Solar 3C 3C382B Troubleshooting guide

Installations, User and Service Manual
Section A
Domestic Hot Water Cylinder
3C382B | 3C510B | 3C382HP | 3C510HP
Section B
Solar 3C Heating System
Important -This manual should be left with the cylinder after installation
Solar 3C
01242 253817
[email protected]
Solar 3C
Unit 1
20 Winchcombe Street
Cheltenham
GL52 2LY
Version 6.1
14/07/2014

Installations, User and Service Manual
Section A
Domestic Hot Water Cylinder
3C382B | 3C510B | 3C382HP | 3C510HP
Important - This manual should be left with the
cylinder after installation
2

Solar 3C Cylinder Range
Installation and Service Manual Index
Section
1 Introduction
2 Technical specications
3 Check list
4 General requirements
5 Primary circuit installation
6 Secondary circuit installation
7 Discharge arrangement
8 Electrical installation
9 Filling and commissioning
10 Servicing and maintenance
11 Spare parts list
12 Fault nding
13 User instructions
14 Warranty
15 Installation, commissioning and service record
1. Introduction
The Solar 3C Cylinder is a high quality stainless steel hot water cylinder suitable for use on unvented or
open vented hot water systems. The indirect heat exchange surfaces are designed to provide rapid heat up.
The indirect units incorporate 2 x 3kW electric immersion heaters as backup. When the unit is supplied for
unvented applications, it comes complete with all the necessary safety equipment to comply with legislation
governing the installation of such systems. The temperature and pressure relief valve is factory tted.
The Solar 3C Cylinder range has 3-coils; the bottom coil is for the solar thermal connection, the middle coil
for conventional boiler or heat pump back up (both middle & bottom are input coils) and a top coil which
is designed as an output coil. This coil, sat in a reservoir of energy hopefully supplied via the solar thermal
collectors, will enable the energy to be taken from the cylinder indirectly to the heating load via the Solar 3C
purpose control box and jig.
All the installation, user and service instructions given for the Solar 3C Cylinder range apply to the 3C382B,
3C510B, 3C382HP and 3C510HP cylinders unless otherwise stated.
3

4
Solar 3C 3- Coil Indirect Cylinders
3C382B 3C510B 3C382HP 3C510HP
Storage capacity (litres) 382 510 382 510
Overall diameter (mm) 580 663 580 663
Overall diameter incl. immersion heater mm 642 725 642 725
Overall height with exp. vessel on cold feed supply (mm) 2100 2057 2100 2057
Weight when full (kg)
Primary ow/return connections (mm) 22 22 22 22
Secondary return (mm) 15 15 15 15
Cold feed/ hot draw off connections (mm) 28 28 28 28
Maximum water supply pressure (bar) 10 10 10 10
System operating pressure (pre-set) (bar) 3 3 3 3
Expansion vessel charge pressure (bar) 2 2 2 2
Expansion relief valve set pressure (bar) 6 6 6 6
Temperature and pressure relief value set:
Lift pressure (bar) 7 7 7 7
Lift temperature (ºC) 90+/-5 90+/-5 90+/-5 90+/-5
Maximum primary working pressure (bar) 3 3 3 3
Performance
Hot water generation time from 15 to 65 (ºC) for ‘indirect’ cylinder (min) 51mins 63mins 51mins 63mins
Regeneration time for 70% of contents for ‘indirect’ cylinder (min) 39mins 53mins 39mins 53mins
Heat Loss (kW/h per day) 3.42 4.14 3.42 4.14
3- Coil Indirect Cylinders
3C382B 3C510B 3C382HP 3C510HP
Cylinder assembly 382 litre 1 - - -
Cylinder assembly 510 litre - 1 - -
Cylinder assembly 382 litre - - 1 -
Cylinder assembly HP 510 litre - - - 1
Expansion vessel 35 Litre 1 - 1 -
Expansion vessel 80 Litre - 1 - 1
Pressure reducing valve 1 1 1 1
Expansion relef valve 1 1 1 1
T/P valve, pre tted 1 1 1 1
15/22 Tundish 1 1 1 1
22mm DHW motorised valve 1 1 1 1
22mm High temp motorised valve 1 1 1 1
Control/ limit thermostat 2 2 2 2
Immersion heater pre tted 2 2 2 2
2. Technical specications
3. Check list
Note: e expansion vessel should be tted on the cold water supply.

4. General requirements
4.1. The Solar 3C domestic hot water cylinder MUST be installed by a competent person in accordance
with WRAS and section G3 of the current Building Regulations.
4.2. Important - It is important that the installer reads and understands these instructions, unpacks and
familiarises themselves with the equipment before commencing the installation. Failure to observe
these installation instructions could invalidate the warranty.
4.3. Water supply - The warranty requires that the water to be heated is wholesome and of drinking
water quality and that if water treatment equipment is installed, it must function correctly.
Where possible the unit should be fed via at least Ø22mm (mains water) supply pipe. It requires
a supply pressure of 1.0 bar with a ow rate of at least 10 Litres per minute as a minimum for it to
function. Even with these rates, ow from the outlets will be disappointing/poor if several outlets are
used simultaneously. Generally speaking, the higher the supply pressure, the better the system will
function. The cylinder control equipment is factory set to limit the system operating pressure to 3
bar. The maximum supply pressure in to the pressure-reducing valve is 10 bar.
4.4. Taps and ttings - All taps and ttings incorporated in the unvented system should have a rated
operating pressure of 7 bar or above.
4.5. Location – The unit is designed to be oor standing, vertically mounted, indoors, in a frost-free
environment. When choosing a suitable location for the cylinder, consideration should be given to
the routing of the discharge pipe to a convenient point and also the availability of an adequate
power supply for connecting the immersion heater(s). The cylinder may stand on any at and level
surface without any special foundation preparations, provided that it is sufciently robust to support
the full weight of the cylinder. (Refer to technical specications for weights). The position of the
cylinder should be such that easy access is provided for servicing the controls and replacing the
immersion heater should the need arise. Generally, pipe runs should be made as short as possible
and lagged to prevent heat loss. All pipework connections are to meet and be installed to any/all
relevant standards at the time of installation.
4.6. Storage and handling – If the cylinder is not being installed immediately, it should remain in its
packaging with all pipe end protective caps in situ to prevent damage. We recommend that the
cylinder be transported to its installation position on a sack truck or similar with the outer packaging
in place.
5

'SOLAR3C'
OUTPUT COIL
ONLY
BOILER
INPUT
COIL
SECONDARY
RETURN
12 2
911 10
8
7
SOLAR
INPUT
COIL
SOLAR SYSTEM
PROBE
HOT OUT
SOLAR3C
PROBE
CYLINDER
STAT
SOLAR
HIGH-LIMIT
STAT
COLD IN
3
7
4
6
5
1
5
4
7
6
Fig.1a. Solar 3C Cylinder Three Coil pipe work connections - 382B and 510B cylinders
Item Description Quantity
1 Triple Coil Cylinder 1
2 Expansion Vessel 1
3 3/4” T&P Relief Valve 1
4 1 3/4” Immersion heater 2
5 Cylinder Thermostat 1
6 Auxillary sensor pocket 0
7 Probe Pocket only 2
8 22mm 2 Port zone valve 1
Item Description Quantity
9 Tundish 1
10 28mm monobloc inlet kit 1
11 10 bar Pressure Gauge 1
12 22mm 2 Port Solar Zone Valve 1
For illustration purposes only.

'SOLAR3C'
OUTPUT COIL
ONLY
HEAT PUMP
INPUT
COIL
SOLAR
INPUT
COIL
12
SECONDARY
RETURN
HOT OUT
COLD IN
SOLAR3C
PROBE
*3C382HP
ONLY
SOLAR SYSTEM
PROBE
CYLINDER
STAT
SOLAR
HIGH-LIMIT
STAT
2
911
10
78
10 11
3
7
4
6
5
1
4
5
4
7
7
Fig.1b. Solar 3C Cylinder Three Coil pipe work connections - 382HP and 510HP cylinders
Item Description Quantity
1 Triple Coil Cylinder 1
2 Expansion Vessel 1
3 3/4” T&P Relief Valve 1
4 1 3/4” Immersion heater 2*
5 Cylinder Thermostat 1
6 Auxillary sensor pocket 0
7 Probe Pocket only 2
8 22mm 2 Port zone valve 1
Item Description Quantity
9 Tundish 1
10 28mm monobloc inlet kit 1
11 10 bar Pressure Gauge 1
12 22mm 2 Port Solar Zone Valve 1
* Middle immersion heater is only on 3C382HP cylinder
For illustration purposes only.

5. Primary circuit installation
5.1. Solar 3C cylinders are suitable for connecting to most fully pumped domestic central heating (an open vented
or sealed system), having a maximum working pressure of 3 bar and a maximum working temperature of 90
degrees centigrade. If you are in any doubt concerning the suitability of the boiler, consult the boiler
manufacturer. Solid fuel or wood burning boilers, and gravity circulation systems MUST NOT be used on the
primary circuit of an unvented hot water system.
5.2. Systems - For the best results we recommend that the Solar 3C Cylinder be connected to a “S” plan type
system. Solar 3C Cylinder can be used on “S” plan or “Y” plan systems only.
This cylinder incorporates a solar coil, situated below the boiler primary coil. The boiler/primary coil
connections should be made in accordance with the instructions given at the beginning of this section.
ENSURE THAT YOU CONNECT THE PRIMARY ENERGY SOURCE, NORMALLY A GAS/OIL BOILER OR AIR
SOURCE HEAT PUMP TO THE MIDDLE BOILER/HEAT PUMP COIL ONLY.
THE TOP COIL MARKED ‘OUTPUT COIL ONLY’ IS ONLY TO BE USED AS AN OUTPUT COIL (SEE FIGURES
1A AND B) AND NOT TO BE USED AS AN INPUT COIL.
5.3. The following wiring diagrams are for guidance only. The system must be wired in accordance with the boiler
manufactures instructions and any regulations with regard to unvented cylinders. Solar 3C accepts no liability
for connection to the cylinder.
The lower/bottom solar coil is used for energy input from a secondary source (examples include solar
collectors) having a maximum working pressure of 3 bar and a maximum working temperature of 90 degrees
centigrade. The lower coil has its own temperature sensing point – this is a stainless steel pocket. In addition
there is a further sensing pocket should overall control of the cylinder temperature be required. Thermostats
for these sensing points are not supplied.
The ow from the secondary energy source should be connected to the top connection on the bottom/solar
coil and the return to the bottom. The motorised valves (including high temperature motorised valve) must
be connected to the high limit on the cylinder thermostat in such a way as to isolate the cylinder from the
primary and secondary energy sources if the cylinder temperature exceeds the high set point. Please see the
section on electrical installation.
THIS IS ESSENTIAL TO ENSURE A SAFE WORKING PRODUCT & TO AVOID EXCESSIVELY HOT WATER.
CORRECT WIRING OF THE THERMAL CUTOUT MUST BE UNDERTAKEN.
5.4. Connections - The primary ow and return connections should be made in accordance with Figs 1a and 1b.
using 22mm compression ttings, (not supplied). Note, connections for the boiler are shown with the return
above the ow; however, you can also connect the ow above the return.
5.5. The 2 port valve - To prevent gravity circulation when the boiler switches off, the 2 port motorised valve
supplied with the unvented hot water kit, MUST be tted in the primary ow pipe to the cylinder and wired in
accordance with Figs 2, 3 and 4 (depending on system design) to comply with current legislation.
5.6. Hard water areas - If the cylinder is to be used in a hard water area, we recommend that the primary ow
temperature be limited to 75 degrees centigrade. This will help reduce the migration of suspended solids in
the water and help prevent the buildup of lime scale.
5.7. ON ALL SYSTEM CONFIGURATIONS: Secondary circulation – Solar 3C cylinders provide a secondary
return connection for a secondary circulation circuit, 15mm leg incorporating a check valve (see Figs 1a and 1b
for position of secondary return).
IMPORTANT: If a secondary circulation circuit is installed then a larger expansion vessel may be required to
handle the increase in volume. Please ensure all installation and design considerations are met and double
checked prior to hand over to the end user. 8

L N
230V
50Hz
3A RATED
ST9400A/C
E
GREY
WHITE
ORANGE
BLUE
G/YELLOW
N 1
C
ROOM STAT.
CYLINDER
STAT.
MID POSITION
ZONE VALVE
3
1
BOILER
EN L
PUMP
1 2 3 4 5 6 7 8 9 10
L
N
HW ON
HW OFF
HTG
L
E
N
NOTE:
1. It is recommended that the 10
way junction box should be used to
ensure rst time, fault free wiring.
Pump overrun
C
BOILER
EN L
PUMP
7 8 9 10
L
PL
SL
E
N
LINK 8 TO 10
V4043
2 PORT
ZONE VALVE
BLUE
BROWN
2
NOTE:
ORANGE AND GREY
WIRES NOT REQUIRED
ELECTRICALLY ISOLATE
So
l
ar 3C Ji
g
S
pace
H
eat
i
ng
Radiators
Boiler
Solar 3C
Cylinder
2 Port
Zone Valve
3 Port
Mid-Postion Valve
Cylinder
Stat.
9
Fig.2. “Y” Plan wiring layout and system schematic
For illustration purposes only.

L N
230V
50Hz
3A RATED
ST9400A/C
E
GREY
WHITE
ORANGE
BLUE
G/YELLOW
N 1
C
ROOM STAT.
CYLINDER
STAT.
MID POSITION
ZONE VALVE
3
1
BOILER
EN L
PUMP
1 2 3 4 5 6 7 8 9 10
L
N
HW ON
HW OFF
HTG
L
E
N
NOTE:
1. It is recommended that the 10
way junction box should be used to
ensure rst time, fault free wiring.
Pump overrun
C
BOILER
EN L
PUMP
7 8 9 10
L
PL
SL
E
N
LINK 8 TO 10
V4043
2 PORT
ZONE VALVE
BLUE
BROWN
2
NOTE:
ORANGE AND GREY
WIRES NOT REQUIRED
ELECTRICALLY ISOLATE
So
l
ar 3C Ji
g
S
pace
H
eat
i
ng
Radiators
Boiler
Solar 3C
Cylinder
2 Port
Zone Valve
2 Port
Zone Valve
Cylinder
Stat.
10
Fig.3. “S” Plan wiring layout and system schematic
For illustration purposes only.

L N
230V
50Hz
3A RATED
2 PORT
ZONE VALV E
HTG
V4043H
ZONE VALV E
HW
E
MOTOR
GREY
BROWN
ORANGE
BLUE
G/YELLOW
CYLINDER
STAT.
MOTOR
BOILER
ENL
PUMP
1 2 3 4 5 6 7 8 9 10
LN
HWHTG
LN
HWHTG L
E
N
1
ROOM STAT.
3
NOTE:
1. We recommend a 10 way junction box
or Sundial Wiring Centre is used.
2. If using the V4043H1080 (1” BSP) or
V4043H1106 (28mm), the white wire
must be electrically isolated.
Pump overrun
BOILER
ENL
PUMP
7 8 9 10
L
PL
SL
E
N
N
1
C
BLUE
BROWN
G/Y
ORANGE
GREY
Solar 3C
Control
Panel
See Section B for full wiring instructions for the Solar 3C Control Panel
11
Fig. 4a. “S” Plan wiring layout and system schematic for Solar 3C Heating System
Solar 3C Jig
Space
Heating
Radiators
Boiler
Solar 3C
Cylinder
For illustration purposes only.

Fig. 4b. System schematic for Solar 3C Heating System with Towel Rail
L N
230V
50Hz
3A RATED
2 PORT
ZONE VALV E
HTG
V4043H
ZONE VALV E
HW
E
MOTOR
GREY
BROWN
ORANGE
BLUE
G/YELLOW
CYLINDER
STAT.
MOTOR
BOILER
ENL
PUMP
1 2 3 4 5 6 7 8 9 10
LN
HWHTG
LN
HWHTG L
E
N
1
ROOM STAT.
3
NOTE:
1. We recommend a 10 way junction box
or Sundial Wiring Centre is used.
2. If using the V4043H1080 (1” BSP) or
V4043H1106 (28mm), the white wire
must be electrically isolated.
Pump overrun
BOILER
ENL
PUMP
7 8 9 10
L
PL
SL
E
N
N
1
C
BLUE
BROWN
G/Y
ORANGE
GREY
Solar 3C
Control
Panel
See Section B for full wiring instructions for the Solar 3C Control Panel
MOTOR
BROWN
BLUE
G/Y
3 PORT
DIVERTER
VALVE
Solar 3C Jig Towel Rail
S
pace
H
eat
i
ng
R
adiators
Diverter
valve
Boiler
So
l
ar 3C
Cy
l
in
d
er
Check
valve
For illustration purposes only.
12

13
Fig. 5. Wiring layout and system schematic for solar collectors using the high temp zone valve
L N
230V
50Hz
3A RATED
EMOTOR
BROWN
BLUE
G/YELLOW
CYLINDER
STAT.
ENL
L N E S L
LN LN
1
C
2 PORT
HI-TEMP
VALVE
SOLAR
SOLAR
CONTROLLER
SOLAR
PUMP STATION
E
For illustration purposes only.

6. Secondary circuit installation
6.1. Connections – Secondary circuit connections MUST be made to the cylinder in accordance with
Figs 1a and 1b. A drain cock (not supplied) should be tted in the position shown in Figs 1a and 1b
to facilitate draining of the cylinder.
6.2. Cold water supply – Where possible, for best results, the cylinder should be fed by an uninterrupted
22mm supply pipe into the pressure reducing valve (PRV) with a supply pressure of between 3 and
12 bar maximum. In the UK, supply pressures this high are not always available. However the system
will still work satisfactorily with pressures below this. The cylinder should not be used on any system
with a supply pressure below 1 bar and a ow rate of less than 10 Litres per minute.
6.3. Temperature and pressure relief valve – The temperature and pressure relief valve (TPV) is supplied
factory tted to the cylinder. The TPV must not be removed from the cylinder or tampered with in
any way. The valve is pre calibrated to lift at 7 bar or 90 degrees centigrade and any attempt to
adjust it will invalidate the warranty.
6.4. Expansion vessel – A suitable expansion vessel with a pre-charge pressure of 3 bar is supplied for
tting to all cylinders. All Solar 3C Cylinders must be tted with a potable water expansion vessel
(supplied) and the expansion vessel MUST be connected into the cold water supply after the
pressure reducing valve. If the expansion vessel is connected into the cold water supply, it MUST be
tted between the expansion relief valve and the cylinder. The expansion vessel MUST be positioned
with the entry point at the bottom.
IMPORTANT: Regular checks must be carried out to ensure that the expansion vessel is correctly
pressurised to 1.5 bar at all times.
6.5. Pressure reducing valve – Taking due account of the directional arrow, t the pressure reducing
valve (PRV) in accordance with Figs 1a and 1b. This can be connected to a supply pressure of
between 1 and 10 bar maximum. The included pressure gauge to check ow pressure is to be
removed after the pressure is set.
6.6. Expansion relief valve – Fit the expansion relief valve (ERV) in accordance with Figs 1a and 1b. This
valve has been pre-set to lift at 6 bar. No other valve should be tted between the expansion relief
valve and the cylinder.
6.7. Check valve (28mm monoblock inlet kit) – Taking due account of the directional arrow, t the check
valve (CV) in accordance with Figs 1a and 1b. The monoblock can be used for balance cold outlet.
6.8. Secondary circulation – The Solar 3C Cylinder provides a secondary return connection to which a
secondary circulation circuit, 15mm leg incorporating a check valve, could be connected (see Figs 1a
and 1b for position of secondary return).
IMPORTANT: If a secondary circulation circuit is installed then a larger expansion vessel may be
required to handle the increase in volume within secondary up to capacity of expansion vessel.
Please ensure all installation and design considerations are met and double checked prior to hand
over to the end user.
6.9. Tundish – The tundish must not be positioned above or in close proximity of any electrical current
carrying devices or wiring.
14

7. Discharge Arrangement
The user must install a Tundish in a position so that it is clearly visible and positioned away from electrical
devices. In addition, the discharge pipe from the Tundish should terminate in a safe place where there is no
risk to persons in the vicinity of the discharge, be of metal and:
(a) Must be at least one pipe size larger than the normal outlet size of the safety device unless its total
equipment hydraulic resistance exceeds that of a straight pipe 9m long, i.e. discharge pipes between 9m and
18m. Equivalent resistance length should be at least two sizes larger than the normal outlet size of the safety
device, between 18m and 27m at least three sizes larger and so on. Bends must be taken into account in
calculating the ow resistance. Refer to the diagram, tables and worked example detailed in Fig 7.
(b) Have a vertical section of pipe at least 600 mm long below the Tundish before any elbows or bends in the
pipe work.
(c) Be installed with a continuous fall.
(d) Have discharges visible at both Tundish and the nal point of discharge, but where this is not possible or
practically difcult, examples of acceptable discharge arrangements are;
• Ideally below a xed grating and above the water seal in a trapped gully.
• Downward discharge at low level, i.e. up to 100 mm above external surfaces such as car parks, hard standings,
grassed areas, etc. are acceptable providing that where children play or otherwise come into contact with
discharges, a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.
• Discharge at high level, e.g. into a metal hopper and metal down pipe with the end of the discharge pipe
clearly visible (Tundish visible or not) or onto a roof capable of withstanding high temperature discharges of
water and 3m from any plastic guttering system that would collect such discharges (Tundish visible).
• Where a single pipe serves a number of discharges such as in blocks of ats, the number served should be
limited to not more than six systems so that any installation discharging can be traced reasonably easily. The
single common discharge pipe should be at least one pipe size larger than the largest individual discharge
pipe to be connected. If unvented hot water stored systems are installed where discharges from safety devices
may not be apparent i.e. in dwellings occupied by blind, or disabled people, consideration should be given to
the installation of an electrically operated device to warn when discharge takes place.
WARNING: THE DISCHARGE WILL CONSIST OF SCALDING WATER AND STEAM. ASPHALT, ROOFING FELT AND
NON-METALLIC RAINWATER GOODS MAY BE DAMAGED BY SUCH DISCHARGES.
Fig 7. Table, worked example and diagram for discharge arrangement.
15
Valve outlet
size, di-
ameter in
‘inches’
Min size of dis-
charge pipe D1 in
‘mm’
Min size of dis-
charge pipe D2
from tundish in
‘mm’
Max resistance allowed,
expressed as a length
of straight pipe, i.e. no
elbows or bends
Resistance creat-
ed by each elbow
or bend in ‘m’
1/2 15 22
28
35
Up to 9
Up to 18
Up to 27
0.8
1.0
1.4
3/4 22 28
35
42
Up to 9
Up to 18
Up to 27
----
----
1.7
1 28 35
42
54
Up to 9
Up to 18
Up to 27
1.4
1.7
2.3
Sizing of copper discharge pipe “D2” for common temperature relief valve outlet sizes

Worked example
The example below is for a ½”diameter temperature relief valve with a discharge pipe (D2) having 4 No
elbows and a length of 7m from the tundish to the point of discharge.
Maximum resistance allowed for a straight length of Ø22mm copper discharge pipe (D2) from a ½” diameter
temperature relief valve is - 9.0 m.
Subtract the resistance for quantity of 4 Ø22mm elbows at 0.8 m each = 3.2m.
Therefore, the maximum permitted length equates to 5.8m.
5.8m is less than the actual length of 7m, therefore, calculates the next largest size.
Maximum resistance allowed for a straight length of Ø28mm-pipe (D2) from a ½” diameter temperature relief
valve equates to - 18m.
Subtract the resistance for a quantity of 4 Ø28mm elbows at 1.0 each = 4m.
Therefore the maximum permitted length equates to 14m.
As the actual length is 7m, an Ø28mm diameter copper pipe will be satisfactory
16
600 min
A typical discharge pipe arrangement
For illustration purposes only.

8. Electrical installation
WARNING - THIS EQUIPMENT MUST BE EARTHED.
8.1. All electrical wiring must be carried out by a competent person and in accordance with the current
I.E.E. Wiring Regulations. A suitable Earthing point is provided on the cylinder pedestal directly
below the immersion heater (see Fig 8).
8.2. The control equipment supplied will ensure that the cylinder functions safely. All control equipment
must be supplied via a 3Amp supply and a double pole switch with a minimum 3mm gap. From an
economic and convenience point of view, it is intended that these controls operate in conjunction
with other control packages for example: Solar 3C Solar Heating System or “S” and “Y” plan systems
which incorporate a programmable time clock etc.
8.3. The immersion heaters – 2 x 3kW 230v 50Hz-immersion heaters should be wired in accordance
with the instructions given in Fig 8. The cable MUST be routed through the strain relief bush. We
recommend that the control thermostat is set at 60°C; the high limit trip is factory set at 85°C. The
immersion heater conforms to EEC Directive 76/889 for radio interference and complies with
BS 800:1977.
WARNING: NEVER FIT AN IMMERSION HEATER WITHOUT A THERMAL CUT OUT.
8.4. The indirect temperature controller - The control and high limit thermostat for use with indirect
systems is supplied separately with the unvented hot water safety kit. It should be tted into
the sensor pocket in the cylinder (see Fig 1 for position). The control thermostat has an adjustment
range between 30°C and 90°C, however it is recommended this it be set to 60°C
WARNING: THE MANUAL RE-SET HIGH LIMIT THERMOSTAT MUST NOT UNDER ANY CIRCUMSTANCES
BE BYPASSED. THIS IS PRE-SET TO 80°C AND TO PREVENT NUISANCE TRIPPING THE CONTROL
THERMOSTAT SHOULD ALWAYS BE AT LEAST 15°C BELOW THIS.
8.5. The 2 port valve - To prevent gravity circulation when the boiler switches off, the 2 port motorised
valve supplied with the unvented hot water kit MUST be tted in the primary ow pipe to the
cylinder and wired in accordance with Figs 2, 3, 4 (depending on system design), to comply with
current legislation.
Installation and Servicing Manual
Immersion heater installation and wiring instructions
1. Ensure the main’s voltage corresponds to the voltage rating of the immersion heater as shown on the
rating label on the terminal cover.
2. Install the immersion heater into the domestic hot water cylinder using the gasket provided. Use a shaped
spanner-Stillsons or pipe grips should not be used. The use of sealing compound is not recommended.
3. Wire the immersion heater in accordance with Fig 8. It should be wired through a double pole isolator
switch or controller, having contact separation of at least 3 mm, using 1.5mm sq. exible cable, 85°C
rubber insulated HOFR sheathed, to comply with BS 6141 table 8 and must be fully earthed.
4. The BEAB approval certication on this immersion heater only applies if rod type thermostats, types Sunvic
VKL or Cotherm SHD are used. The temperature setting of the control thermostat must not exceed 60°C.
5. In the event of the manual reset cut-out operating, isolate the immersion heater from the mains supply,
investigate and identify the cause of the operation of this cut-out, rectify the fault before manually resetting
the cut-out via the reset button on the cut-out. Finally switch the mains electricity supply back on. 17

9. Filling and commissioning
9.1. Check that the expansion vessel charge pressure is 3 bar.
9.2. Check that all connections are made tight including the immersion heater.
9.3. Open the main stopcock and ll the secondary system rst. Open successive taps (hot and cold)
starting with the tap furthest from the cylinder. Leave each tap open for a few moments to
allow all air and possibly debris from the system to exit. Manually lift (by rotating the knob)
both the expansion relief (EV) and the temperature and pressure relief valve (TPV) for a short
period to remove trapped air from behind the valve seating and to prove the correct function of the
discharge arrangement.
9.4. Check all joints for leaks and rectify as necessary.
9.5. Check that the control and high limit settings for the indirect system and the immersion heater are
as required.
9.6. Fill the primary side, (note: it will be necessary to manually open the 2 port valve whilst lling the
system, this is achieved by moving the lever on the valve head sideways). Check for leaks and rectify
as necessary. Vent all heat emitters of air and following the manufacturers lighting instructions ignite
the boiler.
9.7. Check that while the cylinder is heating up, no water leaks from either the expansion relief or the
temperature and pressure relief valve and when the cylinder reaches temperature, that the 2 port
valve closes. 18
Fig 8. Immersion Heater Wiring
WARNING: THIS APPLIANCE MUST BE EARTHED

10. Servicing and maintenance
10.1. A competent unvented hot water installer must only carry out servicing and maintenance.
10.2. Before any work whatsoever is carried out on the installation, it MUST rst be isolated from the
main’s electricity supply.
WARNING: BOTH THE PRIMARY AND SECONDARY SYSTEMS WILL CONTAIN VERY HOT WATER THAT
WILL SCALD, THEREFORE CARE SHOULD BE TAKEN WHEN OPENING ANY JOINTS, SEALS OR VALVES.
10.3. Only use spare parts authorised by Solar 3C. The use of unscheduled spare parts will invalidate the
warranty.
10.4. Drain the cylinder – When draining the cylinder, always switch off the boiler and the immersion
heater rst. Turn off the water supply at the stopcock (Figs 1a and 1b). Connect a hose pipe to the
drain cock (Figs 1a and 1b) and route it to a convenient gully. Open the drain cock and all hot taps
that are served by the cylinder. The cylinder may take several minutes to empty completely.
10.5. In hard water areas it may be necessary from time to time to remove and de-scale the immersion
heater element. Replace the gasket each time it is removed.
10.6. Remove the cartridge from the pressure-reducing valve (PRV). Check the strainer and if necessary
remove any debris from in front of it. Replace the cartridge.
10.7. Check the charge pressure in the expansion vessel and top up as necessary. The charge pressure
should be 3 bar.
10.8. Flush system inline with current Building Regulations at time of installation.
10.9. Close the drain cock, disconnect the hose, and ret the immersion heater and close all hot water
taps before reopening the stopcock. Allow the cylinder time to ll whilst checking for any leaks.
Release any air from the system by opening each hot water tap individually, starting with the one
furthest from the cylinder.
10.10. Manually lift the expansion relief, temperature and pressure relief valve one at a time, every 12
months (more frequently in hard water areas) to prevent debris from building up behind the
valve seat. Whilst carrying out this operation, check that the discharge to waste is unobstructed.
Check that each valve seals correctly when released. As the valves are pre-calibrated, they require no
further maintenance.
10.11. Finally switch on the mains electricity supply to the immersion heater and the boiler. As the system
heats up, check again for any leaks and rectify as necessary.
19

11. Spare Parts List
1 80 Litre Expansion vessel ZI-11A0008000
1 35 Litre Expansion vessel ZI-11A0003500
1 3/4” T & P relief valve 309570
3 1 3/4” Immersion Heater CESTC 340
2 Dual thermostat TLSC/542794
1 10BAR Pressure Gauge WI-557410
1 2 Port Direct Valve HQ-272848
1 Tundish AP-400010
1 Pressure relief valve 536060
1 SRV 311560
1 28mm Inlet Unvented Kit AI-900106
1 2 Port High Temp Valve SMV2530
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