Solahart Streamline Closed Circuit User manual

“Streamline Closed Circuit”
SOLAR STORAGE
SOLAR WATER HEATER
OWNER’S MANUAL
AND
WARRANTY / INSTALLATION INFORMATION
WARNING: Plumber – Be Aware
Use copper pipe ONLY. Plastic pipe MUST NOT be used.
It is a requirement of a solar water heater installation that all
pipe work be in copper and not plastic, due to the effects of
high water temperatures.
Solahart Industries Pty Ltd
ABN 45 064 945 848
This water heater must be installed and serviced by an authorised person.
Please leave this guide with the householder.

PATENTS
This water heater may be protected by one or more patents or registered designs.
® Registered trademark of Solahart Industries Pty Ltd or Rheem Australia Pty Ltd.
™ Trademark of Solahart Industries Pty Ltd or Rheem Australia Pty Ltd.
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.
WARNING: Plumber – Be Aware
•The solar hot and solar cold pipes between the solar storage tank and the solar
collectors MUST BE of copper and fully insulated with closed cell polymer insulation
or similar (minimum thickness 13 mm). Thicker insulation may be required to comply
with the requirements of AS/NZS 3500.4. The insulation must be weatherproof and
UV resistant if exposed. All compression fittings must use brass or copper olives.
•Plastic pipe MUST NOT be used, as it will not withstand the temperature of the
closed circuit fluid generated by the solar collectors under stagnation conditions. The
solar collectors can generate extremely high closed circuit fluid temperatures of up to
150°C. Plastic pipe cannot withstand these temperatures and MUST NOT be used.
Failure of plastic pipe can lead to the release of high temperature closed circuit fluid
and cause severe water damage and flooding. Refer to Warning on page 25.

3
CONTENTS
HOUSEHOLDER – We recommend you read pages 5to 13.
The other pages are intended for the installer but may be of interest.
Introduction................................................................................................................... 4
About Your Water Heater ............................................................................................. 5
How Your Water Heater Works.................................................................................... 8
Regular Care ............................................................................................................... 10
Save A Service Call .................................................................................................... 11
Installation – Solar Storage Tank .............................................................................. 14
Installation – Solar Collectors ................................................................................... 22
Connections – Plumbing............................................................................................ 26
Connections – Electrical ............................................................................................ 29
Auxiliary Pump............................................................................................................ 31
Commissioning........................................................................................................... 34
Draining The Water Heater......................................................................................... 48
Water Supplies............................................................................................................ 52
Warranty ...................................................................................................................... 53
Solahart Offices .......................................................................................................... 56

4
INTRODUCTION
Congratulations on choosing a “STREAMLINE CLOSED CIRCUIT SOLAR PREHEAT” solar water
heater. We are confident that your purchase will provide you many years of trouble free hot water.
All over the world, the Solahart name is synonymous with quality in water heating. From humble
beginnings in the pioneering days of Western Australia, a reputation has been built up over nearly a
century.
In 1905, two enterprising plumbers formed the company known as S. W. Hart, a name that was
retained for over 70 years. Even in its early stages, S. W. Hart was involved in the manufacture of metal
products for water storage and water heating. Since 1953, S. W. Hart, now Solahart Industries Pty Ltd,
has been producing thermosiphon solar hot water systems, which is well over 40 years of hot water
experience.
Solahart is the market leader in Australia and a dominant brand throughout the world. Our network of
distributors covers over 70 countries in Europe, North America, Africa and Asia. In our home market of
Australia, we offer the widest range of thermosiphon solar water heater products, along with the
Streamline brand of active solar hot water systems and Synergy heat pump. Our product is positioned
within the hot water market as a reliable, durable product with state of the art manufacturing technology.
It is with the above in mind that we at Solahart Industries Pty Ltd are confident that your purchase of the
“STREAMLINE CLOSED CIRCUIT SOLAR PREHEAT” solar water heater will provide you reliable hot
water with quality after sales service back up.
Thankyou

5
ABOUT YOUR WATER HEATER
MODEL TYPE
Congratulations for choosing a Solahart®water heater. Your Solahart Streamline closed circuit solar
water heater is designed for the solar collectors to be roof mounted and the solar storage tank to be
installed at ground or floor level. The solar storage tank is suitable for installation either outdoor or
indoor and with either Solahart ‘J’, ‘KF’, ‘LC’, ‘LCS’ or ‘BT’ solar collectors. The system is suitable for
installation in areas subject to frost or freeze conditions. Freeze conditions occur below 6°C.
This water heater is installed as a solar preheater to an in-series water heater. For information relating
to the function and operation of the in-series water heater, refer to the Owners Guide and Installation
Instructions supplied with the water heater.
HOW HOT SHOULD THE WATER BE?
The solar control unit will circulate the closed circuit fluid through
the solar collectors until a temperature of approximately 75°C is
reached in the solar storage tank. During periods of low solar
energy gain, the in-series booster water heater will boost the
water temperature automatically to its temperature setting when
required.
typical maximum
temperature from solar
gain
minimum recommended in-
series booster setting and
minimum recommended
stored water temperature
To meet the requirements of the National Plumbing Standard the
temperature setting of the in-series booster water heater must
not be below 60°C. maximum recommended
supply temperature to
bathrooms and ensuites
Solahart recommends the thermostat of the in-series booster
water heater be set at 60°C to maximise solar contribution.
Warning: Temperature controllers must not be fitted to the
in-series booster water heater as part of a solar water heater
system because water at a temperature much higher than the
controller setting can be delivered.
HOTTER WATER INCREASES THE RISK OF SCALD INJURY
This water heater can deliver water at temperatures which can cause scalding. 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.
WARNING
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, or by children. Children should be
supervised to ensure they do not interfere with the water heater.
This water heater uses 240 V AC electrical power for operation of the control systems and the
electrically operated components. The removal of the front covers will expose 240 V wiring. They must
only be removed by an authorised or qualified person. The power lead from the water heater must be
plugged into a weatherproof electrical outlet if installed outdoors. Take care not to touch the power plug
with wet hands.
Care should be taken not to touch the pipe work connecting the solar storage tank and the solar
collectors. Very high temperature closed circuit fluid can be generated by the solar collectors under
certain conditions and flow through the pipe work from the solar collectors to the solar storage tank.

ABOUT YOUR WATER HEATER
6
SAFETY
This water heater is supplied with temperature sensors, a pressure relief valve and a combination
temperature pressure relief valve. These devices must not be tampered with or removed. The water
heater must not be operated unless each of these devices is fitted and is in working order.
If the power supply cord or plug to the solar storage tank is damaged, it must be replaced by an
authorised person in order to avoid a hazard. The power supply cord and plug must be replaced with a
genuine replacement part available from Solahart. Phone your nearest Solahart Dealer to arrange for
an inspection.
The warranty can become void if relief valves or other safety devices are tampered with or if the
installation is not in accordance with these instructions.
TO TURN OFF THE WATER HEATER
If you plan to be away from home for a few nights, we suggest you leave the water heater switched on.
If it is necessary to turn off the water heater:
•Switch off the electrical supply at the power outlet to the solar storage tank.
•Close the cold water isolation valve at the inlet to the water heater.
TO TURN ON THE WATER HEATER
•Open the cold water isolation valve fully at the inlet to the water heater.
•Open all of the hot water taps in the house (don’t forget the shower).
Air will be forced out of the taps.
•Close each tap as water flows freely from it.
•Plug in the water heater at the power outlet and switch on the electrical supply.
The power outlet must be switched on for the solar controls to operate and solar gain to be
achieved.
HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY?
Installation requirements are shown on page 21. The water heater must be installed by an authorised
person and the installation must comply with National Standards AS/NZS 3500.4, AS/NZS 3000 and all
local codes and regulatory authority requirements. In New Zealand, the installation must conform with
the New Zealand Building Code.
Temperature controllers must not be fitted to the in-series booster water heater (refer to warning
under “How Hot Should The Water Be?” on page 5).
PIPE WORK AND INSULATION
The solar hot and solar cold pipe work between the solar storage tank and the solar collectors and
between the solar storage tank and in-series water heater MUST BE of copper and fully insulated with
closed cell polymer insulation or similar (minimum thickness 13 mm). The insulation must be
weatherproof and UV resistant if exposed. The insulation will offer corrosion protection to a metal roof
against water runoff over the copper pipe, assist in avoiding accidental contact with the solar pipe work
and also reduce pipe heat losses.
The insulation must be fitted up to the connections on both the solar collectors and the solar storage
tank, as very high temperature closed circuit fluid can flow from the solar collectors to the solar storage
tank under certain conditions.
There must be a continuous fall in the pipe work from the solar collectors to the solar storage tank. The
continuous fall is essential to assist in the drain back function of the solar system.

ABOUT YOUR WATER HEATER
7
Plastic pipe MUST NOT be used, as it will not withstand the temperature of the closed circuit fluid
generated by the solar collectors under certain conditions (refer to Warning on page 25).
RAIN WATER TANK
If the solar collectors and solar pipe work are installed on a section of roof which is part of a rain water
runoff collection system, then it is recommended this section of roof and its gutter be isolated from the
rain water collection system. The gutter should be isolated to a width greater than the solar collectors
and pipe work and must have suitable drainage. This is to ensure in the event of a leak from the solar
collectors or pipe work, a rainwater tank cannot be contaminated with closed circuit fluid.
The closed circuit fluid contains food grade additives (rust inhibitor and anti-freeze agent), is non-toxic
and is harmless to the environment. However, if it enters a rain water tank, it can kill off microscopic
algae which are typically present in the water causing an unpleasant odour to develop and resulting in
the rain water tank having to be drained and cleaned.
DOES THE WATER QUALITY AFFECT THE WATER HEATER?
The water heater is suitable for most public water supplies, however some water qualities may have
detrimental effects on the cylinder and fittings. If you are in a known harsh water area you must read
page 52. If you are not sure, have your water quality checked against the conditions described on
page 52.
HOW LONG WILL THE WATER HEATER LAST?
There are a number of factors that will affect the length of service the water heater will provide. These
include the water quality, the water pressure, temperature (inlet and outlet) and the water usage
pattern. However, your Solahart water heater is supported by a comprehensive warranty (refer to
page 54).
ANODE PROTECTION
The anode(s) installed in your water heater will slowly dissipate whilst protecting the cylinder. The life of
the water heater cylinder may be extended by arranging for an authorised person to inspect the
anode(s) and replace if required.
The suggested time after installation when the anode(s) should be inspected is 8 years.
For softened water supplies or in areas of poor water quality, it is recommended the anode(s) be
inspected 3 years earlier than shown (refer to “Water Supplies” on page 52).
FREEZE PROTECTION
The solar circuit must be installed with a continuous fall in the pipe work from the solar collectors to the
solar storage tank, the solar hot and solar cold pipes must be fully insulated with closed cell polymer
insulation (minimum thickness 13 mm) and the system charged with correctly mixed closed circuit fluid
to offer protection against freeze damage. The system has NO WARRANTY for freeze damage if there
is not a continuous fall in the solar hot and solar cold pipes, or they are uninsulated, or the closed circuit
fluid has been incorrectly mixed (refer to “Warranty Exclusions” on page 53 and to “Pipe Work and
Insulation” on page 6).
The anti freeze control of the solar circuit is designed so there is no closed circuit fluid in the solar
collectors or solar cold and solar hot pipes when the pump is off.
Notes:
•Pipe work to and from the water heater must be adequately insulated to prevent freezing.
•The water heater is not suitable for installation in areas where the ambient temperature falls below
-20ºC.
•Refer to
“Warranty Exclusions” on page 53.

8
HOW YOUR WATER HEATER WORKS
SOLAR OPERATION
The Solahart Streamline closed circuit solar water heater has its vitreous enamel lined solar storage
tank installed at ground or floor level, remotely from the solar collectors. This water heater is an indirect
solar hot water system with a heat exchanger in the solar storage tank. The heat exchanger is filled with
closed circuit fluid and is connected to the solar collectors forming a closed circuit.
As the sun heats the solar collectors, the increase in temperature
activates the pump. The pump switches on whenever the solar
collectors are hotter than the water in the tank. The pump moves
the closed circuit fluid from the solar storage tank heat exchanger
through an insulated copper pipe to the solar collectors to be
heated by the sun’s energy and then back to the heat exchanger.
Heat transfers from the closed circuit fluid in the heat exchanger to
the water stored in the solar storage tank.
This process continues while solar energy is available and until the
water in the solar storage tank reaches a temperature of
approximately 75°C. The pump is then deactivated and the closed
circuit fluid in the solar collectors and solar pipe work drains back
into the heat exchanger in the solar storage tank.
The closed circuit provides protection to the solar collectors and
solar circuit in harsh water areas. The drain back principle provides
protection to the system in freezing conditions.
Automatic safety controls are fitted to the water heater to provide safe and efficient operation.
BOOSTER WATER HEATER OPERATION
Water stored in the solar storage tank passes through the in-series booster water heater when a hot tap
is opened. The booster water heater is for heating the water at times of low solar energy gain, such as
during cloudy or rainy weather, or during winter months.
Solar heated water can reach temperatures up to 75°C in the solar storage tank. When the solar heated
water temperature is above the temperature setting of the in-series booster water heater, the booster
water heater will not boost the water temperature.
MAINS PRESSURE
The water heater is designed to operate at mains pressure by connecting directly to the mains water
supply. If the mains supply pressure in your area exceeds that shown on page 15, a pressure limiting
valve must be fitted. The supply pressure should be greater than 350 kPa for true mains pressure
operation to be achieved.

HOW YOUR WATER HEATER WORKS
9
SOLAR MONITOR
The solar storage tank incorporates a solar monitor. The solar monitor is located on the lower front
cover and houses both a green and a red LED.
The green LED, marked “Solar”, indicates the current operational mode of the solar water heater and
the red LED, marked “Attention”, indicates a fault mode.
The green LED will emit either a constant glow or a series of flashes, with a 2 second interval between
flashes.
The red LED will emit a series of flashes, with a 2 second interval between flashes, only if there is a
particular fault condition with the system.
The operational modes are:
Flashes Operational Modes
solid green
(remains on) Standby mode
1 x green Flooding solar circuit
2 x green Checking solar contribution
3 x green Pump flow control
4 x green Pump flow established
5 x green Tank at maximum temperature
no green
(remains off) Call for service
If the power supply to the water heater is on and the green LED is off or the red LED is flashing, this
indicates there is a fault with the water heater. The red LED may emit up to five flashes in each series
of flashes. Count the number of flashes and phone your nearest Solahart Dealer to arrange for an
inspection.
GOING ON HOLIDAYS
It is not necessary to switch off the electrical supply at the power outlet to the water heater if you are
going away. However, if it is necessary to switch off the power to the water heater, refer to “To Turn Off
The Water Heater” on page 6.

10
REGULAR CARE
TEMPERATURE PRESSURE RELIEF VALVE
This valve is near the top of the water heater 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.
lift until water
flows from the
drain line –
lower gently
drain
line
water
heater
Continuous leakage of water from the valve and its drain line
may indicate a problem with the water heater (refer to
“Temperature Pressure Relief Valve Running” on page 12).
Warning: Never block the outlet of this valve or its drain line
for any reason.
Operate the easing lever on the temperature pressure relief
valve once every six months. It is very important you raise
and lower the lever gently.
Warning: Failure to do this may result in the water heater
cylinder failing.
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 temperature pressure relief 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 (refer to “Water Supplies” on page 52).
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. The expansion control valve may
discharge a small quantity of water from its drain line during the heating period instead of the
temperature pressure relief valve on the water heater.
Operate the easing lever on the expansion control valve once every six months. It is very important
you raise and lower the lever gently. 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 GLASS
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. If the collector glass becomes dirty, hose down or if the
solar collectors are accessible, wash the collector glass with water and a soft brush when the solar
collectors are cool. Have any trees trimmed which may shade the solar collectors.

11
SAVE A SERVICE CALL
Check the items below before making a service call. You will be charged for attending to any condition
or fault that is not related to manufacture or failure of a part.
NOT ENOUGH HOT WATER (OR NO HOT WATER)
•Solar Controller
Check the power supply cord is plugged in and the power outlet switched on.
Is power available in the house? Try using another electrical
appliance.
•Insufficient sunlight
Insufficient sunlight due to cloudy weather during summer
months or low solar energy contribution in winter months
may mean the booster water heater operates more often.
•Collectors shaded
If trees or other objects shade the solar collectors or if the
glass is dirty, the effectiveness of the solar collectors will be
greatly reduced. Have the trees trimmed or the solar
collectors relocated if the obstruction is permanent or clean
the collector glass (refer to “Collector Glass” on page 10).
•Collector area is too small
For most installations, the number of solar collectors recommended in Solahart literature has been
proven to provide the required solar energy to meet the average family needs. However, in some
circumstances, it may be necessary to install an additional solar collector.
•Are you using more hot water than you think?
Is one outlet (especially the shower) using more hot water than you think?
Very often it is not realised the amount of hot water used, particularly when showering. Carefully
review the family’s hot water usage. As you have installed an energy saving appliance, energy
saving should also be practised in the home. Adjust your water usage pattern to take advantage of
maximum solar gains.
Have your plumber install a flow control valve to each shower outlet, basin and sink to reduce water
usage.
•Temperature pressure relief valve running
Is the relief valve discharging too much water? (Refer to “Temperature Pressure Relief Valve
Running” on page 12).
•Water heater size
Do you have the correct size water heater for your requirements? The sizing guide in the sales
literature and on the Solahart website (www.solahart.com.au) suggests average sizes that may be
needed.
NO WATER FROM THE HOT TAP
No flow of water from the hot tap may indicate a restriction in or failure of the cold water supply to the
water heater. Check for water flow at other taps and that the cold water isolation valve (refer to
page 26)is fully open.

SAVE A SERVICE CALL
12
IN-SERIES BOOSTER WATER HEATER OPERATING TOO FREQUENTLY
You may find that the in-series booster water heater operates more frequently than expected. This will
occur when the solar preheat water temperature is lower than the temperature setting of the in-series
booster water heater. This may be experienced during periods of low solar energy gain or if there has
been heavy hot water usage.
COLLECTOR GLASS
Warranty DOES NOT cover breakage of solar collector glass. Check your household insurance policy
covers collector glass breakage.
Warning: Collector glass must not be replaced whilst the solar collector is on the roof.
The collector glass is not offered as a replacement part and no attempt should be made to remove it.
Should the solar collector require replacement, contact your nearest Solahart Dealer.
TEMPERATURE PRESSURE RELIEF VALVE RUNNING
•Normal Operation
It is normal and desirable this valve allows a small quantity
of water to escape during the heating cycle. However, if it
discharges more than a bucket full of water in 24 hours,
there may be another problem.
•Continuous dribble
Try gently raising the easing lever on the relief valve for a
few seconds (refer to “Temperature Pressure Relief Valve”
on page
10). This may dislodge a small particle of foreign
matter and clear the fault. Release the lever gently.
•Steady flows for long period (often at night)
This may indicate the mains water pressure sometimes rises
above the designed pressure of the water heater. Ask your
installing plumber to fit a pressure limiting valve.
Warning: Never replace the relief valve with one of a higher pressure rating.
•Heavy flows of hot water until the water heater is cold - then stops until water reheats
The water heater must be switched off at the isolating switch or switchboard. Phone your nearest
Solahart Dealer to arrange for an inspection.
EXPANSION CONTROL VALVE RUNNING
If an expansion control valve is fitted in the cold water line to the water heater (refer to page 26)it may
discharge a small quantity of water instead of the temperature pressure relief valve on the water heater.
The benefit is that energy is conserved as the discharged water is cooler.

SAVE A SERVICE CALL
13
HIGH GAS OR ELECTRICITY BILLS
With the installation of your new solar hot water system, maximum energy savings can be achieved
with careful planning of hot water usage. Should you at any time, feel your energy account is too high,
we suggest you check the following points:
•Is the relief valve running excessively? (Refer to
“Temperature Pressure Relief Valve Running” on page 12).
•Is one outlet (especially the shower) using more hot water
than you think? (Refer to “Not Enough Hot Water” on
page 11).
•Is there a leaking hot water pipe, dripping hot water tap, etc?
Even a small leak will waste a surprising quantity of hot
water and energy. Replace faulty tap washers, and have
your plumber rectify any leaking pipe work.
•Is the booster water heater operating too frequently? (Refer
to “In-Series Booster Water Heater Operating Too
Frequently” on page 12).
•Consider recent changes to your hot water usage pattern
and check if there has been any increase in tariffs since
your previous account.
IF YOU HAVE CHECKED ALL THE FOREGOING AND STILL BELIEVE YOU NEED ASSISTANCE,
CALL YOUR NEAREST SOLAHART DEALER.

14
INSTALLATION – SOLAR STORAGE TANK
THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING.
The system is suitable for installation with Solahart ‘J’, ‘KF’, ‘LC’, ‘LCS’ or ‘BT’ solar collectors.
The solar circuit must be installed with a continuous fall of a minimum 5° in the pipe work from the solar
collectors to the solar storage tank, the solar hot and solar cold pipes must be fully insulated with closed
cell polymer insulation (minimum thickness 13 mm) and the system charged with correctly mixed closed
circuit fluid to offer protection against freeze damage. The system has NO WARRANTY for freeze
damage if there is not a continuous fall in the solar hot and solar cold pipes or they are uninsulated or
the closed circuit fluid has been incorrectly mixed (refer to “Warranty Exclusions” on page 53 and to
“Warning: Plumber Be Aware” on page 25). Thicker insulation may be required to comply with the
requirements of AS/NZS 3500.4.
SOLAR WATER HEATER STORAGE TANK LOCATION
The solar storage tank is suitable for either outdoor or indoor installation. The solar storage tank should
be installed close to the most frequently used outlet and its position chosen with safety and service in
mind.
Consideration must also be given to the position of the solar storage tank in relation to the solar
collectors. There are limitations on both the maximum length of the solar hot and solar cold pipes and
the maximum height between the solar storage tank and the solar collectors. Refer to “Solar Collector
Location” on page 22 and to “Pipe Lengths” on page 23.
Clearance must be allowed for servicing of the solar
storage tank. The solar storage tank must be
accessible without the use of a ladder or scaffold. Make
sure the temperature pressure relief valve lever is
accessible and the front covers can be removed for
service.
You must be able to read the information on the rating
plate. If possible leave headroom of one water heater
length so the anode can be inspected or replaced.
Remember you may have to remove the entire solar
storage tank later for servicing.
The installation must comply with these installation
instructions and with the requirements of
AS/NZS 3500.4, AS/NZS 3000 and all local codes and
regulatory authority requirements. In New Zealand, the
installation must conform with the New Zealand
Building Code.
The water heater must not be installed in an area with a corrosive atmosphere where chemicals are
stored or where aerosol propellants are released. Remember the air may be safe to breathe, but when
it goes through a flame, chemical changes take place which may attack the water heater.
It is recommended the solar storage tank be installed at ground or floor level and must stand vertically
upright. Remember all local authorities have regulations about putting water heaters into roof spaces.
Note: It is important for the solar storage tank to be orientated vertically upright in order for the falling
film of closed circuit fluid to operate efficiently.
The top of the solar storage tank must be a minimum of 500 mm below the bottom of the solar
collectors for the system to operate correctly.

INSTALLATION – SOLAR STORAGE TANK
15
SAFE TRAY
It is a requirement of AS/NZS 3500.4 that for a new installation,
a water heater be installed in a safe tray where in the event of a
leak, property may otherwise be damaged. Construction,
installation and draining of a safe tray must comply with the
above mentioned Standard.
FROST PROTECTION
The water heater has a frost protection system. The frost protection system will protect the water heater
from damage, by preventing ice forming in the waterways of the water heater, in the event of freezing
conditions occurring.
The solar collectors and solar cold and solar hot pipes only contain closed circuit fluid when the pump is
operating during periods of solar gain when heating is required. When the solar pump stops operating,
the closed circuit fluid drains back into the storage tank heat exchanger. The closed circuit fluid is an
anti-freeze agent which, when mixed to the correct specification, can withstand temperatures of -20°C
before it may freeze.
Damage to the water heater caused by freezing of the pipe work to or from the water heater is not
covered under warranty. Refer to AS/NZS 3500.4 for precautions to be taken for installations in frost
prone areas. The water heater is not suitable for installation in areas where the ambient temperature
falls below -20ºC.
MAINS WATER SUPPLY
Where the mains water supply pressure exceeds that shown in the table below, an approved pressure
limiting valve is required and should be fitted as shown in the installation diagram (refer to diagram on
page 26).
Model 270
Relief valve setting 1000 kPa
Expansion control valve setting * 850 kPa
Max. mains supply pressure
With expansion control valve 680 kPa
Without expansion control valve 800 kPa
* Expansion control valve not supplied with the water heater.
TANK WATER SUPPLY
If the water heater is supplied with water from a tank supply and a pressure pump system is not
installed, then the bottom of the supply tank must be at least 1 m above the highest point of the hot
water plumbing system, including the solar storage tank. Care must be taken to avoid air locks. The
cold water line to the water heater should be adequately sized and fitted with a full flow gate valve or
ball valve. Consideration must be given to any minimum water supply pressure requirements of an in-
series booster water heater.

INSTALLATION – SOLAR STORAGE TANK
16
RAIN WATER TANK
If the solar collectors and solar pipe work are to be installed on a section of roof which is part of a rain
water runoff collection system, then it is recommended this section of roof and its gutter be isolated
from the rain water collection system. The gutter should be isolated to a width greater than the solar
collectors and pipe work and must have suitable drainage. The installer should ensure in the event of a
leak from the solar collectors or pipe work, a rainwater tank cannot be contaminated with closed circuit
fluid.
The section of roof and gutter should be isolated from the rainwater collection system before the
commissioning of the solar water heater, so that any leak or spillage during commissioning does not
make its way into the rainwater tank.
This section of roof and guttering can be isolated by either:
•blocking this section of gutter from the remaining gutter and fitting two separate down pipes, one to
take any run-off water from that section of roof away to drain and the other to the rainwater
collection side of the gutter to take the rain water run off to the rain water tank.
•blocking this section of gutter from the remaining gutter and fitting a tube or pipe of a material
compatible with the gutter material in this section of the gutter and penetrating the separation
pieces at either end to allow rainwater runoff to pass from one part of the rainwater collection
system to the other. It may be necessary to fit a down pipe to the section of blocked gutter to take
any run-off water from that section of roof away to drain.
•installing a false gutter inside of the existing gutter, with a down pipe penetrating the existing gutter
to take any run-off water from that section of roof away to drain. The false gutter should be no
deeper than half of the depth of the existing gutter, so as to enable rain water run off to flow under
the false gutter.
•installing a flashing from the underside of the roofing material, with a continuous fall, to over the
outside lip of the gutter. The flashing should extend wider than the collectors and pipe work and
turned up at the ends so if there is leakage of closed circuit fluid, it cannot enter the gutter.
If any of these solutions are not practical, then the installer should discuss alternative options to suit the
installation with the house holder.
Any alterations to the roof drainage system must comply with the relevant building regulations, codes
and standards.

INSTALLATION – SOLAR STORAGE TANK
17
HOT WATER DELIVERY
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 in-series
booster 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 so that
scalding water temperatures are not delivered to a bathroom, ensuite or other ablution area.
The temperature limiting device used with a solar water heater should have a specified minimum
temperature differential, i.e. between the hot water inlet and the tempered water outlet, of no greater
than 10°C.
Where a temperature limiting device is installed adjacent to the in-series booster water heater, the cold
water line to the temperature limiting device can be branched off the cold water line either before or
after the isolation valve, pressure limiting valve and non return valve to the solar storage tank. If an
expansion control valve is required, it must always be installed after the non return valve and be the last
valve prior to the solar storage tank.
If a pressure limiting valve is installed on the cold water line to the solar storage tank and the cold water
line to a temperature limiting device branches off before this valve or from another cold water line in the
premises, then a pressure limiting valve of an equal pressure setting may be required prior to the
temperature limiting device.
Two Temperature Zones Using Temperature Limiting Device

INSTALLATION – SOLAR STORAGE TANK
18
CIRCULATED HOT WATER FLOW AND RETURN SYSTEM
A solar water heater should not be installed as part of a circulated hot water flow and return system in a
building. The benefits of solar gain will be significantly reduced and energy gained from the sun lost
through the pipe work.
If a circulated flow and return system is required, it is necessary to connect the return line after the solar
preheat system and prior to the in-series booster water heater supplied from the solar preheat system.
The in-series booster water heater must be able to provide a hot water outlet temperature of at least
60°C. Note: The thermostat must always be set to at least 60°C. Refer to the diagram on page 18.
Temperature Limiting Device
A temperature limiting device cannot be installed in circulated hot water flow and return pipe work. The
tempered water from a temperature limiting device cannot be circulated.
Where a circulated hot water flow and return system is required in a building, a temperature limiting
device can only be installed on a dead leg, branching off the circulated hot water flow and return pipe.
If circulated tempered water were to be returned back to the water heater, depending on the location of
the return line connection on the water supply line to the water heater, then either:
•water will be supplied to the cold water inlet of the temperature limiting device at a temperature
exceeding the maximum recommended water supply temperature, or
•when the hot taps are closed no water will be supplied to the cold water inlet of the temperature
limiting device whilst hot water will continue to be supplied to the hot water inlet of the temperature
limiting device.
These conditions may result in either water at a temperature exceeding the requirements of
AS/NZS 3500.4 being delivered to the hot water outlets in the ablution areas, or the device closing
completely and not delivering water at all, or the device failing. Under either condition, the operation
and performance of the device cannot be guaranteed.
Circulated Hot Water Flow and Return System – Solar Water Heater

INSTALLATION – SOLAR STORAGE TANK
19
REDUCING HEAT LOSSES
The cold water line to and the hot water lines from the water heater must be insulated in accordance
with the requirements of AS/NZS 3500.4. The insulation must be weatherproof and UV resistant if
exposed.
The pipe work between the solar storage tank and the solar collectors must be fully insulated with
closed cell polymer insulation or similar (minimum thickness 13 mm). Thicker insulation may be
required to comply with the requirements of AS/NZS 3500.4. The insulation must be weatherproof and
UV resistant if exposed. The insulation must be fitted up to the connections on both the solar storage
tank and the solar collectors.
ANODE TYPES
The correct anode type for the water supply being used must be fitted in the water heater (refer to
“Water Supplies” on page 52). The black anode is fitted as standard.
Total Dissolved Solids in water supply to the water heater Anode colour code
0 – 40 mg/L Green
40 – 600 mg/L Black
600 – 2500 mg/L Blue
SADDLING - PIPE WORK
To prevent damage to the cylinder when attaching pipe clips or saddles to the water heater jacket, we
recommend the use of self-drilling screws with a maximum length of 13 mm. Should pre drilling be
required, extreme caution must be observed when penetrating the jacket of the water heater.
Note: Damage to the cylinder as a result of saddling to the jacket will void the warranty.

INSTALLATION – SOLAR STORAGE TANK
20
DIMENSIONS AND TECHNICAL DATA
Model DBV 270 00 Capacity 270 litres Mass 145 kg (empty) 415 kg (full)
Specifications are subject to change with ongoing product improvements.