Manual 02 - Section 07







Non-Residential Solar Information Manual
SECTION 7: Heat Store Installation

7.1 LOCATION

The Heat Store MUST be installed BELOW the collector array.

Locate the Heat Store package as close as possible to the collector array and to the highest hot water demand or the existing hot water system. Consideration must also be given to the location of the Heat Store to ensure that it is accessible for maintenance and replacement of anodes.

The Heat Store is suitable for both internal or external locations.

7.2 LIFTING

Use either a forklift or overhead mobile crane to place the Heat Store in its correct location. The Heat Store is provided with lifting lugs. Remove the top hat channel from the roof of the Heat Store to reveal the lifting lugs.

7.3 CONCRETE PAD

Position the Heat Store on a concrete pad with a minimum thickness of 150 mm. The table below shows the size of the concrete pad for each size of Heat Store.

    Model           Width (mm)        Length (mm)
 
    2500J              1600              3000
    3500J              2000              3000
    6500J              2400              3000

7.4 HEAT STORE BASE DIMENSIONS (mm)




    Model     L (mm)    W (mm)    L1 (mm)    L2 (mm)    L3 (mm)
 
    2500J      2740      1450       870       1300        800
    3500J      2740      1755       870       1300       1000
    6500J      2740      2210       870       1300       1400

7.5 PIPE CONNECTIONS AND DRAINS

Connect the flow and return pipes from the collector array directly to the marked pipe outlets at the Heat Store cabinet. Although the Heat Store was pressure and leak tested in the factory it will be necessary to pressure test the Heat Store on site to check for any loosening of joints during transit.

Connection of the potable cold water supply is also provided on the outside of the cabinet. Internally, each Heat Store is fitted with a 500 kPa reducing valve and 550 kPa cold relief valve.

Each electric boosted potable water storage vessel has its own pre-piped Pressure & Temperature relief valve. All the relief lines are manifolded and piped to a tundish. Similarly the relief line from the common cold water relief valve mounted in a spur line from the potable water hot pipe is also piped to a tundish. If the Heat Store is to be located indoors, it is recommended that the outlet from the tundish be piped separately to a floor waste to prevent flooding should any of the valves discharge.

7.6 GAS BOOSTER CONNECTIONS

Gas boosted Heat Stores are supplied with external gas boosters or boilers. Where the Heat Store is to be installed indoors appropriate fluing arrangements are necessary to comply with local statutory regulations.

For both types of gas boosting (Type 1 & Type 2) only one gas connection is required.

Where the Heat Store system is to have in line gas boosting install the potable hot water pipe work from the Heat Store to each of the gas boosters in a parallel connection arrangement.

7.7 TEMPERATURE DIFFERENTIAL THERMOSTAT

The temperature differential thermostat is located in the Heat Store electrical switch box. The cold sensor is located in a pocket in the base of the Heat Store and the hot sensor and lead is coiled in the electrical switch box. The hot sensor lead is approximately 16 metres long, however longer lengths can be supplied on request.

7.8 HOT SENSOR BOX

Mount the hot sensor box in a location that receives similar radiation to the collector array or at the collector array. Ensure that the hot sensor box is not shaded at any time, either by adjacent buildings or collectors and receives identical radiation to that of the main collector array.

7.9 HOT SENSOR AND LEAD

Run the sensor and lead to the location of the hot sensor box and clip to adjacent building structure or pipe work away from damage alternatively use flexible plastic conduit as required. Insert the hot sensor into the tube provided in the hot sensor box and fix the flexible plastic conduit to the terminator assembly.

7.10 SUITABILITY OF WATER FOR CLOSED CIRCUIT

The closed circuit can be filled with tap water where the total dissolved solids' content is less than 700 mg/l (ppm) and where total hardness does not exceed 500 mg/l (ppm) and total alkalinity does not exceed 400 mg/l (ppm).

Where any of the above limits are exceeded it is recommended that the system be filled through a water softener or by using distilled, condensate water that meet the above requirements.

7.11 HIGH HEAD INSTALLATION

The closed circuit fluid pump fitted and supplied with the Heat Store is selected to satisfy most types of installations where the highest point for the collector array is up to 13.5 metres above the top of the Heat Store. On the 6500J model the height may be up to 16 metres.

Installations where the highest point of the collector array exceeds these heights it will be necessary to fit a booster pump. The maximum combined lift from the top of the Heat Store to the highest point of the collector array when a booster pump is fitted is 28 metres. The booster pump must be installed in a weather proof area or enclosure at a point not higher than 13.5 metres above the Heat Store. The booster pump must be arranged to operate in series with the pump mounted within the Heat Store. The electrical wiring and contactor to the booster pump must be connected to enable the booster pump to be controlled in unison with the pump in the Heat Store.

7.12 POTABLE WATER SYSTEM

All installations are to be made in accordance with the building and plumbing codes applicable in your area. Local codes in Australia require all plumbing work to be performed by a qualified plumber.

The following potable water circuit valves are fitted and supplied with the Heat Store:

Where the water supply is from an open overhead tank, and the pressure to the solar storage tank cannot exceed 500 kPa, the pressure reduction, cold water pressure relief and check valves may be omitted from the potable water circuit.

The pressure and temperature relief valves are pre-piped to a tundish at the base of the Heat Store and should be run to a waste away from the Heat Store.

The Heat Store potable water storage vessels are all pre-piped, insulated and tested to the connections on the external case of the Heat Store. The case is marked `COLD' and `HOT' adjacent the appropriate connections.

7.13 CLOSED CIRCUIT SYSTEM

The following valves and devices are fitted and supplied with the Heat Store on the closed circuit system:

A pressure relief valve set at 90 kPa (0.90 bar) pressure is mounted into the top of the closed circuit reservoir. The valve discharge is piped to a tundish at the base of the Heat Store. After commissioning this is a safety device which under normal operation does not open. During the commissioning process there will be some discharge until the correct operating pressure and fluid levels are achieved.

A fill/drain valve is mounted on the closed circuit pipe connected to the base of the Heat Store and is used during closed circuit filling or draining operations.

This valve is mounted at the operating level on the Heat Store and is used during the filling operation of the closed circuit to confirm the correct closed circuit fluid level.

The pipe circuit within the Heat Store is arranged to automatically drain the fluid in the collectors back into the Heat Store through the collector hot return pipe, provided, this pipe is continually graded from the Heat Store to the highest point on the collector array.

Should continuous grading not be possible a vent line in nominal 15 mm diameter copper pipe complete with vent check valve must be fitted.

REFER THIS TYPE OF INSTALLATION TO SOLAHART FOR INSTRUCTIONS, PRIOR TO INSTALLATION.

This valve, if required as shown on the typical collector pipe circuit diagrams, is installed in the collector cold flow pipe where an inverse flow pipe is fitted to allow the collectors to drain back to the Heat Store whenever the closed circuit circulating pump is turned off.

This valve is mounted in the collector hot return vent line to the Heat Store and is pre-set to allow full collector flow to be established before closing automatically and allowing the orifice plate to regulate the water flow through the collectors to a pre-set rate. This valve also form's part of the collector venting system that permits the nitrogen blanket to be rapidly moved from Heat Store to collector array and back as the circulation pump cycles.

The orifice plate controls the closed circuit fluid flow rate through the collector array when the circulation pump is ON and full flow has been established.

Each Heat Store is supplied with two sizes of orifice plate to match with the number of collectors for the installation. The following table gives the range of collectors and the corresponding orifice plate size.

The orifice plate should be adjusted to suit the range of collectors on the project.


    Model             Range 1                        Range2
             Collectors  Orifice Plate      Collectors  Orifice Plate

    2500J     10 to 20       6.0 mm           20 to 30       6.8 mm  
    3500J     20 to 30       7.5 mm           30 to 40       8.8 mm
    4500J     30 to 50       9.8 mm           50 to 70      11.0 mm

7.14 PIPE WORK INSULATION

All collector flow and return pipes from the Heat Store to the collector array must be insulated with a minimum of 10 mm thick expanded rubber preformed pipe insulation material or equivalent.

Slip pipe insulation on to pipes prior to silver soldering pipe joints and ensure the insulation is of sufficient length to butt up to the adjoining section after soldering is complete.

If flexible rubber pipe insulation is used, cut lengths 10% longer than measured to compensate for shrinkage in service.

7.15 ELECTRICAL NOTES

All installations are to be made in accordance with local electrical codes and regulations in your area.

The Heat Store is fitted and supplied with 4.8 kW, 220/250 volt, electrical elements arranged for continuous supply connection.

Supply voltage and the current drawn by the elements are listed below:



                    4.8kW (12 ohms)      2.4kW (24 ohms)			3.6kW (16 ohms)		
		                            Supply Voltage								
ELEMENTS      220v   240v	 250v	220v	240v	 250v	 220v	240v	 250v
                                                 Amps								
2500J	2     36.7     40     41.7	18.3	 20	 20.8	 27.5	 30	 31.3
	4     73.3     80      83.3	36.7	 40	 41.7	 55	 60	 62.5
										
3500J	2     36.7     40      41.7	18.3	 20	 20.8	 27.5	 30	 31.3
	5     91.7    100     104.2	45.8	 50	 52.1	 68.8	 75	 78.1
	7    128.3    140     145.8	64.2	 70	 72.9	 96.3	105	109.4
										
6500J	3     55.0     60      62.5	27.5	 30	 31.3	 41.3	 45	 46.9
	7    128.3    140     145.8	64.2	 70	 72.9	 96.3	105	109.4
       10    183.3    200	208.3	91.7	100	104.2	137.5	150	156.3

All electrical elements are factory pre-wired to the electrical control box located in the Heat Store. Check the stamping on the electrical heater elements to confirm suitability for the local power supply. A wiring diagram is provided in the electrical control box showing all connected components.

For normal single phase connections connect L1, L2 and L3 wires to top terminals of the three pole main isolating switch. Connect the `Neutral' wire to a terminal on the neutral link and the `Earth' wire to a terminal on the earth link.

Where high levels of electrical boosting is required, a three phase 5 wire supply must be used. The 240 volt electrical booster load must be balanced over the three phases to reduce the size of the incoming electrical connection. The electrical booster elements are pre-wired via individual fuses and contactors within the electrical control box.

All electrical wiring should be enclosed in weatherproof plastic or metal conduit with watertight fittings.

The electrical control box is fitted with a three pole isolating switch, electric booster contactors, fuses, control switch, earth terminal bar and neutral link. The electric booster elements, water circulating pumps, safety thermostats and temperature differential thermostat are pre-wired and tested prior to dispatch.

Where an extra booster pump is required to satisfy a particularly high lift requirement, space is available in the switchboard for the extra pump contactor.

DO NOT TURN ON THE POWER UNTIL BOTH POTABLE AND CLOSED CIRCUITS HAVE BEEN COMPLETELY FILLED WITH WATER.