satisfied
provided the storage booster is permanently switch on and its thermostat setting is 60°C or higher.
IN-TANK BOOSTING
In-tank boosting by electricity or gas both work on the same principle. An isolating switch is installed in the electrical meter
box for an electrically boosted unit or a power point is installed near the water heater for an in-tank gas boosted unit. This
should be left switched on to allow the booster heating unit to operate if required. The booster heating unit is for heating the
water at times of low solar energy gain, such as during very cloudy or rainy weather, or during the colder months.
The booster heating unit will only activate if heating is required and power is available from the switchboard or power
point. When the water is below the thermostat setting, the booster heating unit will turn on and heat the water. The booster
heating unit will automatically turn off when the temperature of the water reaches the thermostat setting. If the water
temperature drops below the setting again the booster will re-activate.
The water heater features a tradesperson adjustable thermostat. This requires a licensed tradesperson to make any
temperature adjustments. The thermostat is factory set at 60°C and has a maximum temperature setting of 70°C.
Leaving the isolating switch switched on will also provide a sufficient period of time each day for the booster heating unit
to operate, if required, to satisfy the requirements of AS 3498.
The amount of water heated by the raised booster heating unit of a thermosiphon storage tank is:
150 model
180 model
220 model
300 model
440 model
75 litres
90 litres
110 litres
150 litres
200 litres
The overall performance and energy savings that you will obtain from your Solahart water heater will depend on your hot
water usage pattern and your operation of the in-tank booster. A time clock may be fitted to the system to turn the booster
on when required. This method can increase energy savings.
The following hints are provided to assist you in with your operation of your solar water heater:
1) Solar energy input is greater on sunny days between 10am and 3pm. If possible, schedule your large hot water
demands (e.g. heavy washing or laundry) for as close as possible to the middle of the day.
2) If a timer is installed, boost your tank‟s water after this 10am to 3pm hot period. The sun has made its maximum
contribution by this time, the booster will then raise the water to the desired temperature if the sun has not done so
(in winter for example).
3) Keep trees in the sun's path at a level where the collectors are not shaded at any time during periods of effective
solar radiation.
Off Peak Electricity & Boosting
If your Solahart water heater‟s in-tank electric booster is connected to an „Off Peak‟ (night rate) electrical supply, it is
important to remember that the booster may only operate late at night. On cloudy days the tank may only gain a small
amount of energy during the day. Careful planning will be required to avoid running out of hot water if large quantities are
drawn during the day. In areas where a „Day Rate‟ electrical switch is permitted, the storage tank can be boosted to ensure
hot water is available at the end of the day.

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 5
Timer Control of the Tank Boosting
A timer control switch can be installed and will help maximise energy savings with an electrically boosted solar water
heater connected to a continuous, time of use or extended Off-Peak (overnight and day) electricity supply.
If used with an extended Off-Peak (overnight and day) electricity supply, the timer switch should:
Be operated by a continuous power supply on its own circuit from the switchboard with the booster heating unit
operated by the Off-Peak power supply.
A double pole isolating switch is required to be installed at the switchboard to simultaneously isolate both circuits.
Or
Be of a type which has an internal rechargeable battery to keep time when the power supply is not available to the
timer
If the water heater has an in-tank FD15 gas booster, then the timer can be of a type which plugs into the power point which
supplies the gas booster with power.
Programming the Timer
Power must be available to the timer control switch before the booster heating unit can be activated.
The timer control switch should be programmed:
to suit the hot water consumption pattern of the household,
with the end of the boost period to coincide with the commencement of the evening hot water usage,
to enable a boosting period of not less than the recommended continuous length of time for boosting, and
for a period when power will be available for the booster heating unit to operate.
It may be necessary to program a second period into the timer, such as prior to the morning hot water usage.
Note: When daylight saving time applies, you may consider resetting the timer accordingly.
The recommended continuous length of time for boosting (for a 240 V power supply) is:
Cool/temperate climate
Minimum winter cold water supply temperature = 10°C
Thermostat set point = 60°C
Temperature rise = 50°C
Booster Heating Unit
150 model
180 model
220 model
300 model
440 model
1.5 kW
3 hours
3¾ hours
4 ½ hours
6 hours
8 ¾ hours
1.8 kW
2 ½ hours
3 hours
3 ¾ hours
5 hours
7 ½ hours
2.4 kW
2 hours
2 ¼ hours
2 ¾ hours
3 ¾ hours
5 ½ hours
2.5 kW
2 hours
2 ¼ hours
2 ¾ hours
3 ¾ hours
5 ¼ hours
3.6 kW
1 ½ hours
1 ½ hours
2 hours
2 ½ hours
3 ¾ hours
4.8 kW
1 hour
1 ¼ hours
1 ½ hours
2 hours
2 ¾ hours
FD15 Gas Booster
2 hours
2 ½ hours
2 ¾ hours
3 ¾ hours
5 ½ hours
Temperate/sub tropical climate
Minimum winter cold water supply temperature = 15°C
Thermostat set point = 60°C
Temperature rise = 45°C
Booster Heating Unit
150 model
180 model
220 model
300 model
440 model
1.5 kW
2 ¾ hours
3¼ hours
4 hours
5 ½ hours
8 hours
1.8 kW
2 ¼ hours
2 ¾ hours
3 ¼ hours
4 ¾ hours
6 ¾ hours
2.4 kW
1 ¾ hours
2 hours
2 ½ hours
3 ½ hours
5 hours
2.5 kW
1 ¾ hours
2 hours
2 ½ hours
3 ¼ hours
4 ¾ hours
3.6 kW
1 ¼ hours
1 ½ hours
1 ¾ hours
2 ¼ hours
3 ¼ hours
4.8 kW
1 hour
1 hours
1 ¼ hours
1 ¾ hours
2 ½ hours
FD15 Gas Booster
1 ¾ hours
2 ¼ hours
2 ½ hours
3 ½ hours
5 hours

6 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
Temperate/sub tropical climate
Minimum winter cold water supply temperature = 20°C
Thermostat set point = 60°C
Temperature rise = 40°C
Booster Heating Unit
150 model
180 model
220 model
300 model
440 model
1.5 kW
2 ½ hours
3hours
3 ½ hours
4 ¾ hours
7 hours
1.8 kW
2 hours
2 ½ hours
3 hours
4 hours
6 hours
2.4 kW
1 ½ hours
2 hours
2 ¼ hours
3 hours
4 ½ hours
2.5 kW
1 ½ hours
1 ¾ hours
2 ¼ hours
3 hours
4 ¼ hours
3.6 kW
1 hour
1 ¼ hours
1 ½ hours
2 hours
3 hours
4.8 kW
¾ hour
1 hour
1 ¼ hours
1 ½ hours
2 ¼ hours
FD15 Gas Booster
1 ½ hours
2 hours
2 ¼ hours
3 hours
4 ½ hours
The recommended boosting periods are sufficient to allow the booster heating unit to heat up the boost volume of the solar
storage tank to 60°C where the winter cold water temperatures do not fall below those shown. This may be necessary
during periods of very low solar energy gain through the solar collectors, such as during constant rain or extremely cloudy
weather, particularly in winter when the incoming cold water temperature is lower. The period will also provide a sufficient
heat up time for the electric booster to operate, if required, to satisfy the requirements of AS 3498.
The booster heating unit will only activate if heating is required and power is available from the timer. When the water is
below the thermostat setting, the booster heating unit will turn on and heat the water. The booster heating unit will
automatically turn off either when the temperature of the water reaches the thermostat setting or at the end of the timer
period, whichever comes first.
IN-SERIES GAS BOOSTING
An in-series gas booster (also known as an instantaneous gas booster) can be installed between the solar water heater and
the hot outlets in the house. This booster should be permanently active. The booster senses the temperature of the water
passing through it: if the water temperature is above its temperature setting it does nothing; if below it will automatically
heat the water up to the preset outlet temperature setting. This device ensures hot water delivery for a variety of hot water
demands without the need for user intervention while enabling maximum solar energy contribution to the water heating. For
more information on this booster, consult the owner‟s manual for the product.
TEMPERATURE STABILISATION
Temperature stabilisation is the reduction in water temperature as the hot water at the top of the storage cylinder transfers
some of its heat to the cooler water in the lower section of the cylinder. This effect is often perceived as heat loss, but is
actually the redistribution of stored heat more evenly over the entire contents of the storage tank. This may make it
necessary to use the booster to raise the water in the top section of the cylinder back to an acceptable temperature.
Over-night temperature stabilisation is most evident in the morning if the booster switch or time clock is left OFF over-
night and more prevalent in the cooler months. Day time temperature is quite evident on days of lower solar radiation
particularly during the cooler months if the power to the booster heating element is not available, or the booster switch or
time clock is left OFF.

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 7
Using Your Solahart Water Heater As A Pre-Heater
This water heater is designed to be installed as an electric boosted solar water heater with its booster heating unit connected
to a power supply; however it may be installed with an in-series continuous flow or storage booster.
If this water heater is installed with an in-series booster, then the electric booster heating unit will not be connected to a
power supply and the references to the electric booster heating unit, thermostat and boosting controls in these installation
instructions will not be applicable to the installation.
Your Solahart can be used as a pre-heater to an existing water heater provided that:
1) The power supply to the Solahart is not connected.
2) The existing water heater is thermostatically-controlled not flow-controlled, except when used in conjunction with
an electronic instantaneous water heater.
3) The operating pressures of the two water heaters are compatible or reduced to the lower of the two heaters.
4) The existing water heater has sufficient thermal capacity in its own right to supply normal water requirements and is
complete with its own controls and valves and these are not interfered with.
5) If using the Solahart water heater as a pre-heater to an instantaneous water heater, a temperature controlled by-pass
valve is installed to the instantaneous heater if required (consult the instantaneous water heater‟s installation
manual).
6) If using the Solahart water heater as a pre-heater to a storage water heater, the water supply from the Solahart heater
be tempered to the temperature setting of the storage heater OR a temperature controlled by-pass valve be installed
to the storage heater to divert water from the Solahart heater when at a temperature above this setting. These
configurations ensure that the storage heater‟s thermal cut-out does not operate unnecessarily, resulting in the
storage heater no longer operating.
Note: With flow-controlled water heaters the Solahart water heater can act as a supplementary heat source only not as a pre-
heater. The Solahart heater can be connected in a parallel circuit only via a changeover valve(s).
Troubleshooting –Save A Service Call
Should your Solahart not provide hot water please check the following before requesting a service call:
1) Shading from trees is not excessive and is not covering the collectors for all or part of the day.
2) Hot water usage is not excessive.
3) Hot water is not leaking from within the plumbing system.
4) Booster switch and/or time switch is turned ON.
5) Booster circuit fuse or circuit breaker is sound.
6) Electric or gas meter speeds up when the booster switch is turned ON after being OFF.
Contact your local Solahart Dealer if all of the above have been checked and there is still no hot water.
Collector Glass Breakage
WARNING: NO ATTEMPT SHOULD BE MADE TO REPAIR BROKEN COLLECTOR GLASS
The collector glass is not offered as a replacement part. Should the solar collector require replacement, contact your local
Solahart Dealer.
NOTE: The product warranty DOES NOT cover breakage of collector glass. It is recommended that the household
insurance policy cover the collector glass and/or damage to the water heater, especially in cyclonic areas and in locations
where severe hail is likely to occur.
The Solahart collector glass meets Australian Standards requirements for hail impact damage resistance. The fitment of
glass guards for this purpose is not required. Stone Guards are available for protection against accidental damage or
vandalism if considered necessary. Contact your Solahart dealer for more information.
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8 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
MAINTENANCE
Minor Six Month Maintenance
It is recommended minor maintenance be performed every six months by the dwelling occupant.
The minor maintenance includes:
1) If accessible, operate the easing lever on the temperature pressure relief valve. It is very important you raise and
lower the lever gently. Refer to “Temperature Pressure Relief Valve” on page 9.
WARNING: EXERCISE CARE TO AVOID ANY SPLASHING OF WATER, AS WATER DISCHARGED FROM
THE DRAIN LINE WILL BE HOT. STAND CLEAR OF THE DRAIN LINE‟S POINT OF DISCHARGE WHEN
OPERATING THE VALVE‟S LEVER.
If the temperature pressure relief valve is not readily accessible, contact your local Solahart Dealer.
2) Operate the easing lever on the expansion control valve. It is very important you raise and lower the lever gently.
Refer to “Expansion Control Valve” on page 9.
Major Service
This major service should be performed to coincide with the anode replacement OR at five years, whichever is sooner
(refer to the Anode Replacement Period section). Only genuine replacement parts should be used on this water heater.
THE MAJOR SERVICE CAN ONLY BE CARRIED OUT BY A QUALIFIED PERSON. CONTACT YOUR
LOCAL SOLAHART DEALER OR AUTHORISED SERVICE REPRESENTATIVE.
The major service addresses the following aspects:
1) Check the closed circuit fluid level (Closed Circuit Series only).
2) Replace the pressure/temperature relief valve (Part No. 45-1104).
3) Flush the cold water relief valve (Part No. 45-1103).
4) Where fitted, check the electric element for excessive calcium build up or corrosion. Replace if necessary.
5) Visually check the unit for any potential problems, e.g. broken glass, excessive dust build-up, shading etc.
6) Carefully inspect all connections.
7) Drain and flush out tank sediment build-up if required (see “To Empty the Water Heater” on page 27).
8) Drain and flush collectors (‟L‟ Series only) (see “To Empty the Water Heater” on page 27).
9) Replace the anode.
10) For units fitted with a Gas Booster, check the following: condition of the spark electrode, condition of the flue
terminal gasket and for build up of dust on the fan.
Note: The five year service and routine replacement of any components, such as the anode and relief valves, are not
included in the Solahart warranty. A charge will be made for this work.
For units fitted with a tempering valve or a water softener, the operation should be checked at this time. These checks are
not covered within the major service.
Anode Inspection & Replacement
Corrosion protection of the water heater‟s tank is obtained by using two coats of high quality vitreous enamel and the use of
a sacrificial anode.
The anode installed in your water heater will slowly dissipate whilst protecting the cylinder. The life of the cylinder may be
extended by replacing the anode. The following table shows the when the anode should be replaced.
Water Quality
Total Dissolved Solids (ppm)
Anode
Recommended Anode Replacement Period
0 - 600
Standard anode
5 years
Free-Heat anode
10 years
600 - 1,000
Aluminium anode
3 years
Over 1,000
Aluminium anode
Less than 2 years
Water quality details should be obtained from the water authority where special water supplies are used. Generally, where
the water is supplied from a bore or well, the quality of the water will be such that a three-year anode change (or less) will
be required. A water analysis is recommended for these locations.
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33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 9
Pressure Relief Valve - Six Monthly Maintenance
The easing gear of pressure relief valves fitted to your water heater system must be operated every six months to assure
their continuing function.
WARNING: FAILURE TO HAVE THE TEMPERATURE PRESSURE RELIEF VALVE EASING GEAR
OPERATED AT LEAST ONCE EVERY SIX MONTHS MAY RESULT IN THE WATER HEATER EXPLODING.
WARNING: NEVER BLOCK THE OUTLET OF A RELIEF VALVE OR ITS DRAIN LINE FOR ANY REASON.
CAUTION: IT IS VERY IMPORTANT THAT THE LEVER IS RAISED AND LOWERED GENTLY.
NOTE: Continuous leakage of water from a relief valve or its drain line may indicate a problem with the water heater.
TEMPERATURE PRESSURE RELIEF VALVE
This valve is fitted in the top of the water heater tank and is essential for its safe
operation. It is possible for the valve to release a little water through the drain line
during each heating period. This occurs as the water is heated and expands by
approximately 1/50 of its volume.
Operate the easing lever on the temperature pressure relief valve once every six
months. If water does not flow freely from the drain line when the lever is lifted,
then the water heater should be checked by your nearest Solahart Dealer.
WARNING: EXERCISE CARE TO AVOID ANY SPLASHING OF
WATER, AS WATER DISCHARGED FROM THE DRAIN LINE WILL
BE HOT. STAND CLEAR OF THE DRAIN LINE‟S POINT OF
DISCHARGE WHEN OPERATING THE VALVE‟S LEVER.
The temperature pressure relief valve should be replaced at intervals not exceeding 5 years, or more frequently in areas
where there is a high incidence of water deposits.
EXPANSION CONTROL VALVE
In many areas, including South Australia, Western Australia and scaling water areas, an expansion control valve is fitted to
the cold water line to the water heater. Water will flow from its drain line during the heating period.
Operate the easing lever on the expansion control valve once every six months. If water does not flow freely from the drain
line when the lever is lifted, then the water heater should be checked by your nearest Solahart Dealer. The expansion
control valve should be checked for performance or replaced at intervals not exceeding 5 years, or more frequently in areas
where there is a high incidence of water deposits.
Collector Care
Ensure the glass on your solar collectors is free of dust, salt spray or any other matter which may reduce the effectiveness of
the solar collectors. Rainfall should keep the collector adequately clean. It is recommended that the collector glass be
washed clean at least every three months should adequate rain not have fallen in this period. Collector glass can be hosed
down or if the solar collectors are accessible, wash the collector glass with water and a soft brush when the solar collectors
are cool, such as early in the morning. In extremely dusty areas, such as mining towns and locations adjacent to dust
forming plants, extra attention should be given to this matter.
Have any trees trimmed which may shade the solar collectors.
water
heater
drain
line
lift until water
flows from the
drain line –
lower gently
!
!

10 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
INSTALLATION INSTRUCTIONS - ALL MODELS
General
INSTALLATION STANDARDS
The water heater must be installed:
by a qualified person, and
in accordance with the installation instructions, and
in Australia, in compliance with Standards AS/NZS 3500.4, AS/NZS 3000, AS 5601 or AS/NZS 5601.1, as applicable
under local regulations, and all local codes and regulatory authority requirements, or
in other countries, in compliance with national and local codes and regulatory authority requirements.
In New Zealand, the installation must also conform with NZS 5261, as applicable under local regulations, and Clause G12
of the New Zealand Building Code.
INSTALLATION MUST COMPLY WITH LOCAL ELECTRICAL AND PLUMBING CODES
Victorian Installers
Notice to Victorian Installers from the Victorian Plumbing Industry Commission if this solar water heater is installed in a
new Class 1 dwelling in the State of Victoria. The system model number is to be recorded on the Certificate of Compliance.
It is also a requirement to provide the householder with permanent documentation recording the system model number
exactly as it is shown in the „List of systems capable of complying with the regulations‟ published by Sustainability Victoria
(see www.sustainability.vic.gov.au). This documentation may be in the form of an indelible label adhered to the solar
storage tank, or other suitable form placed in an accessible location, such as the meter box, for later inspection.
WATER HEATER APPLICATION
This water heater is designed for the purpose of heating potable water. Its use in an application other than this may shorten
its life.
If this water heater is to be used where an uninterrupted hot water supply is necessary for the application or business, then
there should be redundancy within the hot water system design. This should ensure the continuity of hot water supply in the
event that this water heater was to become inoperable for any reason. We recommend you provide advice to the system
owner about their needs and building backup redundancy into the hot water supply system.
LOCATION
The installation should be as close as possible to the most frequently used hot water outlet or existing water heater system
in retrofit installations. The water heater must be installed in an area that is free of shade all year round. Ensure that trees do
not shade the heater, particularly in winter.
NOTE: The element/anode end of the Tank should be placed no nearer than ¾ length of the Tank, to any wall or
obstruction, so that the anode can be replaced during a service.
WARNING: THE WATER HEATER MUST BE INSTALLED ON AN ADEQUATELY SUPPORTED
AREA OF ROOF. IN CYCLONE AREAS ADDITIONAL MOUNTING RESTRAINTS ARE REQUIRED
Refer to the Technical Specifications section for the weight of the water heater. It is advisable that the weight of the water
heater be braced to a load bearing wall. If in any doubt of the construction or the condition of the roof, obtain advice from a
registered builder or structural engineer. The installer must ensure that the structural integrity of the roof is not
compromised by the installation of the solar water heater.
In areas susceptible to cyclones, hurricanes or very high winds, a suitable With Pitch frame is required. Refer to your local
Solahart Dealer for details. The installation of this solar water heater on a suitable frame, subject to the frame‟s design
criteria not being exceeded:
is suitable for installation in geographic locations up to and within Wind Region D (With Pitch frame) or up to and
within Wind Region C (Fixed Pitch frame), as defined in the Building Code of Australia, Australian / New Zealand
Standard AS/NZS 1170.2:2002 and the Australian Standard AS 4055-2006, or equivalent location, and
also provides an acceptable method of installation where it is necessary to satisfy the requirements of the Building
Code of Australia and AS/NZS 3500.4 Clause 6.5.3.4 for high wind areas, or equivalent requirements.
!

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 11
Orientation of Solar Collectors
To help maximise system performance, solar collectors should be installed with an optimum orientation facing true north
(in the southern hemisphere) or true south (in the northern hemisphere). Always check for true north or true south using a
compass or other suitable device.
The solar performance of a system reduces as the orientation of the collectors moves away from the optimum orientation,
resulting in the need for increased boosting to supply the same hot water load. Solar collectors facing up to 45° from the
optimum orientation will receive about 4% to 5% less total solar radiation.
However, the optimum orientation of solar collectors is not always practical or achievable. Solar collectors may be installed
up to 90° from the optimum orientation. Where the orientation is greater than 60° from the optimum, either an additional
solar collector or selective surface collectors in lieu of non selective surface collectors should be installed to make up for
the reduction in solar performance. Each of these options should be discussed with the system owner. If neither of these
options is possible nor acceptable to the system owner, then the system owner needs to be made aware of, understand and
accept that much more boosting may be required to meet their hot water requirements.
If it is not possible to face the equator, the decision of either an EASTERLY or WESTERLY bias must be made. If the
majority of hot water usage is before 2 p.m. favour an EASTERLY bias. If the majority of hot water usage is after 2 p.m.
favour a WESTERLY bias.
Inclination of Solar Collectors
To help maximise system performance, solar collectors should be installed with an optimum inclination. This is equal to
90% to 100% of the local latitude angle when collectors are oriented within 60° of true north or true south, and between 10°
and 20° if the collectors are oriented between 60° and 90° from the optimum orientation.
Generally, improved summer performance is obtained from an
angle of inclination less than the optimum angle and improved
winter performance is obtained by an angle of inclination
greater than the optimum angle. If the angle of inclination
varies by 20° from the optimum angle, the solar collectors will
receive about 10% less total annual solar radiation.
However, the optimum inclination of solar collectors is not
always practical or achievable. Solar collectors may be
installed at the roof angle for simplicity of installation and
appearance, but must never be less than 10° for a thermosiphon
water heater installation
A Fixed Pitch frame can be installed to increase the angle of
inclination of a thermosiphon water heater and should be used
if the roof pitch either is less than 10° or varies by more than
20° from the optimum angle. At pitches greater than 30°, the
system must be installed mounted on a With Pitch frame. A
suitable frame is available from your local Solahart Dealer.
The use of a Fixed Pitch frame should be discussed with the system owner. If this option is neither possible nor acceptable
to the system owner, then the system owner needs to be made aware of, understand and accept that increased boosting may
be required to meet their hot water requirements.
FROST / FREEZE PROTECTION
An Open Circuit system does not have freeze protection and is not suitable for installation in areas prone to freeze
conditions. Freeze conditions occur below 5°C (41°F). This system has NO WARRANTY for freeze damage. In areas that
are prone to frost / freezing, a Closed Circuit system should be used.
Solahart recommends using a minimum of 1 complete 4.5 litre bottle of „Hartgard‟ in each system (or a minimum
concentration of 20% in large capacity systems) as standard where ambient temperatures do not fall below 0°C.
Alternatively, the concentration of „Hartgard‟ in the closed circuit should be determined to suit the minimum ambient
temperature that the system will be exposed to. The Freezing Point temperature of varying concentrations of „Hartgard‟
solution in water is given below:
20% Hartgard by volume
-7°C
18°F
40% Hartgard by volume
-22°C
-8°F
30% Hartgard by volume
-13°C
7°F
50% Hartgard by volume
-34°C
-29°F
If the system is to be installed in an area where the temperature falls below -34°C (-29°F), please contact your local
Solahart dealer for advice.

12 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
Electrical
ELECTRICAL CONNECTION AND CODES
All electrical work and permanent wiring must be carried out by a qualified person. All installations are to be in accordance
with national and local electrical codes and regulatory authority requirements applicable in your area. In Australia, this
must also be in accordance with the Wiring Rules AS/NZS 3000.
WARNING: DO NOT TURN POWER ON UNTIL THE WATER HEATER IS FILLED WITH WATER
OR DAMAGE TO THE HEATING ELEMENT WILL RESULT
The power rating and current requirement of your Solahart water heater will be specified on the heater‟s data plate, located
on the cover to the electrical cavity. The temperature rating of the power supply lead‟s insulation should suit this
application. All electric wiring should be enclosed in suitable weatherproof conduit with watertight fittings.
An isolation switch MUST be installed in the meter box for service work on the unit. The isolating switch should be left
switched on. Leaving the isolating switch switched on will also provide a sufficient period of time each day for the booster
heating unit to operate, if required, to satisfy the requirements of AS 3498.
If water and/or power are not available on completion of installation, isolation switch in the meter box in the OFF position
and place a warning label “Do not turn on electricity until filled with water”on the electrical isolation switch.
Timer Control Switch
A suitably rated timer control switch can be installed and will help maximise energy savings with an electrically boosted
solar water heater connected to a continuous, time of use or extended Off-Peak (overnight and day) electricity supply.
If used with an extended Off-Peak (overnight and day) electricity supply, the timer switch should:
Be operated by a continuous power supply on its own circuit from the switchboard with the booster heating unit
operated by the Off-Peak power supply.
A double pole isolating switch is required to be installed at the switchboard to simultaneously isolate both circuits.
Or
Be of a type which has an internal rechargeable battery to keep time when the power supply is not available to the
timer.
If the water heater has an in-tank FD15 gas booster, then the timer can be of a type which plugs into the power point which
supplies the gas booster with power.
Refer to “Programming the Timer” on page 5.
Timer Control Switch Wiring Diagram
Timer With Contactor (if required)
Timing Wiring Diagrams Electric Boosted Solar Water Heater
Continuous
Power Supply
Switchboard
Extended Off-Peak
Power Supply
Switchboard
Timer
Terminal Block
Timer Without Contactor
Timer
Terminal Block
!

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 13
CONTROL THERMOSTAT/SAFETY CUT-OUT COMBINATION SWITCH
A combination thermostat/safety cut-out is installed to control the electrical heating element to the factory pre-set
temperature of 60°C. Individual situations may require this setting to be altered. Only qualified electricians or Solahart
service contractors are permitted to adjust the thermostat. The safety cut-out (also called a thermal cut-out) will de-energise
the element should the temperature within the tank reach 83°C when the element is activated. This cut-out is of a type that
DOES NOT require additional control devices to prevent its operation due to solar heating of the tank water above this
temperature.
WARNING: OPERATION OF THE SAFETY CUT-OUT MAY INDICATE A DANGEROUS FAULT
Plumbing
All plumbing work must be carried out by a qualified person. All installations are to be in accordance with national and
local electrical codes and regulatory authority requirements applicable in your area. In Australia, this must also be in
accordance with AS/NZS 3500.4 and in New Zealand, the installation must conform with Clause G12 of the New Zealand
Building Code.
Note that any pipes that are required to enter to the house either through a wall, ceiling cavity or roof need to be fully sealed
and waterproofed and should comply with local building codes and practices.
WARNING: PLASTIC PIPING SHOULD NOT BE USED IN ANY HOT WATER PIPING RUNS DUE
TO THE HIGH OPERATING TEMPERATURE AND PRESSURE OF SOLAR WATER HEATER. USE
ONLY SOLAHART PARTS TO CONNECT THE COLLECTORS TO THE TANK.
TEMPERATURE & PRESSURE RELIEF VALVE
A combined temperature and pressure relief (TPR) valve (Part No. 45-1104) is fitted to the connection end of the tank to
limit both the tank water pressure to 1000 kPa and the tank water temperature to 99°C. It is MANDATORY that this TPR
valve be fitted in all cases, except where the storage tank is vented to atmosphere through an open pipe.
The TPR valve is shipped in the pipe kit and must be fitted before the water heater is operated. Before fitting the TPR
valve, make sure the probe has not been bent. Seal the TPR valve thread with Teflon tape (never hemp) ensuring that the
tape is at least 3 mm back from the end of the thread to prevent tape fouling the valve seat. Screw the valve into the correct
opening leaving the valve outlet pointing downwards. Do not use a wrench on the TPR valve body - use the spanner flats
provided.
Continuous leakage of water from the TPR valve or its drain line may indicate a problem with the water heater
WARNING: NEVER BLOCK THE OUTLET OF THE TPR VALVE OR ITS DRAIN LINE FOR ANY
REASON.
TPR VALVE DRAIN
A copper drain line must be fitted to the TPR valve to carry the discharge clear of the water heater. Connect the drain line
to the TPR valve using a disconnection union. The pipe work from the TPR valve to the drain should be as short as possible
and run away from the water heater in a continuously downward direction and with no restrictions. It should have no more
than three right angle bends in it. Use DN15 pipe. The outlet of the drain line must be in such a position that flow out of the
pipe can be easily seen (refer to AS/NZS 3500.4) but arranged so hot water discharge will not cause injury, damage or
nuisance. The drain line must discharge at an outlet or air break not more than 9 metres from the TPR valve.
In locations where water pipes are prone to freezing, the drain line must be insulated and not exceed 300 mm in length. In
this instance, the drain line is to discharge into a tundish through an air gap of between 75 mm and 150 mm.
NOTE: As the function of the TPR on this water heater is to discharge high temperature water under certain conditions, it is
strongly recommended the pipe work downstream of the TPR valve be capable of carrying water exceeding 93 C. Failure
to observe this precaution may result in damage to pipe work and property.
!
!
!

14 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
EXPANSION CONTROL VALVE
Local regulations may make it mandatory to install an expansion control valve (ECV) in the cold water line to the water
heater. In other areas, an ECV is not required unless the water saturation index is greater than +0.4. For this Solahart Water
Heater an RMC H50 Cold Relief Valve (part no 45-1103) is supplied in the parts kit for use as the ECV. Solahart
recommend its fitment in all instances.
The ECV must always be installed after the TRIO valve (part no 33-1675), and must be the last valve installed prior to the
water heater (see a typical cold water configuration page 14). A copper drain line must be run separately from the drain of
the TPR valve. The TRIO valve in the cold water inlet line also enables the water to be turned OFF for servicing purposes.
DRAIN LINES - GENERAL
The TPR valve and ECV should both have drain pipes connected to their outlets. These pipes should run to ground level
where hot water discharge is safe and clear of any paved areas. Do not seal or block the ends of these drain pipes or the
valve outlets. Do not allow water from the valve outlets or drain pipes to drip or discharge onto roofing materials or roof
gutters.
Where a drain line crosses over a metal roof, the pipe work must be fully insulated with weatherproof lagging to offer
corrosion protection to the metal roof against water runoff over the copper pipe. The insulation must be UV resistant if
exposed.
WATER PRESSURE
Solahart advises the limiting of water pressure to 500kPa with a pressure limiting valve to suit this solar water heater and its
associated pressure relief valves. Refer to local plumbing codes (e.g. AS/NZS3500.4) for specific requirements of
permissible supply pressure and associated reduction/limiting valve type applicability.
COLD SUPPLY LINE VALVE LOCATION
All the valves in the inlet cold supply line (i.e. the TRIO valve and ECV) must be located at least 1 metre away from the
water heater and readily accessible from ground or floor level to enable homeowner operation without the need for a ladder.
The valves should not be located on the house roof and NOT IN THE CEILING SPACE.
SUPPLEMENTARY ENERGY SUPPLIES –CONSIDER THE TPR VALVE RATING
The standard TPR valve that is fitted to the tank is rated at 10 kW. Supplementary energy supplies giving a combined total
heat input in excess of 10 kW including the electric booster should not be fitted to the water heater unless the TPR valve is
replaced with another of a larger capacity.
TPR Valve (45-1104) Typical Cold Water Inlet Configuration
TRIO Valve (33-1675)
Non Return & Isolating
Valve with Strainer
H50 Cold Relief
Valve (45-1103)

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 15
TEMPERATURE LIMITING DEVICES
This water heater can deliver water at temperatures which can cause scalding.
It is necessary and we recommend that a temperature limiting device be fitted between the water heater and the hot water
outlets in any ablution area such as a bathroom or ensuite, to reduce the risk of scalding. The installing plumber may have a
legal obligation to ensure the installation of this water heater meets the delivery water temperature requirements of
AS/NZS 3500.4, or other plumbing codes applicable in your area, so that scalding water temperatures are not delivered to a
bathroom, ensuite or other ablution area. Refer to plumbing codes applicable in your area to see if a temperature limiting
device is required for this installation for the supply of hot water from the solar water heater.
The temperature limiting device used with a solar water heater should have a specified „minimum temperature differential‟
between the hot water inlet and the tempered water outlet of no greater than 10°C. In addition, a temperature limiting
device capable of receiving a hot water supply temperature of up to 99°C should be used in conjunction with a
thermosiphon system. Refer to the specifications of the temperature limiting device.
For safety reasons Solahart recommends the fitment of temperature limiting devices in all instances.
EXTERNAL PIPE INSULATION
Refer to local plumbing codes (e.g. AS/NZS 3500.4) for the requirement for insulation of external pipe work.
Solahart recommends:
That all hot water pipe work should have closed cell insulation of minimum 13 mm thickness; this includes tank to
collector inter-connecting pipe. Thicker insulation may be required on external pipes to comply with the energy
efficiency requirements of AS/NZS 3500.4 in certain regions. Insulation should be suitable to the temperature of
operation; be suitable for at least 90⁰C for hot water supply pipes; be suitable for at least 120⁰C for tank to collector
connections in these thermosiphon systems.
Where potable water piping is in an external location or attic space where the temperature can be as low as -7°C
(18°F) it should be insulated with a minimum 19mm closed cell insulation; where the temperature can fall to -11°C
(12°F) the insulation thickness should be increased to 38mm.
Insulation in external locations should be weatherproof and resistant to UV radiation.
Insulation will improve system performance and will also protect against burns where heater is in trafficable location.
STOVE COIL BOOSTERS
Manually fed boosters such as stove coils, back boilers or coils in open fired grates are not permitted to be connected to
Solahart water heaters unless the storage cylinder is open vented. Such auxiliary energy sources must not be connected into
the closed circuit. Installation details for these devices are available from Solahart on application. In Australia, refer to
AS3500.1 for additional information. Refer also to your local water authority requirements for details of vent design,
header tank and reduction valves.
IN-SERIES GAS BOOSTING
Refer to the installation manual provided with the booster.
PACKING, STORAGE & TRANSPORTATION
All Thermosiphon products are to be kept in the original packaging materials and should be stored or transported in the
vertical position - note there is an arrow to indicate the „UP‟ direction for Tanks.
SYSTEM DECOMMISSIONING
Decommissioning of the system should be undertaken by an installer or suitable qualified plumber and / or electrician (if
required). All materials used in this product can be passed to your local material recycling centre for disposal - refer to
local council regulations for details.
For installation checklist please see page 27.

16 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
Thermosiphon Pipe Shroud Cover
The function of the Pipe Shroud Cover is to cover the plumbing pipe-work and electrical connections to the thermosiphon
tank, including the drain line from the temperature pressure relief valve, without restricting pipe runs for the installation or
the operation of the TPR valve.
KIT CONTENTS
The Thermosiphon Pipe Shroud Cover Kit consists of:
Component
Part No
Kit 12104050 Thermosiphon Pipe Shroud Cover Kit
Component Description
Quantity
208002
Pipe shroud cover
1
330370
Screw 8G x ½” pan head stainless steel
5
207501
Installation instructions
1
PIPE WORK AND CONNECTIONS
The installation of the pipe work and electrical connection is to be planned so their position aligns with the cut-outs at the
rear of the Pipe Shroud Cover.
The pipe work should also be positioned with any roof penetrations behind the solar storage tank to maintain the
aesthetics of the installation.
The pipe work, including the TPR valve drain line, shall not obstruct the hexagonal electrical cover.
The pipe work is to be installed to allow the fitting of the Pipe Shroud Cover without any distortion.
The TPR valve drain line must have a continuous fall and be installed in accordance with the installation instructions.
The installation of valves must be in accordance with national and local codes and regulatory authority requirements.
Penetrations through the roofing material must be at the high point of the roof tile or metal sheet, made neatly and kept
as small as practicable and be waterproofed.
Installation with a HartStat Over Temperature Protection System
Installation without a HartStat Over Temperature Protection System

33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12 17
FITTING THE PIPE SHROUD COVER
The Pipe Shroud Cover contains a number of preformed cut outs.
Each cut-out can be removed using a pair of snips
by following the preformed cut-out lines.
Remove only the necessary cut-outs to suit the
installation.
Caution: Practise safe working procedures when
using the snips and care is to be taken to avoid
potential injury from cut edges.
Additional cut outs other than those moulded into
the cover should not be made.
To fit the Pipe Shroud Cover to the jacket end after the
plumbing pipe work and electrical connection has been
made:
Position the cover so the five connection points
line up over the five screw penetrations in the tank
end cover.
Screw in the five screws provided, taking care not
to over tighten the screws.
Only use the screws provided.
Note: The Pipe Shroud Cover when fitted must be flush with the jacket end of the solar storage tank. There is to be no
distortion of the cover due to poorly installed pipe work. Correct the pipe work if the cover does not fit correctly.
OTP Expansion
vessel flexible
hose cut out
pipe work
cut outs
electrical and
pipe work
cut out
additional
pipe work
cut outs

18 33-1197 Solahart Owner‟s Manual – Thermosiphon Systems - Revision F –Jan. 12
INSTALLATION INSTRUCTIONS –CLOSED CIRCUIT SERIES
WARNING: THE TANKS AND COLLECTORS ARE HEAVY. IMPROPER LIFTING TECHNIQUES COULD
RESULT IN PERSONAL INJURY DURING INSTALLATION. IT IS THE INSTALLER‟S RESPONSIBILITY TO
USE ONLY APPROVED LIFTING AND SAFETY DEVICES AND TECHNIQUES WHEN LIFTING COLLECTORS
AND TANKS ON ROOFS.
WARNING: DO NOT REMOVE THE SOLAR COLLECTOR PACKAGING COMPLETELY PRIOR TO THE
INSTALLATION AS THE SOLAR COLLECTOR SURFACE CAN BECOME VERY HOT. THIS WILL ASSIST IN
PREVENTING POTENTIAL PERSONAL INJURY AND ALSO PREVENT PREMATURE HEATING OF THE
HARTGARD SOLUTION PRIOR TO COMPLETION OF THE COMMISSIONING PROCESS. REMOVE ONLY
SUFFICIENT PACKAGING MATERIAL TO ENABLE THE INSTALLATION OF THE SOLAR COLLECTORS.
Select the location of the storage tank. The front mounting foot of the tank should be positioned directly over a tile batten.
Remove several tiles to expose the rafters and this batten.
Measure down 2050 mm (1270 mm for 301 & 221 Closed Circuit System) from the centre of the batten to determine the
location of the collector rail (refer to drawings, Page 46), mark this location. Remove several roofing tiles from this
location to expose the rafters. Hook the two stainless steel straps (Part No. 33-0847, three for the 303 Closed Circuit
System) to the rail and line up the straps with the rafters. Ensure that they are no more than 1.6 m apart and not closer than
1 m. After positioning the rail level, raise the left hand side 12 mm for each collector fitted (i.e. 12 mm for a single
collector system, 24 mm for a two collector system, 36 mm for a three collectors etc) and fix the straps to the rafters.
Replace the tiles (refer to drawings, Page 46).
Move back up to where the storage tank is to be positioned. Place the aluminium flashing over this row of tiles and tuck the
top of the flashing under the row above.
Now using a lifting device, lift the collectors onto the roof and place them carefully into the collector rail. Remove the red
transit plugs from the collector sockets.
Join the collectors together using the collector connector assemblies (Part No. 33-7121). On systems that use conetite
fittings, ensure the fittings are fully inserted into the sockets before tightening the nuts. Only medium spanner pressure will
be required. The conetite fittings should be used only once. If for any reason, assemblies with conetite fittings need to be
removed, replace them completely with new assemblies.
Fit the fill assembly (Part No. 33-7134) and the collector bung assembly (Part No. 33-7135) into the bottom left and top
right hand corners (respectively) of the left and right hand collectors (respectively) using medium spanner pressure.
Centralise the collectors on the rail, and lock the collectors to the rail with the 4 collector clamps and tighten, using the nuts
and bolts provided.
For roof installations, slide the tank-to-collector spacers (Part No. 33-7144) over the top of the collectors. These should be
located 200 mm from the outer edge of the collectors, and on a high spot of the tiles (or profile for metal roofs).
Now using a lifting device, lift the tank onto the roof. Place the tank onto an aluminium flashing and locate the tank central
to the collectors before sliding it down onto the spacers.
Secure the tank to the roof rafters in a similar manner to that for the collectors, using the tank straps (Part No. 33-0845) and
the aluminium clamps (Part No. 33-0847). Loosely attach the tank clamps to the rear foot of the tank base, and clip in and
bolt the tank straps as per drawings, Page 46. Ensure the bolt heads fit into the valley of the tile.
Remove the yellow instruction label from the cold pipe. Fit the cold pipe first at the right hand side of the tank and insert
the other end of the pipe to the lower collector socket and tighten. Remove the yellow instruction label from the hot pipe.
Fit the hot pipe first at the left hand side of the tank. Tighten collector-side nut, before tightening tank-side nut. The floating
conetite should always be on the tank-side. Note that neither the hot nor the cold pipes (collector return and flow lines)
require insulation on these systems. It is recommended however insulation be fitted to these should the system be installed
on a metal or trafficable roof.
When in position, secure the tank straps to the roof rafters as for the collector strap. Ensure the straps are tight. Replace the
roof tiles. Fit the Pressure/Temperature Operated Relief Valve (Part No. 45-1104) into the tank as per water connection
diagrams, Page 45.
If the installation involves the HartStat System this should now be fitted. Refer to “Systems Installed with an Over
Temperature Protection (OTP) System” on page 20 and to the installation instructions provided with the HartStat Kit for
details.
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