Manual 01 - Section 10







Residential Solar Information Manual
Section 10 - Installation Instructions

INSTALLATION INSTRUCTIONS ALL MODELS

Installation must comply with local electrical and plumbing codes.

LOCATION

For optimum performance the heater should be installed to face the equator (South in the Northern Hemisphere, North in the Southern Hemisphere) ALWAYS USE A COMPASS TO CHECK ORIENTATION. Deviation from the equator up to 45o east or west has little effect on total annual solar contribution (approximately 4 per cent). Should it not be possible to face the equator the decision of either EASTERLY or WESTERLY bias must be made. (a) If major hot water draw is before 2 p.m. favour EASTERLY (b) If major water draw after 2 p.m. favour WESTERLY.

NOTE: The westerly direction is more commonly used. The heater should be installed on a roof of pitch or angle that is the same as the latitude angle of the site. Roof angles within 20o of the latitude angle will have little effect on the total annual solar contribution (4%). Minimum roof angle is 10% for with pitch installations.

NOTE: If it is necessary to face the solar hot water heater 45o east or west of the equator then a flatter (lower pitch) installation will give better performance. The addition of a third panel facing east or west is more aesthetically, economically and thermally beneficial then mounting the heater on roof brackets to face the equator. It is required that the heater be installed on an ADEQUATELY SUPPORTED AREA of the roof, as close as possible to the most frequently used hot water outlet, or existing water heater in retrofit installations. The heater must be installed in an area that is free of shade all year round. Check high trees for winter shade. All installations are to be made in accordance with ALL LOCAL BUILDING PLUMBING AND ELECTRICAL CODES APPLICABLE IN YOUR AREA and the instructions detailed in this Owner's Manual. In Australia, all water heaters should be installed in accordance with Australian Standard AS 3500.4.

INSTALLATION DETAILS

Before commencing an installation it is recommended that both the client and installer discuss and understands the installation details.

ELECTRICAL CODES

Local codes in Australia require all electrical work to be performed by a qualified electrician. All installations are to be made in accordance with local electrical codes applicable in your area. The standard Solahart heater is supplied with a 240V, 2.4W electric heater element that requires a 10 amp single phase electrical supply. In certain areas the Solahart heater is supplied with alternative size heating elements of either 1.8kW, 3.6kW or 4.8kW as indicated on the heater's name-plate. The ampere rating of these elements is listed on the Technical Data Plate. No wiring should be exposed to weather. Electric wiring should be enclosed in weatherproof plastic or metal conduit with watertight fittings. An `ON-OFF' switch may be installed in the home at a convenient location, eg. kitchen, laundry. An isolation switch shall be installed in the meter box for service work on the unit. Do not turn on the electrical power to the heater's element until the vessel is filled with water. If water and/or power is not available on completion of installation, tape the booster control switch in the `OFF' position and place a warning label `Do not turn on electricity until filled with water' on the electrical booster control switch.

CONTROL THERMOSTAT - SAFETY COMBINATION

A combination control and safety thermostat is installed to automatically control the electric heating element to a factory pre-set temperature 60 oC.

Individual situations may require the control thermostat to be altered from the factory setting. Only a qualified electrician or a Solahart service contractor are permitted to adjust the thermostat. The safety combination switch, integral with the control switch, is set to de-energise the element should the temperature within the cylinder reach 87 oC when power is being supplied to the element. Should this occur your local Solahart dealer must be contacted as the safety combination switch will require replacement.

PLUMBING NOTES

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.

Valves

The following valves are supplied with your Solahart water heater:

(a) A combined Pressure and temperature Relief Valve (Part No. 33-0660) set to relieve water at 700 kPa pressure and/or above 99oC water temperature. The valve is installed into the connection end of the storage tank and it is MANDATORY that this valve be fitted in all cases, except where the storage tank is vented to the atmosphere through an open pipe. When applying Teflon sealing tape to the thread of this valve ensure tape is 3 mm back from the end of the thread to prevent tape fouling the valve seat.

(b) A Combination Valve (Part No. 33-0666) which is a combined pressure limiting valve, expansion valve, check valve and strainer is installed in the cold water inlet pipe to the storage tank. It is set to limit the incoming, main's pressure to 450 kPa. The expansion value component is set at 600 kPa. During heating, the water in the storage tank expands. This valve prevents excess pressure in the tank by relieving cold water from the tank during expansion. In addition to the above, a stop cock must be installed before the Combination Valve in the cold line to enable water to be turned off for servicing purposes. (The stop cock is provided by the plumber).

Valve location

All the valves in the cold inlet line must be located at least 1 metre away from the storage tank, and should be located where they are within easy reach, no more than 1.8 metres above ground level. THE VALVES SHOULD NOT BE LOCATED ON THE HOUSE ROOF AND NOT IN THE CEILING SPACE.

Water Pressure

If the supply water pressure never exceeds 600 kPa the Combination Valve may be omitted from the installation - but a check valve and cold relief must be included. In such a case the occurrence of any pressure in excess of 600 kPa under any circumstances will automatically invalidate the Warranty given by Solahart. Where supply water pressure frequently exceeds 850 kPa, an additional pressure limiting valve will be necessary to limit incoming main's pressure to 600 kPa.

Drain lines

The Pressure & Temperature Relief Valve on the storage tank, and the expansion valve on the Combination Valve assembly, should both have a drain pipe connected to their outlet and run to ground level. Do not seal or block the end of the drain pipes or the valve outlets. Do not allow water from the valve outlet or drain pipes to drip onto roofing materials or roof gutters. The jacket relief valve may also need to be piped to waste.

Pressure & Temperature Relief Valve

The storage cylinder is provided with a combination Pressure & Temperature Relief Valve, mounted directly onto the container at the connection end. This valve is installed to:

(i) Relieve excessive pressure built up in the container, as a back-up system for the cold water expansion valve, and set to operate at 700 kPa.

(ii) Relieve excessive temperature which could occur should the electrical booster element control and safety devices fail to operate and is set at 99oC.

Additional information for users and installers. Supplementary energy supplies, Solahart safety devices

The cylinder contains a Pressure Temperature Operated Relief Valve rated at 7.2 kW. Supplementary energy supplies giving a combined total heat input in excess of 7.2 kW including electric booster should not be fitted to the heater unless the relief valve is replaced with one of larger capacity.

Stove Coil Boosters

Stove coil or other manually fed boosters such as back boilers or coils in open fired grates are not permitted to be connected to a Solahart heater unless the cylinder is open vented. Such auxiliary energy sources MUST NOT be connected into the closed circuit. Warranty is void if connected to the closed circuit. installation details on application from Solahart. IN AUSTRALIA, REFER TO AUSTRALIAN STANDARD AS3500.4 FOR ADDITIONAL INFORMATION, REFER ALSO YOUR LOCAL WATER AUTHORITY REQUIREMENTS FOR DETAILS OF VENT DESIGN, HEAD TANK AND REDUCTION VALVES ETC.

INSTALLATIONS IN CYCLONE, HURRICANE AREAS

In areas susceptible to cyclones, hurricanes or very high winds, a separate set of instructions and a modified mounting kit is available from Solahart.

This kit is suitable for with pitch and low pitch installations only.


INSTALLATION INSTRUCTIONS J & K SERIES ONLY

Select the location of the storage tank. The front mounting foot of the tank should be positioned directly over a tile batten. Remove several tiles to expose the rafters and this batten. Measure 2050 mm down (1270 mm for 301 J & 301K) from the centre of the batten to determine the location of the collector rail. Mark this location. Remove several roofing tiles from this location to expose the rafters. Hook the two stainless steel straps (Part No. 33-0847, three for 303 J & 303K) to the rail and line up the straps with the rafters. Ensure that they are not more than 1.6m apart and no closer than 1 m. After positioning the rail level, raise the left hand side 10 mm and fix the straps to the rafters. Replace the tiles. Move back up to where the storage tank is to be positioned. Place the aluminium flashing over this row of tiles and tuck the top of the flashing under the row above.

Now using a lifting device lift collectors onto the roof and place the collectors carefully into the collector rail. Remove red transit plugs from collector with a screwdriver.

Join the collectors together using the collector connector assemblies (Part No. 33-7121). Ensure conetite fittings are fully inserted into the sockets before tightening the nuts. Only medium spanner pressure will be required. As a rule the conetite fittings should be used only once. If for any reason, assemblies with conetite fittings need to be removed, replace them completely with new assemblies. Fit the fill assembly (Part No. 33-7134) and the collector bung assembly (Part No. 33-7135) into the bottom left and right hand corners (respectively) of the left and right hand collectors (respectively) using medium spanner pressure. Centralise the collectors on the rail, and lock collectors to rail with the 4 collector clamps and tighten, using the nuts and bolts provided.

For roof installations slide the tank to collector spacers (Part No. 33-7144) over the top of the collectors, these should be located 200 mm from the outer edge of the collectors, and on a high spot of the tiles (or profile for metal roofs).

Now using a lifting device lift the tank onto the roof. Place the tank onto an aluminium flashing, and locate the tank central to the collectors before sliding down onto the spacers. Secure the tank to the roof rafters in a similar manner to that for the collectors using the tank straps (Part No. 33-0845) and the aluminium clamps (Part No. 33-0847). Loosely attach the tank clamps to the rear foot of the tank base, and clip in and bolt the tank straps. Ensure the bolt heads fit into the valley of the tile.

Remove the yellow instruction label from the cold pipe. Fit the cold pipe first at the right hand side of the tank. Insert the pipe with the rubber flow diverter in the collector and tighten collector side nut, before tightening tank side nut, this sequence is important.

Note: The conetite fitting on the collector side of the pipe is crimped onto the copper pipe in the correct position for the flow diverter, and the conetite for the tank side is floating.

Remove the yellow instruction label from the hot pipe. Fit the hot pipe first at the left hand side of the tank. Tighten collector side nut, before tightening tank side nut. The floating conetite should always be on the tank side. When in position, secure the tank straps to the roof rafters as for the collector strap. Ensure straps are tight. Replace roof tiles.

FILLING AND COMMISSIONING OF THE STORAGE TANK

Do not turn on electric power/gas until after the tank has been filled with water. Turn on at least one hot water outlet tap, preferably over a bath or laundry trough. Turn on main's water supply tap on the line to the water heater and allow the water to fill the storage cylinder dispelling air out of the top of cylinder through the open tap.. As soon as water flows freely (without air bursts) from the tap, close the tap and allow the cylinder to pressurise. Check all joints for water tightness. Turn on the electric power/gas to the booster element ensuring that the power/gas is correctly connected ie. `Active' line to `Active' terminal etc. Fit the Pressure & Temperature Relief Valve (Part No. 33-0660) into the tank as per water connection diagrams. Operate both pressure relief valves easing gear to ensure that the valves are functional. The storage tank is now filled and ready to operate as an electric/gas water heater. To operate as a solar water heater, the closed circuit must be commissioned by an authorised Solahart installer or service contractor.

FILLING AND COMMISSIONING THE CLOSED CIRCUIT

The solar collectors and tank heat exchange jacket are connected together in a sealed closed fluid circuit that is entirely separate from the potable water in the storage cylinder. Only Solahart trained and authorised installers are permitted to fill the closed fluid circuit. REFER TO YOUR Solahart DEALER FOR INFORMATION. For authorised installers a special set of instructions and installation tools are provided. THE STORAGE TANK MUST BE FILLED WITH WATER BEFORE STARTING TO FILL THE CLOSED CIRCUIT. The quality of water required for filling the solar collectors is defined in the section `Water Quality' in this booklet. Only `Hartgard', an approved non toxic heat transfer fluid with blue coloured dye must be used, and only by authorised Solahart installers and service contractors. Under no circumstances can any fluids other than the above be used as heat transfer fluid. `DO NOT TAMPER WITH THE CLOSED CIRCUIT'.

Remove the fill plug from the fill assembly and place one end of the hose over fill assembly, fill the collectors with water from the relief outlet of the tank. Continue filling until the water overflows from the jacket relief valve outlet and air bubbles stop.

Insert test block into the PR6 (Part No. 33-0686) valve location socket, and screw PR6 valve into test block. Now remove the hose and screw in the fill plug. Connect a bicycle pump to the test block and pump up closed circuit to 80 kPa. Check all connections for evidence of leakage. Ensure that the pressure remains constant. Should the pressure show any decrease the leakage point must be located then rectified and the leak test procedure carried out again.

Under no circumstances must a pressure decrease be left without rectification. Release pressure from the closed circuit by removing the PR6 valve from the test block. When the pressure is released refit the PR6 valve in the test block. Now remove the fill plug and connect the hose. Remove the PR6 and siphon the entire contents from the blue Hartgard container into the collector. During this operation water will flow from the PR6 port on the test block.

When the Hartgard container is completely empty, reconnect the hose to the relief outlet of the tank, flush the hose clean and allow water to flow through PR6 valve port for at least 20 seconds. This will ensure that the Hartgard is mixed with the water.

Refit the PR6 valve into the test block. Replace the fill plug. Pump the closed circuit up again to 80 kPa, check for leaks.

Release pressure from the closed circuit by again removing the PR6 from the test block. Remove the test block from the tank and refit the PR6 valve in its place ensuring the `O' ring is in place.

The unit is now ready for the electrical connections, these connections must be made by a licensed electrician. Switch off electrical mains before you start any electrical connections. The fittings of a separate fuse and control switch is essential. Use the parts that apply to your local by-laws.

Finally remove all packaging and unused items and ensure the roof is clean and tidy. The Solahart brand name sticker is fitted to the tank in the factory, however the stickers for the "Black Chrome Miracle", and the "Natural Wonder" (Gas Boosted) heaters must be fitted on site.

Fill in the completion report and obtain the client's signature.

FIBRO CEMENT OR METAL SHEET ROOFING

Select a location for the storage tank close to a purlin. Avoid locating tank at mid-span of seating. Fixing and assembly procedures are similar to that detailed for tiled roofs, with the exception that the tank straps and the collector straps are fixed with coach screws to the purlins below.

METAL TILED ROOF

Select a location for the storage tank. The front mounting foot of the tank should be positioned directly over a tile batten. Fixing and assembly procedures are similar to that detailed for tiled roofs, except that the tank and collector straps are fixed with spring head galvanised nails directly through the metal tiles into the rafters below. Seal under the straps with a weatherproof mastic sealer.

INSTALLATION OF COLLECTORS

In areas where air temperatures fall below -15oC at any time or where snow will remain on the ground for more than 24 hours continuously, refer to Solahart for specific recommendation on suitability of location.

In area's subject to heavy snowfalls, care should be taken that snow cannot build up behind the tank and that the brackets installed are capable of withstanding the expected snow loading. In these cases install tanks as close as possible to the roof ridge.

WATER QUALITY

The storage tank is suitable for use with potable water supplies where the total dissolved solid's content is less than 1,000 ppm, total hardness does not exceed 500 ppm and total alkalinity does not exceed 400 ppm.

Where the total dissolved solid's content exceeds 600 ppm the anode will require changing before five years. Refer to Solahart dealer for instruction.

Where total hardness or total alkalinity exceeds the limits quoted the water supply must be treated by a softening process otherwise scaling and damage may occur to the electric booster element in areas where the element is frequently used, ie. where solar contribution is normally less than 90%.

The fluid in the solar collectors is in a sealed closed circuit separated from the water in the storage tank. Only potable water can be used in conjunction with Hartgard. This may comprise distilled, demineralised or city main's water that has a TDS content less than 500 ppm, and a total hardness less than 500 ppm (as CaCO3) and a salinity (as Cl) less than 300 ppm.

PIPE AND VALVE FROST DAMAGE

In areas where temperatures may fall below 0oC special care must be taken to ensure that the hot and cold pipes to the solar hot water heater, where exposed to the weather, are insulated and moisture proofed. Ensure that pipes and valves are located away from freeze locations wherever possible.

Note that freezing can permanently damage the valves.

Take particular care at roof penetrations. Install the combination inlet valve and strainer/check valve indoors (eg. laundry) or in other locations not subject to freezing, but NOT in the ceiling space. If these valves are located external to the building they must be insulated with at least 19 mm of fibreglass or foam insulation material, sealed to prevent entry of moisture. A satisfactory location in frost areas is on an external wall high under the eaves. In locations frequently subject to atmospheric temperature below 10oC, hot and cold pipes and valves may freeze even when insulated.

It is recommended that in these cold locations the cold pipes and valves to the Solahart storage tank and the hot pipe from the tank should have an electric heater tape under the insulation. The electric heater tape should have a heat output of between 10 and 20 W/m. The tape should be a self-limiting tape such as `Raychem' or should be controlled by a thermostat set at 1oC. Connect the heater tape to a normally `ON' power supply.

JACKET RELIEF VALVE PR6

The heat exchange jacket has a relief valve located in the vent pipe of the jacket. This relief valve is to prevent an over pressure condition in the sealed closed circuit either due to incorrect filling or abnormal operating conditions. During the heater's first summer season, fluid will discharge from the relief valve until the ideal closed circuit fluid volume is established. Discharges from the valve after this point in time could indicate the heater is not operating efficiently.


HEAT DUMP KIT (Assembly and Installation)

Every domestic 302K & 303K solar installation in Australia (except Tasmania) must be fitted with Heat Dump Kit. The Heat Dump Kit can only be omitted for commercial applications with a guaranteed minimum daily water use of 150 litre/day, 365 days per year.

A Heat Dump Kit comprises of a thermostatic valve, heat control pipe and connections. The thermostatic valve is installed in the centre tail end connection and is set to open at tail end socket temperatures of 70oC and above. This allows water to thermosiphon through the valve, along the Heat Control Pipe, which is fitted behind the tank and back into the tank at the opposite lower end where the incoming cold water connection is located. Heat is lost from the lower portion of the tank via the heat control pipe whenever the tank connection is at 70oC or above, ie. during no use high radiation conditions. Under normal use the thermostatic valve remains closed and heat is not lost from the tank. The heat control pipe prevents excessively high tank temperatures that could result in discharging water from the Pressure & Temperature Relief Valves when prolonged no use conditions exist during high radiation (ie. when on holidays). This feature is necessary on all 302K or 303K heaters because of the very efficient black chrome collectors on this model. The Heat Control Pipe may freeze in prolonged hard frost locations. Freezing will not damage the Heat Control Pipe because each end of the pipe is warm and ice pressure releases into these warm areas.

HEAT DUMP KIT - FIXING METHOD

(i) Lay pipes on flat surface, join them loosely and lift pipe (33-0920) 75 mm to centre of pipe. Proceed to silver solder.

(ii) Remove the tank tail end centre brass connections.

(iii) Fit O'rings (part number 33-0168 and 33-0166) to the dual temperature valve.

(iv) Carefully screw in the dual temperature valve, with 'O' ring seals in place, into the tank rear end centre fitting and tighten fully.

(v) Place the Heat Control Pipe around the back of the tank (opposite side to collectors) with the cold water connection fitting towards the connection end of the tank.

(vi) Screw pipe connection nut into tail end centre connection of dual temperature valve and tighten.

(vii) Apply thread tape to (part number 33-0602) brass connector male thread, and screw into the cold water inlet connection on the tank.

(viii) Move Heat Control Pipe (with cold water connection end) down to provide a gentle slope of pipe from tail end socket to the cold water inlet connection end. Enter cold entry pipe into adaptor and tighten with a spanner.

(ix) Connect the cold water inlet into the fitting on the heat control pipe, fill and pressurise the storage tank.

NOTE: To avoid electrolytic action, on metal roofs an insulating material must be used between the pipe and the roof sheeting metal.


INSTALLATION INSTRUCTIONS L SERIES

Select the location of the storage tank. The front mounting foot of the tank should be positioned directly over a tile batten. Remove several tiles to expose the rafters and this batten. Measure 2050 mm down (1170 mm for 30IL) from the centre of the batten to determine the location of the collector rail. Mark this location. Remove several roofing tiles from this location to expose the rafters. Hook the two stainless steel straps (Part No. 33-0847, three for 303L) to the rail and line up the straps with the rafters. Ensure that they are no more than 1.6m apart and no closer 1m. After positioning the rail level, raise the right hand side 10 mm and fix the straps to the rafters. Replace the tiles. Move back up to where the storage tank is to be positioned. Place the aluminium flashing over this row of tiles and tuck the top of the flashing under the row above.

Now using a lifting device lift collectors onto the roof, place the collectors carefully into collector rail. Remove red transit plugs from collector with a screwdriver. Silicon O'rings are supplied in the part's box and must be fitted at each pipe connection.

Join the collectors using the collector unions provided (Part No. 33-0695, apply medium pressure with a spanner). Centralise the collectors on the rail, and lock collectors to rail with the 4 collector clamps and tighten, using the nuts and bolts provided. Fit the copper blanking discs (Part No. 33-0606) and collector nuts (Part No. 33-0600) into the top left hand corner of the left hand collector and into the bottom right hand corner of the right hand collector.

Now using lifting device lift the tank onto the roof. Place the tank onto an aluminium flashing and locate the tank central to the collectors. Fit the collector hot pipe into the top right hand corner of the right hand collector. Fit the collector downpipe into the lower left hand corner of the left hand collector. After lining up the connecting pipes with the tank, fit the hot connecting pipe. Fit the downpipe into the collector thread adaptor, which is fitted into the tank cold inlet.

Secure the tank to the roof rafters in a similar manner to the collector using the tank straps (Part No. 33-0845) and the aluminium clamps (Part no. 33-0847). Loosely attach the tank clamps to the rear foot of the tank base, and clip in and bolt the tank straps. Ensure the bolt heads fit into the valley of the tile. Ensure straps are tight. Replace roof tiles. Fit the Pressure & Temperature Relief Valve (Part No. 33-0660) into the tank.

FIBRO CEMENT OR METAL SHEET ROOFING

Select a location for the storage tank close to a purlin. Avoid locating tank at mid-span of sheeting. Fixing and assembly procedures are similar to that detailed for tiled roofs, with the exception that the tank straps and the collector straps are fixed with coach screws to the purlins below.

METAL TILED ROOF

Select a location for the storage tank. The front mounting foot of the tank should be positioned directly over a tile batten. Fixing and assembly procedures are similar to that detailed for tiled roofs, except that the tank and collector straps are fixed with spring head galvanised nails directly through the metal tiles into the rafters below. Seal under the straps with a weatherproof mastic sealer.

FILLING AND COMMISSIONING THE STORAGE TANK

Do not turn on electric power/gas until after the vessel has been filled with water. Turn on a least one hot water outlet tap. Preferably over a bath or laundry trough. Turn on main water tap on line to water heater and allow water to fill the storage cylinder dispelling air out of the top of the cylinder through the open tap. As soon as water flows freely (without air bursts) from the tap, close the tap and allow the cylinder to pressurise. Check all joints for water tightness. Turn on the electric power/gas to the booster element ensuring that the power/gas is correctly connected ie. `Active' line to `Active' terminal etc. Operate both pressure relief valves easing gear to ensure that the valves are functional. The storage tank is now filled and ready to operate as an electric/gas water heater.


INSTALLATION INSTRUCTIONS CYCLONE KIT

The Cyclone Frame Kit is designed for pitch roof installation in cyclonic areas Terrain Category 2, Cyclonic Factor 1.15.

PARTS SUPPLIED

The mounting kit supplies all parts required, including the tank clamps, collector clamps, nuts, bolts, and washers.

No hardware is supplied for mounting the frame to the roof.

LOCATION

Choose a mounting location with direction in mind that will allow the frame to be centrally located over three rafters (two for 151x, 181x systems) and also provide plate with suitable fixing battens. Locate unit towards centre of roof where possible.

CLEAR OF ROOF MOUNTING

"Clear of roof mounting" MUST be used for tiled roofs - optional for others.

Fasten the frame to the 8 x threaded rods and fit the bottom collector angle to the C-Channel.

ON ROOF MOUNTING

INSTALLATION OF COLLECTORS AND STORAGE TANK

Slide the top of the collector into the Tank/Collector extrusion, and place the bottom of the collector in the Aluminium collector rail.

NOTE: It is important that the tank and the collectors are perfectly aligned before the pipe work is fitted.


INSTALLATION INSTRUCTIONS HOTTOP

Installation must comply with the local building and plumbing codes, and if an electrical booster is included, your local electrical regulations must also be adhered to.

LOCATION

For best performance the system should be installed on a roof with a slope facing the equator. The tilt angle of this slope should be at least 5o, and not more than 60o.

If it is not possible to face the equator exactly this will not make too much difference if the slope is small and you live in the tropics. If you are in more temperate regions and your roof pitch is steep, you should try to install within 45o of facing the equator.

It is required that the system be installed on an ADEQUATELY SUPPORTED AREA of the roof, as close as possible to the most frequently used hot water outlet.

The gross weight of the system when full is 170 kg. Remember that the roof is also required to take the weight of 2 people for installation and service.

The system must be installed in an area that is free from shade all year around.

ALL INSTALLATIONS MUST COMPLY WITH ALL RELEVANT CODES IN YOUR AREA

WATER QUALITY

This system is suitable for use with potable water supplies where the Total Dissolved Solids (TDS) is less than 1500 mg/l (ppm), and Total Alkalinity does not exceed 400 mg/l (ppm).

Where TDS is greater than 600 mg/l the anode will need changing before 5 years. Where a booster element is to be fitted and the TDS or Total Alkalinity exceed the limits quoted, the water supply must be treated by a softening process, otherwise scaling and damage may occur to the electric element.

Where the water supply contains fine solids such as silt etc. the use of valves in the installation should be minimised.

STANDARD INSTALLATIONS

Whilst the maximum operating pressure of the HotTop is 120 kPa (1.2 bar), (17.4 psi) we strongly recommend that the system be installed in open vented configuration.

The open vented configuration is the only approved method for Australian installations.

The head tank may be individual for each installation or central to a small community. Where an existing community head tank is too high for practical use of open vents, one option might be to serve small groups of installations with a second lower tank. For better water areas using a pressure reducing valve installed at ground level, in place of the head tank.

In situations where the user is unfamiliar with hot water supplies and may not always remember to turn off the tap when finished, the provision of a spring loaded valve on the outlet may be necessary.

Regulations regarding the type and quantity of valves required on the cold supply line will vary from place to place, most will require the provision of a non return check valve, some will also require that the pressure limiting valve be replaced by a pressure deduction/cold relief combination with a strainer. IF IN DOUBT CHECK LOCAL REGULATIONS. All valves in the inlet line must be located at least 1 metre away from the HotTop, and should be within easy reach. The valves should not be located on thew roof and NOT inside the roof space.

WATER PRESSURE

If the supply pressure does not exceed 110 kPa the pressure limiting device may be omitted, but in such the occurrence of pressure in excess of 120 kPa within the unit, under any circumstances will invalidate the warranty.

ELECTRICAL BOOSTING

Electric boosting of the HotTop is available for some locations and the temperature control system and housing are supplied in kit form. Electric element, switch and wiring are to be supplied locally. Installation instructions are fully included in the kit.

PLUMBING NOTES

All installations are to be made in accordance with the building and plumbing codes in your area. For instance in Australia local codes require all plumbing work to be carried out by a qualified plumber.

USE AS A PRE-HEATER

The HotTop may be used as a pre-heater to an existing water heater provided that:

(1) Electrical boosting is not used,

(2) The existing heater is thermostatically controller, NOT flow controlled,

(3) The operating pressures of the two systems are compatible or reduced to the lower of the two, (Australian open vented only)

(4) The existing system has enough capacity in its own right to supply the hot water requirements and is complete with its own control and safety devices and that these are not interfered with.

METHOD OF INSTALLATION

If you have not already done so, first remove the two cardboard end covers from the HotTop but do not remove the flat sheet that covers the glass. Check that there are 4 stainless steel straps, (Part No. 52-0440) and 8 pop rivets (Part No 52-0467) included in the package. Then select an area of roof, and measure from the ridge to highest point on the roof and make a mark at least 1,600 mm down from there.

Next draw a line along the roof at this level, and fix two of the mounting straps to the roof, as near as possible to 600 mm apart, lining up with your mark as shown.

The type of roof you have will determine the distance between your straps, but they must not be more than 650 mm apart.

If your roof has tiles, slates or shingles you will need to remove a few of these in order to make your fixing to the timber or metal supports underneath. If the structure is timber then the straps can be fixed using screws, for metal you will need either screws or rivets.

The type of fixing that you will need will depend upon the structure of your roof. For metal sheeting, self drilling screws into the crest of the corrugations are commonly used but in high wind and cyclonic areas it is recommended that at least one coach screw or bolt per strap is passed through the sheeting and secured into the structure beneath that the remaining two straps be employed to anchor the top of the system firmly to the roof.

With the bottom two straps firmly located (and the tiles replaced), position the system on the roof with the circular service cover to the bottom, against the upturned ends of the straps. Drill through the pre-punched holes in the straps and into the case as shown, (Use a short drill bit and take care not to penetrate the case more than 12 mm (1/2")) and using the 'pop rivets' provided, fix firmly in place.

If you are using the remaining two straps, these may now be fixed in a similar to the top of the unit. Cut off any excess length as required.

It is a good idea to not remove the cover from the glass until you have filled the system with water.

FILLING AND COMMISSIONING THE UNIT

If an electric booster is fitting, do not turn the power on until the unit is filled with water. Turn on at least one hot tap. Turn on the cold supply, allowing water to fill the unit and dispel air from the top of the container through the open tap. As soon as water flows freely, without air bursts, close the tap and allow the system to pressurise, (if applicable) and check all joints for water tightness.