SERVICE INSTRUCTIONS

Transcription

1 SERVICE INSTRUCTIONS Solar Loline 220L TM066 Published: Dec 12 REV: B Issued May 13 Everhot Rheem

2 Contents Introduction... 3 Safety Warning... 3 Model Identification... 4 Water Heater Model Identification... 4 Collector Model Identification... 4 Specifications... 5 Preventative Maintenance To Be Done By Qualified Persons... 6 Product Changes... 8 Wiring Diagram... 9 Plumbing Diagrams Operation Differential Controller Operation Operational Flow Chart Operational Flow Chart In Line Gas Boosting Hot Water Physics Related To Solar Water Heaters Components and their Function Fault Finding Common Faults Solar Monitor LED Indication Sensor Resistance Before Servicing a Solar Water Heater Fault Finding Charts Fault Finding Chart Gas Booster Flow Rate and Outlet Temperature Fault Finding Chart Fault Finding Chart Fault Finding Chart Fault Finding Charts 3 & Fault Finding Charts 4 & Fault Finding Chart Fault Finding Chart Fault Finding Chart Fault Finding Chart Electrical Safety Testing Component Adjustment Procedures Purging Air from the Collector(s) Component Replacement Collector Connectors Exploded View - Storage Cylinder to Gas Booster Connections Exploded View HBT Collectors HBT Collector - Replacement Parts List Exploded View TBT Collectors TBT Collector - Replacement Parts List Exploded View Water Heater Replacement Parts List - Water Heater Revision History

3 Introduction The information provided in these instructions is based on the water heater being installed in accordance with the Installation Instructions provided with each water heater. Should you require further technical advice on a Solar Loline 220L Water Heater, contact your nearest Rheem Service Department where genuine replacement parts are also available. Safety Warning The purpose of this service manual is to provide sufficient information to allow a person with the skills as required by the Regulatory Authorities to carry out effective repairs to a Solar Loline 220L Water Heater in the minimum of time. Safety precautions or areas where extra care should be observed when conducting tests outlined in this service manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended procedure. Live testing to be conducted. Personal Protective Clothing (PPE) shall be worn to reduce the risk of electric shock. Isolate power before conducting the indicated test Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to reduce the risk of scalding. General warning symbol. Observe the instructions accompanying the symbol. Working on roofs should always be considered a hazardous activity; by law you must observe certain minimum safety precautions. These safety precautions are outlined in the WorkCover Code of practice Safe work on roofs Part 1 and 2 and in the Occupation Health and Safety Act 1983 If the supply cord to the water heater is damaged, it must be replaced by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard. 3

4 Model Identification Water Heater Model Identification The identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 8 digits. Type 2 Everhot Solar 5 Rheem Solar Cylinder 1 - Rheemglas No of Elements 1 Single Element Storage Capacity litres Element Rating kW Collector Model Identification The identification numbers are designed to convey detailed information about the collector to which it is attached. The model number consists of 3 letters and 3 digits. Type H - High Performance T Tinox H B T 200 Surface Type B - Selective Surface Glass T - Tempered Surface Area cm² Nominal Surface Area cm² Nominal Surface Area The model number, serial number and date of manufacture should be quoted in all correspondence. 4

5 Specifications Water Heater Storage Capacity (Litres) 220 Minimum Water Supply Pressure (kpa) 200 Maximum Water Supply Pressure (kpa) With ECV 680 Without ECV 800 Booster - Integrated or Remote mounted CFGWH Refer to table below 1 Anode Water Connections - Tank Water Connections - Collector T&PR Valve Quantity 1 Length (mm) 1370 Cold Inlet RP¾/20 Hot Outlet RP¾/20 Solar RP¾/20 HBT Collector Conetite TBT Collector Conetite Diameter RP ½/15 Rating kpa 1000 Power Consumption Solar Controller 4 Watts Constant load Circulator 36 Watts Maximum load at solar heating cycle start up 30 Watts Average load during the solar heating cycle Gas Booster Refer to table below Heating Unit 1200 Watts Consumption when system is in defrost mode Gas Booster Specifications Model Booster Input (MJ/h) Capacity 25ºC rise) Temperature ( C) Power Consumption (W) For complete gas booster specifications refer to relevant Continuous Flow Gas Water Heater Service Manual. 2 With anti-frost heaters activated Solar Flow & Return Pipe Work The maximum recommended combined length of the solar cold and solar hot pipes is: Maximum recommended total pipe length and number of 90 bends Pipe Size Pipe Length 1 or 2 Collector(s) 90 Bends DN15 40 metres 20 DN20 NR NR The maximum height from the solar controller (circulator) to the top of the solar collector is determined by the maximum recommended total pipe length for the system and the water supply pressure. A minimum water supply pressure of 200 kpa should be available at the inlet to the system, otherwise the system performance may be reduced or the solar circuit may not be purged of air. Note: - For each additional 90 bend, reduce the maximum total pipe length by 0.5 metres. - For each additional metre of pipe length, reduce the number of 90 bends by two. - One 90 elbow is equal to two 90 bends. - NR not recommended. 5

6 Preventative Maintenance To Be Done By Qualified Persons Annual Service It is suggested for peak performance that the water heater be serviced annually. 1. Check for discharge from the T&PR valve. Whilst the booster is off, and during periods of low solar contribution there should be no discharge of water. When the booster is operating or during periods of high solar contribution, a small discharge of water may be evident. Operate the valve-easing lever to ensure the valve opens and resets properly. Always open and close the valve gently. 2. Check for leaks at the collector connectors, the hot and cold pipe and all cylinder fittings. 3. Check the collector glass is not cracked and the absorber plate finish is not deteriorating. 4. Confirm all supports and anchors retaining the collector/s to the roof are present, firmly fixed and in good condition. 5. Clean the collector glass. Do not stand on the collectors while cleaning. 6. Check for signs of plant or tree growth that may be shading the collectors. Advise customer to have pruned if possible. 7. Check for signs of excessive corrosion on the water heater jacket, collector panels and roof stand if fitted. 8. Isolate power to the electric booster and check all electrical connections for signs of overheating due to poor connection. 9. If an overflow tray is installed, check to ensure the overflow tray drain pipe is not blocked. 10. Conduct an electrical insulation test on the electric booster circuit (refer to Electrical Insulation Testing on page 36). Major Five Year Service It is recommended a major five year service be conducted on the solar water heater. 1. Replace pressure temperature relief valve. 2. Inspect and flush expansion control valve (if fitted) and replace if required. 3. Inspect and if required, replace the anode. If the anode is not replaced, it should be replaced within three years of this service. 4. Check the electric element for excessive calcium build up or corrosion and replace if required. 5. Check the solar control unit for correct operation. 6. Clean solar collector glass if required. 7. Flush solar collectors (refer to Flushing the Solar Collectors on page 7). 8. Visually check system for any potential problems. 9. Inspect all plumbing and electrical connections. 10. If a safety tray is installed, check to ensure the safety tray drain pipe is not blocked. 6

7 Flushing the Solar Collectors It may be necessary to flush the solar collectors if there is sediment in the water supply. It is recommended that the solar collectors are flushed every five years. This will assist in keeping the solar collectors, solar cold pipe and solar hot pipe clear of sediment (refer to Major Five Year Service on page 6). The following procedure should be performed in the morning, within three hours of sunrise, when the water temperature inside the solar collectors is lowest. To flush the solar collectors: 1. Open a hot water tap and allow water to run for five (5) minutes prior to flushing solar collectors. 2. Close the hot tap. 3. Wait a further five (5) minutes before attempting to flush the solar collectors. This will assist in the transfer of any high temperature water in the solar collectors to the solar storage cylinder. 4. Using a flat bladed screwdriver, open the bleed valve located on the solar hot water inlet (from collector) of the solar storage cylinder by rotating the bleed valve screw. Mains pressure will force water to flow from the solar storage cylinder, through the pipe work and solar collectors, then out through the bleed valve thereby flushing the collectors. This is evidenced by water spurting from the drain line connected to the bleed valve. Allow water to flow from the bleed valve drain line for five (5) minutes. Water under pressure and up to approx. 180ºC may be expelled through the bleed valve during the flushing process; keep hands and face well clear and wear protective clothing to prevent scalding or burns. 5. Using a flat bladed screwdriver, close the bleed valve. 7

8 Product Changes Intentionally Blank 8

9 Wiring Diagram 9

10 Plumbing Diagrams Remote gas booster installation with two temperature zones: Integrated gas booster installation with two temperature zones: LEGEND 10

11 Operation Solar The 220L Solar Loline operates on the temperature differential principle with water in the collector(s) gaining heat from solar radiation which is transferred by circulation to a storage tank mounted at ground level. The collector water temperature is detected by a hot sensor which is mounted at the hot outlet of the collector and the storage tank water temperature is detected by a surface contact cold sensor which is mounted to a cylinder stud inside the bottom access cover of the storage tank. A circulator moves water from the storage tank through the collector(s) and back to the storage tank. Circulator operation is controlled by the differential controller. Defrost - Electric Boost An auxiliary electric heating unit and Robertshaw ST mechanical thermostat are incorporated in the design to provide additional heat if required during Defrost Mode operation. They are located behind the bottom electrical access cover of the storage tank. Differential Controller Operation The differential controller receives information from the hot sensor which measures the water temperature at the collector(s) where heat is gained from solar radiation, and the cold sensor which measures the water temperature at the bottom of the storage tank. Run Mode When the difference between the water temperature detected by the hot sensor and that detected by the cold sensor is 8ºC, the differential controller will energise the circulator. The circulator moves the colder water in the storage tank up to the collector(s) for heating via the cold pipe and the heated water in the collector(s) down to the storage tank via the hot pipe. TE: An electronically controlled 3 tier flow rate method is utilised, the circulator speed is dictated by the hot sensor temperature or by the difference between the hot and cold sensor temperatures. The circulator speed selection switch must be on position (speed 1) for correct operation. The differential controller will de-energise the circulator when the temperature difference between the hot and cold sensors is 3ºC or the cold sensor temperature is 65ºC and the hot sensor temperature is < 130ºC Defrost Mode Defrost Mode is designed for preventing the pipe work to and from the collector(s) and the collector(s) themselves from freezing. If the hot sensor detects a water temperature 4ºC the differential controller will energise the circulator which circulates water from the storage tank through the collector(s). The circulator is de-energised when the hot sensor detects a water temperature 6ºC and the circulator has run for at least 400 seconds. If the water temperature detected by the cold sensor is 8 C during Defrost Mode the antifreeze heating unit is energised to heat the water, heating continues until the cold sensor detects a temperature 12 C or Defrost mode ends. 11

12 Over Temperature Mode Over Temperature Mode is designed to assist in preventing temperature stagnation of the collector(s). If the water temperature detected by the cold sensor is 65ºC, the controller will enter Over Temperature Mode. During Over Temperature Mode if the hot sensor detects a temperature > 130 C the circulator will be turned on to remove heat from the collector(s). The circulator is deenergised when the hot sensor detects a temperature < 110 C, this completes 1 heat dump cycle. The heat dump cycle is repeated a maximum of 8 times provided the cold sensor temperature detected is < 75ºC. If the temperature detected by the cold sensor is > 75 C heat dump mode is terminated and the circulator remains off. If the temperature detected by the cold sensor falls to < 35 C for 5 minutes the controller will exit Over Temperature Mode and return to Standby Mode. If the temperature detected by the hot sensor falls to < 50 C and the temperature detected by the cold sensor is 65 C the controller will enter Night Cool Mode. Night Cool Mode Night Cool Mode is also designed to minimise temperature stagnation of the collector(s) by transferring excess heat from the storage tank back to the collector(s) at night and radiating this to atmosphere. The temperature of the water in the storage tank will be lowered and allow capacity for solar contribution to be gained during the following day. On entering Night Cool Mode the circulator is turned on, the circulator will remain on initially until 30 minutes plus 15 x the number of heat dump cycles completed in over temperature mode (in minutes) has expired i.e. if 4 heat dump cycles had been completed 4 x 15 = = 90 therefore the initial circulator run will be 90 minutes. After the initial time period is completed the circulator will remain on until one of the conditions below is met 1. The cold sensor detects a water temperature < 63 C for 300 seconds, OR 2. The hot sensor temperature minus the cold sensor temperature is > 2ºC for 300 seconds, OR 3. The Timer count exceeds 6hrs. When any of the 3 conditions noted above are met the circulator is de-energised and the controller will enter Standby Mode. Standby Mode Standby Mode is the state the controller returns to when all the conditions of Run Mode, Over Temp Mode, Night Cool Mode or Defrost Mode have been met. In Standby Mode the circulator is de-energised. When returning to Standby Mode from any other mode a 60 second wait occurs before the controller can move to a new state i.e. back to Run Mode. 12

13 Operational Flow Chart 1 Initial power ON, System resets timers, counters and internal self routine check. Is sensor check OK? If faulty sensor is detected RED LED will flash (Refer to fault finding section). Turn circulator and element OFF if ON, A B Is system power ON < 48 hrs? Standby Mode Green LED Solid Standby Mode Green LED Slow Pulse T Hot 4 C? Defrost Mode (T Hot - T Cold) 8 C? Run Mode Circulator ON 3 Tier Flow Control On Refer to the Solar Flow Control section for details on 3 tier flow operation T Cold 65 C? (T Hot - T Cold) 3 C? A Over Temp Mode Overtemp cycle counter reset T Hot > 130 C? Overtemp cycles < 8. Increment overtemp cycle counter T Hot <110 C? Circulator and element OFF T Cold > 75 C? Circulator ON (Full Speed) T Hot < 50 C? Night Cool Mode T Cold < 35 C and 300 sec timer expired? A 13

14 Operational Flow Chart 2 Defrost Mode NIGHT COOL MODE Circulator ON (Full Speed) Circulator ON (Full speed) Element OFF T Cold 8 C? Element ON Timer > (30+15*Overtemp cycle counter) mins? T Cold 12 C? Element OFF T cold < 63 C for 300 seconds? T Hot 6 C? Timer > 400 sec? (T Hot T Cold ) > 2 C? Timer count > 6 hrs? B Solar Flow Control The differential controller utilises a 3 tier flow control strategy to maximise the solar contribution from the collector(s) while maintaining the stratification in the storage cylinder by electronically controlling the circulator speed. The 3 speeds are, Flow 1 (pulsed flow, 10% drive to circulator), Flow 2 (pulsed flow, 18% drive to circulator) and Full Speed (100% drive to circulator) When the circulator is energised in Run Mode the flow rate will be set based on the following parameters; T Hot T Cold 45 C Circulator at full speed for 300 seconds T Hot T Cold 30 C Circulator at full speed for 15 seconds then Flow 1, if the temperature remains 30 C after 300 seconds then Flow 2, if the temperature remains 30 C after 300 seconds then Full Speed. T Hot T Cold 29 C and >10 C The flow rate being used when the difference between T Hot and T Cold fell to 29 C degrees is maintained. T Hot T Cold 10 C Every 300 seconds the flow rate is reduced until Flow 1 is reached. This speed is maintained until the temperature difference rises or Run Mode ends. 14

15 In Line Gas Boosting The Solar Loline system acts as a pre heater only and an integrated or remote mounted gas fired continuous flow water heater is installed to boost the hot water temperature to the house during periods of low solar contribution. The following diagrams detail a typical Solar Loline installation with an integrated or remote mounted booster. Rheem models utilise either an or series continuous flow models while Everhot models utilise or series continuous flow models. Note: The gas booster must be set at a minimum of 70ºC to comply with AS3498. Remote temperature controllers cannot be used in this application as water temperature much higher than that indicated on the remote controller may be delivered from the solar water heater. The continuous flow gas boosters are solar compatible and will automatically determine when to operate. When the inlet water temperature is > 57 C the burner will not operate despite water flowing through the heat exchanger. When the inlet water temperature is < 57 C the burner will fire and boost the outlet temperature to the set point provided the flow rate is > 3 litres per minute. Typical Installation (Integrated Boost) Outdoor Location HOT SENSOR CONNECTION SOLAR HOT PIPE Insulated copper pipe. Use a union connection at the bleed valve and non return valve assembly. Use a union connection at collector Nylon olives must T be used HOT SENSOR LEAD INSULATED FITTINGS BLEED VALVE DRAIN Drainline must terminate away from the base of the water heater. Discharge point must comply with local regulations SOLAR PREHEAT (HOT WATER) OUTLET RATING LABEL AND OPERATING INFORMATION INSULATED SOLAR PREHEAT (HOT WATER) PIPE HOT WATER OUTLET Use a union connection and insulate hot water pipe. RELIEF VALVE DRAIN LINE Drainline must terminate away from the base of the water heater. Discharge point must comply with AS/NZS COLD WATER CONNECTION Cold water connection must comply with local regulations. WATER HEATER SUPPORT As specified in AS/NZS SOLAR COLD PIPE Insulated copper pipe. Use union connection at tank and collector. Nylon olives must T be used CABLE TIE LEAD TO PIPE INSULATION RATING LABEL AT RIGHT (T SHOWN) TEMPERATURE PRESSURE RELIEF VALVE AT RIGHT (T SHOWN) TEMPERATURE PRESSURE RELIEF VALVE DRAIN LINE AT RIGHT (T SHOWN) Drainline must terminate away from the base of the water heater. Discharge point must comply with AS/NZS FLUE OUTLET Clearances must comply with AS/NZS CONTINUOUS FLOW GAS BOOSTER WATER HEATER GAS SUPPLY PIPE Isolating valve and union must be used. ANTIFREEZE HEATING UNIT AND THERMOSTAT COVER POWER SUPPLY CORD All electrical work must be carried out by a licenced tradesperson. Power outlet must be earthed and weatherproof. 15

16 Typical Installation (Remote Boost) Outdoor Location SOLAR HOT PIPE HOT SENSOR Insulated CONNECTION copper pipe. Use a union connection at SOLAR the bleed HOT valve PIPEand non Insulated return valve copper assembly. pipe. Use a union Use connection a union connection at collector Nylon olives at the must bleed T valve be and used non return valve assembly. Use a union connection at collector Nylon olives must T be used HOT SENSOR LEAD HOT SENSOR CONNECTION INSULATED FITTINGS INSULATED FITTINGS BLEED VALVE DRAIN Drainline BLEED must terminate VALVE DRAIN away from Drainline the base must of the terminate water heater. away from Discharge the base of point the must water comply heater. Discharge point must comply with local regulations with local regulations SOLAR PREHEAT SOLAR PREHEAT (HOT WATER) OUTLET (HOT WATER) OUTLET FLUE FLUE OUTLET OUTLET Clearances Clearances must must comply comply with with AS/NZS RATING LABEL AND OPERATING INFORMATION CONTINUOUS FLOW GAS BOOSTER WATER HEATER POWER SUPPLY CORD All All electrical work must be carried out by a licenced tradesperson. Power outlet must must be be earthed and and weatherproof HOT HOT WATER WATER OUTLET Use Use a a union union connection connection and insulate hot water pipe. and insulate hot water pipe. RELIEF VALVE DRAIN LINE RELIEF VALVE DRAIN LINE Drainline must terminate away from Drainline must terminate away from the base of the water heater. Discharge the point base must of the comply water with heater. AS/NZS Discharge point must comply with AS/NZS COLD WATER CONNECTION COLD Cold WATER water connection CONNECTION must comply Cold water with connection local regulations. must comply with local regulations. HOT SENSOR LEAD SOLAR COLD PIPE SOLAR Insulated COLD copper PIPEpipe. Use union Insulated connection copper at tank pipe. and Use collector. union connection Nylon olives at tank must and T collector. be used Nylon olives must T be used CABLE TIE LEAD TO PIPE INSULATION CABLE TIE LEAD TO PIPE INSULATION RATING LABEL AT RIGHT (T SHOWN) RATING LABEL AT RIGHT (T SHOWN) TEMPERATURE TEMPERATURE PRESSURE PRESSURE RELIEF RELIEF VALVE VALVE AT AT RIGHT RIGHT (T (T SHOWN) SHOWN) TEMPERATURE PRESSURE PRESSURE RELIEF RELIEF VALVE VALVE DRAIN DRAIN LINE LINE AT AT RIGHT RIGHT (T (T SHOWN) Drainline must must terminate away away from from the the base base of the of the water water heater. heater. Discharge point point must must comply with with AS/NZS AS/NZS GAS GAS SUPPLY PIPE PIPE Isolating valve valve and and union union must must be used. be used. INSULATED SOLAR SOLAR PREHEAT PREHEAT (HOT (HOT WATER) WATER) PIPE PIPE ANTIFREEZE ANTIFREEZE HEATING HEATING UNIT UNIT AND THERMOSTAT COVER AND THERMOSTAT COVER WATER HEATER SUPPORT WATER HEATER SUPPORT As specified in AS/NZS As specified in AS/NZS POWER SUPPLY CORD All POWER electrical SUPPLY work must CORD be carried out by a licenced All electrical tradesperson. work must Power be carried outletout by must a licenced be earthed tradesperson. and weatherproof. Power outlet must be earthed and weatherproof. OUTDOOR INSTALLATION Typical Installation (Remote Boost) Indoor Location RELIEF VALVE DRAIN LINE Drainline must terminate away from the base of the water heater. Discharge point must comply with AS/NZS COLD WATER CONNECTION Cold water connection must comply with local regulations. ANTIFREEZE HEATING UNIT AND THERMOSTAT COVER SAFE TRAY WITH DRAIN As specified in AS/NZS POWER SUPPLY CORD All electrical work must be carried out by a licenced tradesperson. Power outlet must be earthed and weatherproof. INDOOR INSTALLATION Typical 16 Installation Solar Open Circuit With Remote Gas Boost 220 Water Heater SK A4

17 Hot Water Physics Related To Solar Water Heaters There are physical properties of hot water that are common to all types of heating mediums. However, with solar heating an understanding of these properties will be of assistance to servicing a solar water heater. Stratification - The term used to describe thermal stratification within a water heater where hot water will lie above cooler water without mixing. Stratification allows the storage water heater to deliver hot water from the outlet, while refilling with cold water at the inlet. Stagnation temperature - This is the temperature at which HEAT LOSS is equal to HEAT INPUT. When water stops circulating through the solar collector the temperature will rise to the STAGNATION TEMPERATURE. Flash Steam - This is when water under pressure is heated to temperatures above 100ºC, and then the pressure is suddenly reduced (by opening a hot tap) allowing the excess heat to be converted to steam. This steam requires 1689 times more space than water and fights inside the system to get out, resulting in a rumbling noise commonly referred to as elephants on the roof by customers. The steam is dissipated when it reaches the large volume of water in the storage tank and condenses. Density of water - Water is at its maximum density at 4ºC. When heated above that point up to 100ºC it expands, unequally, an average of 1/23 of its volume. However between 10ºC and 65ºC the expansion is approximately 1/50 of its volume. This is known as THERMAL EXPANSION, or expansion, and is relieved through the temperature and pressure relief valve (T&PR valve). TE: Water will expand relative to its rise in temperature. The discharge from the T&PR valve is usually the result of thermal expansion due to heating, the quantity of the discharge will be affected by: The amount of water being heated The temperature rise from cold to hot The pressure rating of the T&PR valve The number of times a hot tap is opened during a heating cycle The amount of water lost through dripping taps Faulty Non-return valve fitted to cold water inlet It should be noted that a T&PR valve would not discharge water due to thermal expansion when the heating cycle is not on. Boiling point of water - The temperature at which water boils is directly related to the pressure to which the water is subject to. Water will boil at below 100ºC if the pressure is below 101kPa (atmospheric pressure at sea level). At sea level the boiling point of water is 100ºC Water will boil at above 100ºC if the pressure is above 101kPa (water at 1000kPa will boil at approximately 183ºC). Specific heat - The amount of energy required to raise 1kg of a substance by 1ºC. Measured in units of kilo-joules (kj) i.e. 4.2kJ will raise 1 litre of water 1ºC. Latent heat (Hidden or invisible heat) - The energy required to change the state of a substance (water) into another state without a change in temperature i.e. water to steam and steam to water water to ice and ice to water The latent heat of steam is approximately 6 times the specific heat of water, i.e. to convert water at 100ºC to steam at 100ºC will require approximately 252 kj/kg. 17

18 Freezing of water - Water cooled below 4ºC expands insignificantly until it reaches the point of its changing state into ice, at which time it expands by 1/11 th of its volume. Ice contracts on further cooling. Damage to solar collectors occurs when: 1. Water trapped between two plugs of ice is compressed by the ice expansion to a point where the pressure results in a failure of the copper tube. 2. An ice plug forms in a tee or elbow and the expansion cannot be relieved, resulting in a split fitting. Components and their Function Temperature and Pressure Relief Valve (T&PR): A valve designed to provide automatic relief by discharging water in case of excessive temperature, pressure or both. Never fit a T&PR Valve with a pressure rating greater than that indicated on the product-rating label. Outlet Delivery Tube (Dip Tube): A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water from the highest point to the outlet connection. It also acts as a fitting liner. Fitting Liner: A plastic tube installed in the cold-water inlet of the water heater to provide protection against corrosion through the life of the water heater. Cold Pipe (Solar Return): The pipe connecting the solar collectors to the storage water heater through which, the cooler water returns from the storage tank to the collectors. Hot Pipe (Solar Flow): The pipe connecting the solar collectors to the storage tank through which, the solar heated water flows back to the storage tank from the collectors. Circulator: A small centrifugal pump that circulates water through the collectors. Differential Controller: An electronic control unit that interprets low voltage signals indicating water temperature from the hot and cold sensors to switch on and off the 240 volt circulator and anti-frost element. Hot Sensor: A thermistor for sensing water temperature, fitted into the connector at the hot pipe connection on the collector. Supplied with 20 metres of cable for connection to the differential controller. Cold Sensor: A thermistor for sensing water temperature, fitted at stud on the left of thermostat. Anode (Sacrificial): A metal alloy electrode installed in the water heater cylinder that by galvanic action protects the cylinder from corrosion. Thermostat: A device, responsive to temperature, which controls the supply of electrical energy to the anti-frost heating element. The differential controller will control element operation however thermostat is fitted to provide energy cut-out in the event of a failure within the control unit. Heating Unit (Element): A tubular device containing an electric resistance element that converts electrical energy to heat. This unit applies in Defrost Mode of this solar Loline system or Standard element rating is 1.2kW. 18

19 Fault Finding Common Faults When a complaint is lodged about the performance of a hot water system there are a number of causes that should be checked and eliminated. In an attempt to pinpoint the most likely cause it is important to discuss with the customer their reasons for the complaint, the duration of the problem, any change in circumstances or usage and recent weather conditions. This information in conjunction with the following listed common complaints will assist you in locating the most likely cause. All procedures assume there is water flowing through the water heater. Excessive hot water usage: The complaints of insufficient hot water and no hot water can on many occasions be attributed to hot water usage exceeding the capacity of the water heater to provide hot water. When first attending a call of this nature it is essential to establish the probable hot water usage by querying the usage habits of the household and compare this with the potential delivery of the model water heater installed. It can then be established if the usage is within or outside the capacity of the model. The areas to look at for excessive usage are: 1. Automatic washing machines. 2. Showers exceeding 11 litres/minute for mixed water and 5 minutes in duration. 3. Two or more showers operating at the same time. 4. Change of occupancy or number of persons increased. 5. High water pressure area. (Excessive T&PR discharge) 6. Plumbing leaks Discoloured water 1. This may be the result of discoloured water entering from the cold water mains. Check if the cold water is also discoloured. 2. Brown coloured water will generally indicate that the anode has been depleted or the water heater is near the end of its useful life. 3. Milky coloured water is generally air in suspension and will disperse of its own accord. In very hard water areas where anode gassing occurs, milky water may be evident. The use of a blue anode should overcome this problem. Water hammer: A water heater will not cause water hammer, however valves associated with the water heater may be the source of the problem i.e. cold-water stopcock, nonreturn valve, T&PR valve or relief valve. Most water hammer problems are associated with plumbing, hot and cold, or appliances i.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve parts or neighbouring equipment. High water pressure areas will have more complaints of this nature and the use of a pressure-limiting valve (PLV) to reduce the household cold-water pressure will usually solve most problems. 19

20 Roof leaking: This complaint is usually made during or after wet weather and normally soon after commissioning a new water heater. The movement of persons on the roof during installation can crack roofing material if the load is borne on specific points or the roof material is brittle. Replacement of damaged roof materials is essential. Use of a woven plastic roof sheet below the collector will make water penetration more difficult in the future. It should also be established if water is penetrating around the pipe or sensor joints through the roof. Moisture under the collector glass: Small amounts of condensate on the underside of the collector glass are not a sign of collector failure. The condensation is formed from humid air condensing when the collector cools down. Because of high temperatures within the collector, ambient air is transferred in and out of the collector through drain holes. TE: The collector is not hermetically sealed. Hot water plumbing leaks: If hot water has not been used for a period of time, feeling the temperature of the hot water line may give an indication of water flow if the pipe is warm. The method of checking for plumbing leaks is: 1. Turn off the stopcock on the cold water supply to the water heater. 2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock is operating correctly. 3. Turn off the hot tap. 4. Turn on the stopcock to make up the water pressure in the cylinder, and then turn the stopcock off again. 5. Wait approximately 5 minutes then do either of the following: a. With your ear close to the stopcock turn it on slightly and listen for any water passing. If there are no leaks, water should not pass. b. Open a hot tap while listening for any pressure release. If there is a pressure release there will be no leaks in the plumbing system. Mixing or crossed connections: If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or thermostatic mixing valve is installed there is always the possibility that the cold water could mix with the hot water through a faulty or incorrectly installed valve. This is referred to as a cross connection. The complaints of insufficient hot water, water too cold or excessive discharge from the T&PR valve may be attributed to a cross connection. The method of checking for a cross connection is: 1. Turn off the stopcock on the cold water supply to the water heater. 2. Open a hot tap. If water flow is persistent and cold a cross connection exists. 20

21 Solar Monitor LED Indication A solar monitor is located on the top electrical cover and houses a green and a red LED. The green LED, marked Solar, indicates the current operational mode of the solar water heater and the red LED, marked Attention, indicates a fault mode. The green LED will emit either a constant glow or a series of flashes. The red LED will emit a series of flashes, with a 1 second interval between flashes if there is a particular fault condition within the system. Green LED Operational Status Red LED Fault Condition Flash Seq Indicates Flash Seq Indicates Solid Slow Pulse Rapid Pulse 3 Pulse System power is ON 48 hrs and circulator is OFF System power is ON < 48 hrs and circulator is OFF System power is ON 48 hrs and circulator is ON System power is ON < 48 hrs and circulator is ON Solid Rapid Pulse Hot sensor temp >130 C. TE: This can occur during normal operation Run override mode occurs when temp rise across collector 45 C 3 Pulse Hot sensor - short circuit 4 Pulse Hot sensor - open circuit No Green Power outage 5 Pulse Cold sensor - short circuit 6 Pulse Cold sensor - open circuit TE: The Red LED may come on with the Green LED under 2 conditions; 1. When the hot sensor temperature is > 130 C and the controller is in RUN mode. 2. When the difference between the hot and cold sensors is 45 C and the controller is in RUN mode. Sensor Resistance The differential controller can detect if a temperature sensor is open circuit or short circuit however it is possible for the sensor resistance to drift out of tolerance. This can cause the circulator to run continuously or not run at all. In addition to the checking the status of the sensors indicated by the differential controller the resistance of the sensors should also be checked. The table opposite sets out the resistance of the sensors for a given water or air temperature. Temperature Resistance (Hot & Cold Sensor) Degrees C Kilo-ohms

22 Before Servicing a Solar Water Heater Working on roofs should always be considered a hazardous activity, particularly early in the morning, late in the evening or after periods of rain. Safety precautions pertaining to working on roofs are outlined in the Work Cover Code of Practice Safe work on roofs Part 1 and 2 and in the Occupational Health and Safety Act Water under pressure and at temperatures up to approximately 180ºC may be present in the collector/s. Isolate water supply and relieve pressure through a hot tap or the temperature and pressure relief valve prior to opening the collector pipe work. Wear protective clothing to prevent scalding or burns. Certain diagnostic procedures outlined in these service instructions require live testing to be conducted. Caution should always be exercised when conducting these tests to prevent the risk of electric shock. Fault Finding Charts Fault Chart number Page General Fault Finding 23 No hot water In-line gas booster 1 24 Differential controller 2 25 Collector circuit 2.1, , 29 Insufficient hot water 3 30 Excessive discharge from T&PR valve Water too Hot In-line gas booster 1 24 Collector circuit 4 31 High energy bills 5 31 Leaking water heater 6 32 Frost Protection Booster Circuit Noisy water heater 7 35 Electrical Insulation test

23 General Fault Finding Chart Fault Is the complaint for no hot water? Have there been periods of high solar gain? Gas Booster 1 Solar Circuit 2 Is the complaint for insufficient hot water? 3 Is the complaint for water too hot? Does the problem only occur during periods of high solar gain? 1 4 Is the complaint for high energy bills? 5 Is the complaint for leaking? 6 Noisy Water Heater 7 23

24 Fault Finding Chart 1 Incorrect Water Temperature Gas Booster Water too hot Is the water in the storage tank below 57ºC? Is the gas booster operating? Replace inlet sensor Water not hot enough Is a tempering valve fitted? Depending on weather conditions the discharge temperature from the tank can be up to 75ºC. Fit a tempering valve Service or replace the tempering valve Is the gas booster operating? Is the flow rate through the gas booster greater than 3lpm? Advise customer that a minimum flow rate of 3lpm is required to cause the gas booster to operate Refer to section on gas booster flow rate and outlet temperature Conduct fault finding on the gas booster. Refer to Service Instructions appropriate to booster model Is the outlet temperature of the gas booster 70ºC? Service or replace the tempering valve Gas Booster Flow Rate and Outlet Temperature Check pre-set temperature setting on the gas booster. Refer to Service Instructions appropriate to booster model for detail on temperature adjustment Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons. 1. Remove the front panel from the gas booster water heater. 2. Using an insulated tool, turn DIP SWITCH 1 on (up position). Refer to figure 1 3. Press the MIN button until left digit in the display reads: 1 (To view flow rate) or 5 (To view outlet temp) 4. Press the MAX button until the right digit in the display reads Y The maintenance code 1Y (Flow Rate) or 5Y (Outlet Temp) and the value of that code will now be alternating on the LED display. 5. Turn DIP SWITCH 1 off (down position) when diagnosis is complete. 6. Refit the front panel to the gas booster water heater. 24 Figure 1

25 Fault Finding Chart 2 No Hot Water - Differential Controller Is 240V present at the GPO? Test 1 Restore power at the GPO if turned off. Locate household wiring or cord fault and repair. Is the controller cordset open circuit? Test 2 Replace cordset 3 Flashes Short circuit - hot sensor Replace hot sensor Is the red LED flashing? 4 Flashes Open circuit - hot sensor 5 Flashes Short circuit - cold sensor Ensure sensor lead is not severed and is connected correctly to terminal block. If OK, replace hot sensor. Replace cold sensor 6 Flashes Open circuit - cold sensor Ensure sensor lead is not severed and is connected correctly to terminal block. If OK, replace cold sensor. Refer to section on sensor resistance. Are the sensor resistances correct? Replace faulty sensor Is the circulator open circuit? Test 3 Isolate power before conducting test. Replace circulator Is the circulator seized or vibrating abnormally? Replace circulator Does the circulator operate? Is voltage being supplied to the circulator? Test 4 Replace circulator Is wiring loom I/R check OK? Test 5 Replace differential controller No Hot Water - Collector Circuit Repair wirings accordingly. TE: if faulty wirings present inside the loom, tank needs to be replaced. 25

26 Component Tests 1-3 TEST 1 Ensure power point is switched on and using a multimeter on the AC voltage scale, measure between the 3 pin sockets on the power point. The following results should be obtained: Active to Neutral 240 Volts AC. Active to Earth 240 Volts AC. Neutral to Earth 0 Volts. TEST 2 BLUE BLUE WHITE BROWN GREEN/YELLOW Unplug the cord set from the GPO and using a multimeter set on the x1 resistance scale measure each conductor in the cord set. Normal resistance for each conductor should be less than 1 ohm. TEST 3 Disconnect the circulator wiring from the differential controller PCB and using a multimeter set on the x1 resistance scale, measure the resistance of the circulator motor. Normal resistance is 450 ohms +/- 5% 26

27 Component Tests 4 & 5 TEST 4 Using a multimeter set on the AC voltage scale, measure between the brown and blue wires at the circulator 3 pin plug. The following results should be obtained: Speed Control mode - Approx 20 Volts AC pulsing Full Speed mode Volts AC constant TEST 5 BROWN BLUE BLUE WHITE BLUE WHITE BROWN GREEN / YELLOW Remove both top and bottom access covers. Disconnect 4 pin plug coming from the wiring loom and using a multimeter set on the x1 resistance scale, measure the resistance of between wirings. Normal resistance is 0 ohm when checking GREEN/YELLOW 4 pin plug wiring Bottom access area Brown Brown wire at terminal block Blue Blue wire at thermostat pin 3 White White wire at thermostat pin 1 Yellow/Green Yellow/Green at element earth tab TE: Any open circuit or earthing wires found, tank needs to be replaced. 27

28 Fault Finding Chart 2.1 No Hot Water - Collector Circuit Is collector facing within 45º of north? Collector not in optimum position. Discuss options with client: - Reinstall on a side pitch roof stand. - Relocate to a northerly aspect. - Accept reduced solar gain. Are trees or buildings shading the collector at any time of the day? Advise customer to prune trees if possible or reposition collector to shade free location. The ideal collector inclination should be equal to the local latitude. The minimum collector inclination for the system to operate is 10º. Is the collector lying too flat? Reposition collector onto a flat roof stand. Is collector glass broken or dirty? Clean the glass or replace collector. Is the coating on the collector absorber plate deteriorating? Replace the collector. No Hot Water- Collector Circuit (Flow Chart 2.2) 28

29 Fault Finding Chart 2.2 No Hot Water - Collector Circuit (Cont d) Are there any leaks around the collector or heater? Is the leak discharging from the T&PR valve? Rectify leaks at connectors or fittings. Replace collector or tank if leaking. Excessive discharge from T&PR Is the dropper tube fitted, in the correct position or blocked? Replace or clear the dropper tube. Open bleed valve, located in hot water return plumbing from the collector. Warning: Water under pressure and at temperatures up to approximately 180ºC may be present in the collector. Keep hands clear of bleed valve discharge. Does water flow freely from the bleed valve? Locate blockage in collector, solar flow & return pipe work or dropper tube. Replace collector if required. Close the bleed valve and continue with diagnosis Is the solar non return valve jammed? Replace non-return valve Is the daily water usage exceeding solar heating ability? Is hot water required when solar gain is low? i.e: morning usage Advise client to plan hot water usage during high solar gain periods. Alternatively, boosting will be required more often. Is the problem only evident during winter? Advise client that boosting will be required more often during the winter months. Insufficient Hot Water Advise client on usage pattern that will suit needs. 29

30 Fault Finding Charts 3 & 3.1 Insufficient Hot Water Is the water heater of sufficient size for the clients needs? Has the usage pattern changed? i.e: additional appliances or hot water users. Recommend a water heater of sufficient capacity to meet clients needs. Is T&PR valve continuously discharging water? Is the water heater sized to suit the household? Excessive discharge from T&PR Recommend a hot water usage pattern that will suit the water heaters capacity and the clients needs. Is the water supply pressure above 800kPa? Is the correct T&PR valve fitted? Remove incorrect T&PR valve and replace with a 1000kPa relief valve. Do not use reconditioned valves. Is the water temp above 75ºC? Check for cross connection. Replace T&PR valve. Water too hot - Collector Circuit Existing pressure limiting valve faulty. Fit PLV if not already fitted. Replace T&PR valve if required. Are there any plumbing leaks, crossed connections or dripping taps? Repair any leaks. Isolate cross connections. Does the water temp correspond with the thermostat setting? Gas Booster Circuit Collector Circuit No Hot Water - Gas Booster No Hot Water - Collector Circuit Advise client on usage pattern to suit solar water heater. 30

31 Fault Finding Charts 4 & 5 Water too hot - Collector Circuit Is the water temperature at the hot tap above 75º? Advise customer on operation of solar system and benefits of storing water at 70ºC. Tempering valves should be considered for ablution areas if concerns surround small children or elderly occupants. Is the circulator operating when the water temp is in excess of 65ºC? Is a fault code flashing? Replace sensor indicated by code. Refer to section on No Hot Water Chart 2 Is the resistance of all sensors correct? Controller in heat dump mode, cylinder temperature will not exceed 75ºC. Check temperature setting of gas booster. Replace faulty sensor. High Energy Bills Is boosting required during periods of high solar gain to meet hot water demand? No Hot Water - Collector Circuit Are there any water leaks around the collectors or heater? Is the leak, discharge from the ECV/T&PR valve? Rectify leaks at connectors or fittings. Replace collector or tank if leaking Excessive discharge from T&PR Gas booster must operate during periods of low solar contribution to provide hot water. Gas consumption may be reduced by scheduling hot water usage during periods of solar gain. 31

32 Fault Finding Chart 6 Leaking Water Is the leak from the tank? Is the leak from the ECV/T&PR valve? Excessive discharge from T&PR Is the leak from a collector fitting? Is the leak from the anode? Reseal the anode. Ensure fittings are sufficiently tightened. Is the leak from the collector? Is the leak from the heating unit gasket? Replace the heating unit gasket. Condensation may be forming in the collector. This is a normal condition. Is water running from the bottom of the collector? Is the leak from a plumbing fitting? Reseal the plumbing fittings. Tank may be leaking, feel for hot spots on the jacket. Replace tank if necessary. Is the area frost prone? Replace the collector Frost Protection Booster Circuit 32

33 Fault Finding Chart 6.1 Frost Protection Booster Circuit Are the thermostat ECO contacts closed? Test 6 Replace thermostat & damaged collector Is the water in the solar storage tank > 60 C? Isolate power and remove the thermostat from the retaining clamp and allow to cool Are the thermostat contacts closed? Test 7 Replace thermostat & damaged collector Does the element have the correct resistance? Test 8 Replace element & damaged collector Does the differential controller initiate defrost boosting? Test 9 Is voltage being supplied to the circulator? Test 4 Replace damaged collector Is wiring loom I/R check OK? Test 5 Replace differential controller Repair wirings accordingly. TE: if faulty wirings present inside the loom, tank needs to be replaced. TE: The collectors are subject to a number of exclusions relating to frost damage and may not be covered by warranty. Refer to warranty page for details. Are the solar hot and cold pipes adequately insulated? Replace the collector. No Warranty Replace the collector. 33