Solarmaster Combo User manual

FIG 3.

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SOLARMASTER LTD
“Combo” Hot Water Systems
Installation Manual
General Description:
The “Combo” cylinder was developed as a multiple use unit for the use with
Solar, wetback and electric heating, whilst operating at “Mains Pressure”. All
units are designed to operate at 500 KPA. This allows for both hot and cold
water to be distributed at the same pressure.
Materials:
The shell material is a duplex stainless steel.
The insulation is foamed 50mm of polyurethane.
The cladding is galvanised sheeting.
All elements fitted ex factory are “Incolloy” stainless steel.
All thermostats fitted ex factory set by our suppliers at 60°C and incorporate a
fusible link.
-Plumbing Connection Sizes:
Cold Water/Solar Inlet 20mm male
Relief TPR 20mm female
Wetback 25mm male
Solar 20mm male
Other Types:
Solarmaster “ Combo hot water cylinders can be supplied in a
horizontal as well as the standard Vertical form.
Any of the above cylinders can be manufactured specifically to suit your
exact requirements. i.e. shorter, higher, narrower or wider.
Cylinders can be supplied with extra coils to suit underfloor heating
requirements or to function with radiator panels.
Commercial cylinders, Calorifiers, Electric only
Are available in varying volumes and sizes up to 2000 and 3000 litres.
Installation
A recognised registered plumber must install the unit and the installation must
comply with the NZ Building Code, Solarmaster installation instructions, AS/NZ
3000 electrical installations and all local codes and regulatory authority
requirements.

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–Plumbing –( Refer Drg fig 1 )
Wetbacks can be set up with either a hot open vented header tank or a low-
pressure 3.6mm head pressure –reducing valve. Vent pipes must be at the
highest point in the thermosyphon circuit. The easiest way to achieve this is to
screw a Tee into the top wetback fitting. Failing to comply will cause air pockets
and primary circuit not functioning –Result no heating and a banging sound in
the pipes.
Do not use a “HIGHER” rating reducing valve, than 3.6m or the primary
circulating water will tend to take the less resistance and pass up through the
open vent rather than go through the coil in the cylinder.
Wetback piping between cylinder and the fire should be installed with a 1-10
gradient falling towards the fire.
It is very important to set the wetback system up “correctly” as it works by
thermosyphon. Try and maintain a minimum height of 330mm from the bottom
of the cylinder to the centre line of the top outlet connection on the wetback
element in the fire. Failure to achieve this will result in “back syphoning”
Pipes connecting the wetback to the unit must be copper and minimum 25
dia. Both lines to be insulated from the cylinder to the fire. If a pulse flow valve
is fitted these pipes can be reduced to 20 dia. It is very important “NOT” to fit
any non-return valves into the wetback system.
Commissioning:
1. Turn on the water supply to the unit and commence filling.
2. Allow the unit to fill entirely then switch the power on.
3. A suitable electrical meg. test should be completed to ensure the
element is performing satisfactory.
4. Open all outlets in the house and open the main isolation valve to the
unit to allow “FULL” pressure through the entire house piping system
and to force any trapped air OUT.
5. When a full flow of water only is discharging from each tap close it.
6. Check the pipe work system for inherent leaks.
7. Re-check the electrical supply.
A non-return valve must be fitted to the cold water supply line to the unit.
Pipe sizes are recommended to be either the same size as those on the unit or
larger.

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Check the temperature and Pressure Relief Valve ensure the temperature probe
has not been bent or damaged. Apply PTFE tape to the thread and screw the
valve into the socket provided, this is normally off set from the centre outlet.
Fasten the valve with the appropriate spanner with flats rather than using a
wrench around the body.
The open vent side from the TPR valve needs to be piped away to an open area
and preferably above a gully trap outside the house.
NOTE: The first 1.2 metres of the TPR drain must be in copper.
All units to be suitably restrained to meet the seismic requirements refer NZ
Building codes.
Mains incoming water pressure must not exceed stated maximum working
pressure.
Drip Trays are required under storage water heaters where water (from
the failure of the water heater) could penetrate another occupancy in the
same building.
Alternative Wetback set Up ( Pulse Flow Refer Drg Fig 2)
The Pulse flow valve was developed to use where a pumped or natural
thermosyphon system is not a choice.
The valve is mounted on the cold-water inlet (bottom connection) of the wood
fire wetback element.
The valve traps the cold-water in the fire element until it is heated. Once
heated, the water through natural expansion of 3% causes a powerful surge in
the hot outlet pipe, the valve opens and allows a fresh charge of cold water into
the element and the cycle repeats itself.
This surging will only occur while the fire is in operation.
The following guidelines must be strictly adhered to:
Only for use in a low pressure open vented pulse-pumping system.
Requires heated fluids to operate successfully.
Must be installed only in the cold-water inlet side of the heating source.
Must be installed in the correct flow direction
Must be installed in the up position.
Must be installed only to an approved circuit configuration.
-Electrical Connections: ( refer Invensys ST1301133 Fig 3)
All electrical must comply with AS/NZ 3000. All units are designed for
Voltage –230 V AC
Frequency –50 HZ.
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SOLARMASTER ACCEPTABLE WATER QUALITY (At ambient temp.)
PH 7.5 –8.5
Chloride up to 50 ppm
Iron up to 0.01 ppm
Manganese up to 0.01 ppm
Langelier Index Min –1.0 Max +1.0
Figures outside the above will not be covered by Solarmaster warranties. If
water is known to be of “Harsh quality” then consult “Solarmaster Ltd” for
alternative materials.
Water Temperature:
Because our units are manufactured from a duplex stainless steel they can
operate at elevated temperatures close to “Boiling” if they have a wetback or
solar system fitted.
An ideal operating temperature of the unit is normally between 60-70 Degree C.
with a Minimum operating temperature as quoted by the NZ Building code as
being 60 Degree C to prevent Legionella bacteria.
The electric thermostat should be set between 60 –70 Degree C ideally or to
suit your requirements.
Safety:
It is the responsibility of your plumber to fit the following items to the “Combo”
unit.
a) Cold Water Pressure Limiting Valve: This to be fitted to the main cold-
water inlet. This sets both the limit of the hot/cold system to 500 KPA
(72psig).
b) Cold Water Expansion Valve: This is fitted to the same cold water inlet
feed lines as the pressure-limiting valve. This is factory set to 700 KPA
(101 psig). In the event of an over pressure in the cylinder this valve
will open and release cold water only from the bottom of the cylinder.
c) Temperature Pressure Relief Valve (TPR): This valve is fitted on top of
the cylinder, is factory set to 850 Kpa (122psig) In the event that the
cold water expansion valve “fails” then the TPR valve will open due to
over pressure or over temperature and discharge water out through its
own drain pipe until the water temperature in the cylinder falls to
around 70 Degrees C.
Tempering Valve: This valve is fitted in the main hot water outlet on the top of
the cylinder. This valve has independent cold water feed to one side of the
valve. The valve is adjustable for final outlet temperature to suit, but is limited
to a maximum of 55 Degree C legislated by New Zealand Building Codes.

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The warranty applies only to defects occurring under conditions of normal use
for which the water heater has been manufactured and excludes any water
damage to properties. Contaminated water may affect warranty.
Exclusions to Warranties
If cylinder has not been installed by a registered plumber or does not
comply with the NZ Building code AS/NZS 3000 and local building
compliances.
Consequential loss or damage due to direct or indirect water leakage
from the cylinder or the hot water system including the solar and
wetback.
Excessive heat input.
Over pressurising the cylinder passed the relief pressure or subjecting
the cylinder to a vacuum.
Failure of the cylinder due to plumbing, valves, pumps supplied by the
installer.
Any claim made after a 30-day period of detection of the defect.
Where a failed component or CYLINDER is replaced under warranty,
the balance of the original warranty period shall remain effective. The
replaced part or cylinder does not carry a new warranty.
Water Quality:
Normal towns water supply has a Chloride content of approx 10–30 parts per
million. The “Combo” is suitable for use with most town supplies however we
do draw your attention to the fact that some areas in NZ where water is known
to be of “Harsh quality” the supplier must be informed during the purchase. In
general if the chloride levels are below 50 ppm at the normal operating
temperature, you should enjoy an extended life expectancy. Should the levels
be in excess of this figure consult Solarmaster Ltd for an alternative material.
Alternative Water:
Some town water, bore water, river or ground water may need to be treated,
as it can be extremely corrosive.
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Disconnection of the fixed wiring from the main supply must be incorporated
during the initial installation.
The electrical cable should be encased in 20mm plastic flexible conduit and
fitted with 20mm dia plain/screwed fitting.
Connect the power supply direct to the terminal block and earth the tab
connector. There should be no excess of cable inside the element box.
For details refer to wiring diagram inside the element cover.
NOTE: Please ensure the cylinder is earthed to prevent
electrolysis. There is an earth screw –terminal on every
element for this purpose.
Element: Hermetic 3KW 240 Volt Incolloy Code 1140 H
Thermostat: Robertshaw Surface mounted variable temp 50 –80 0 C
Over temperature complete with a refusable line ST1301133 Fig 3
Troubleshooting
“Normal” –Small amount of water from TPR or cold expansion valve draining
during heating phase.
“Not Normal” –Excessive amount of water discharge from TPR valve drain.
i.e. more than 4 litres in 24 hours. There may be a foreign particle lodged in the
valve bonnet. Lift the lever gently for a few seconds and observe if water
continues or stops. Repeat a few times. If water continues running, call for
service. If there is a heavy continuous flow of hot water from the drain of the
TPR valve and then the unit is only left with cold water. Turn off electricity
supply and call service.
Owner should operate the lever on the TPR valve every 6 months to allow
discharge.
Note: On releasing the valve resets it should cease discharging.
Inlet water Pressure - High pressure may cause excessive discharge and
possible premature failure of the operating relief valve. The maximum
water pressure usually occurs during the night, at the time of lowest
water usage.
In any mains pressure water heater installation, if the inlet water
pressure exceeds 80% of the nominal set pressure of the operating
relief valve a Pressure limiting Valve must be fitted to the cold inlet.

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If the TPR valve continually discharges during the use of the wetback then it is
because of the excessive “Temperature” in the unit rather than pressure. Either
turn the fire “Down” or use some hot water i.e. run a bath. If the problem
persists each year, another suggestion is to look at fitting radiators to warm
other areas in the house and also burn up the excess energy.
Insufficient Hot Water –
Has power been turned off?
Is the unit connected to the ripple electrical supply and is it
currently turned off. (Can apply during winter. Authorities Conserve
Power).
Check main switchboard to see if contactor is out of position.
Check fuses in main switch board marked “Hot Water Supply”.
Check the family usage of hot water. Normal recommended flow
rate for shower 8-10 Litres/Min i.e. 4-minute shower 40 litres. Flow
control valve can be fitted to limit this.
Check thermostat setting (may have been set down for summer).
If the Wetback is not performing very well it could be due to an
incorrect installation. Check approx 330 mm from underside of cylinder
to centre line of top connection on the wetback in the fire. If it is not
set up like this it will lead to back syphoning ie during fire cooling down
it will draw hot water out of the cylinder into the fire causing the water
to cool and increase the electricity bill.
Higher Power Accounts –
Too high family usage (mainly shower)
Leaking hot water supply pipe, dripping tap. Replace faulty washers.
Either expansion or TPR discharge excessive amounts of water.
Has power tariff increased since last power account
If a mains pressure cylinder has been fitted into an existing low-
pressure system, fit new showerheads and limiting valves to facilities.
If the Wetback is not performing very well it could be due to an
incorrect installation. Check approx 330 mm from underside of cylinder
to centre line of top connection on the wetback in the fire. If it is not
set up like this it will lead to back syphoning i.e. during fire cooling
down it will draw hot water out of the cylinder into the fire causing the
water to cool and increase the electricity bill.
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WARRANTIES:
Warranty (Domestic):
“Combo” Domestic Water Heaters are backed by comprehensive 12-month
parts and labour warranty, also a guarantee to replace or repair the internal
pressure cylinder for a total of 7 years.
Solarmaster will not be liable for any loss or damage of any unit that has not
been correctly installed.
1st Year warranty:
Solarmaster Ltd will replace or repair any cylinder due to faulty workmanship
during the first twelve months including removal/reinstallation/Freight charges.
Solarmaster will not cover any costs such as cranage or roof removal where the
cylinder has been located in a non-accessible area.
2–7 Year Warranty
Solarmaster will replace or repair any cylinder due to faulty workmanship during
the 2nd –7th year. Any costs incurred for removal/reinstallation are the
responsibility of the owner.
Solarmaster will cover freight costs.
Solarmaster will not cover any costs such as cranage or roof removal where the
cylinder has been located in a non-accessible area.
Where a failed component or cylinder is replaced under warranty, the balance
of the original warranty period shall remain effective. The replaced part or
cylinder does not carry a new warranty.
Warranty (Commercial)
Commercial cylinders have a 12-month replacement warranty.
Any costs incurred for removal/reinstallation/freight are the responsibility of the
owner.
Solarmaster will not cover any costs such as cranage or roof removal where the
cylinder has been located in a bad accessible area.
Solarmaster Warranties will not cover any units that have not been installed in
accordance with the above criteria.