Owner’s Guide and Installation Instructions Solar VSi Storage Tank WARNING: Plumber – Be Aware Use copper pipe ONLY. Plastic pipe MUST NOT be used. It is a requirement of a solar water heater installation that all pipe work be in copper and not plastic, due to the effects of high water temperatures. This water heater must be installed and serviced by a qualified person. Please leave this guide with the householder.
WARNING: Plumber – Be Aware The solar hot and solar cold pipes between the solar storage tank and the solar collectors MUST BE of copper. All compression fittings must use brass or copper olives. The full length of the solar hot and solar cold pipes MUST BE insulated.
CONTENTS HOUSEHOLDER – We recommend you read pages 4 to 20. The other pages are intended for the installer but may be of interest. About Your Water Heater ............................................................................................................ 4 Regular Care .............................................................................................................................. 11 Water Supplies.......................................................................................
ABOUT YOUR WATER HEATER WATER HEATER APPLICATION This water heater is designed for use in a single family domestic dwelling for the purpose of heating potable water. Its use in an application other than this may shorten its life. MODEL TYPE ® Your Vulcan indirect solar VSi water heater is designed for the solar collector to be roof mounted and the solar storage tank to be installed at ground or floor level.
ABOUT YOUR WATER HEATER GAS BOOSTING OPERATION Water stored in the solar storage tank passes through the in-series gas booster when a hot tap is opened. The in-series gas booster is for heating the water at times of low solar energy gain, such as during cloudy or rainy weather, or during colder months. Solar heated water can reach temperatures up to 75°C in the solar storage tank. When the solar heated water temperature is 58°C or above, the in-series gas booster will not boost the water temperature.
ABOUT YOUR WATER HEATER HOTTER WATER INCREASES THE RISK OF SCALD INJURY This water heater can deliver water at temperatures which can cause scalding. Check the water temperature before use, such as when entering a shower or filling a bath or basin, to ensure it is suitable for the application and will not cause scald injury.
ABOUT YOUR WATER HEATER PIPE WORK AND INSULATION The solar hot and solar cold pipes between the solar storage tank and the solar collectors and the pipe work between the solar storage tank and a remote in-series water heater MUST BE of copper. The full length of the solar hot and solar cold pipes MUST BE insulated.
ABOUT YOUR WATER HEATER SOLAR MONITOR The solar storage tank incorporates a solar monitor. The solar monitor is located above the lower front cover and houses both 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, with a 2 second interval between each series.
ABOUT YOUR WATER HEATER TO TURN OFF THE WATER HEATER If you plan to be away from home for a few nights, we suggest you leave the water heater switched on. If it is necessary to turn off the water heater: Switch off the electrical supply at the power outlets to the solar storage tank and to the in-series gas booster if there is no risk of freezing conditions occurring (refer to note below). Close the gas isolation valve at the inlet to the water heater.
ABOUT YOUR WATER HEATER GOING ON HOLIDAYS It is not necessary to switch off the electrical supply at the power outlets to the solar storage tank and inseries gas booster if you are going away. However, if it is necessary to switch off the power to the water heater, refer to “To Turn Off The Water Heater” on page 9.
REGULAR CARE GENERAL MAINTENANCE The jacket of the gas booster can be cleaned with a soft cloth and warm mild soapy water. Under no circumstances should abrasive materials or powders be used. The area around the gas booster can be sprayed with insecticide to rid the area of insects. Insects encroaching into or nesting in the water heater can interfere with the operation of the gas booster and also damage components.
REGULAR CARE MAJOR FIVE YEAR SERVICE For safe and efficient operation, it is recommended a major five year service be conducted on the water heater. Warning: Servicing of a water heater must only be carried out by a qualified person. Phone Rheem Service or their nearest Accredited Service Agent. Note: The five year service and routine replacement of any components, such as the anodes and relief valves, are not included in the Vulcan warranty. A charge will be made for this work.
REGULAR CARE TEMPERATURE PRESSURE RELIEF VALVE This valve is near the top of the water heater and is essential for its safe operation. It is possible for the valve to release a little water through the drain line during each heating period. This occurs as the water is heated and expands by approximately 1/50 of its volume. Continuous leakage of water from the valve and its drain line may indicate a problem with the water heater (refer to “Temperature Pressure Relief Valve Running” on page 19).
WATER SUPPLIES This water heater must be installed in accordance with this advice to be covered by the Vulcan warranty. This water heater is manufactured to suit the water conditions of most public reticulated water supplies. However, there are some known water chemistries which can have detrimental effects on the water heater and its operation and / or life expectancy. If you are unsure of your water chemistry, you may be able to obtain information from your local water supply authority.
WATER SUPPLIES ANODE INSPECTION AND REPLACEMENT The anode installed in a vitreous enamel lined steel water heater cylinder will slowly dissipate whilst protecting the cylinder. The life of the cylinder may be extended by replacing the anode. If the anode is not replaced during a five year service (refer to “Major Five Year Service” on page 12) then the maximum time after installation when the anode should be replaced is 8 years.
WATER SUPPLIES WITHIN WARRANTY SPECIFICATION -1.0 very corrosive 0 no warranty applies to a: -direct (open circuit) solar collector -continuous flow copper heat exchanger no warranty applies to a: temperature pressure relief valve or a water heater cylinder unless an expansion control valve is fitted. no warranty applies to a: -direct (open circuit) solar collector -continuous flow copper heat exchanger SATURATION INDEX (SI) SOLAR WATER HEATERS - INTEGRATED GAS BOOST (CONTINUOUS FLOW) +0.
SAVE A SERVICE CALL Check the items below before making a service call. You will be charged for attending to any condition or fault that is not related to manufacture or failure of a part. COLD WATER FROM THE HOT TAP Close the hot tap, wait 10 seconds and open the hot tap again. Is the hot tap open enough? The in-series gas booster burners will not light if the flow rate is less than 2.5 L / min (244 series).
SAVE A SERVICE CALL IN-SERIES BOOSTER OPERATING TOO FREQUENTLY You may find that the in-series booster operates more frequently than expected. This will occur when the solar heated water temperature is lower than 58°C for the 244 620 or 244 627 in-series gas booster or lower than the temperature setting of another type of in-series booster, which may be experienced during periods of low solar energy gain or if there has been heavy hot water usage.
SAVE A SERVICE CALL COLLECTOR GLASS The Vulcan warranty DOES NOT cover breakage of solar collector glass. Check your household insurance policy covers collector glass breakage. Warning: No attempt should be made to remove or replace broken collector glass. The collector glass is not offered as a replacement part. Should the solar collector require replacement, contact Rheem Service or their nearest Accredited Service Agent.
SAVE A SERVICE CALL ERROR CODE The in-series gas booster provides a diagnostic error code in the event of an interruption to its operation. The error code is displayed on the front of the in-series gas booster on the OK MONITOR as a numerical value on the 244 627 models or a series of flashes on the 244 620 models. If an error code appears: Close the hot tap and switch off the electrical supply to the inseries gas booster.
INSTALLATION – SOLAR STORAGE TANK THIS WATER HEATER IS FOR OUTDOOR INSTALLATION IF AN IN-SERIES GAS BOOSTER IS MOUNTED ON THE STORAGE TANK. THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING. Check the in-series gas booster is suitable for the gas type available. (refer to the rating label on the in-series gas booster) The system is suitable for installation with either one Rheem T200 or two Rheem NPT200 or HBT200 solar collectors.
INSTALLATION – SOLAR STORAGE TANK Victorian Installers Notice to Victorian Installers from the Victorian Plumbing Industry Commission if this solar water heater is installed in a new Class 1 dwelling in the State of Victoria. The system model number is to be recorded on the Certificate of Compliance.
INSTALLATION – SOLAR STORAGE TANK You must be able to read the information on the rating plate. If possible leave headroom of one water heater height so the anode can be inspected or replaced. Remember you may have to remove the entire solar storage tank later for servicing. The solar storage tank is to be installed at ground or floor level and must stand vertically upright on a stable base as acceptable to local authorities.
INSTALLATION – SOLAR STORAGE TANK MAINS WATER SUPPLY Where the mains water supply pressure exceeds that shown in the table below, an approved pressure limiting valve is required and should be fitted as shown in the installation diagram (refer to diagram on page 38). Model 160 Relief valve setting 1000 kPa Expansion control valve setting * 850 kPa Max. mains supply pressure With expansion control valve 680 kPa Without expansion control valve 800 kPa Min.
INSTALLATION – SOLAR STORAGE TANK RAIN WATER TANK If the solar collector and solar pipe work are to be installed on a section of roof which is part of a rain water runoff collection system, then it is recommended this section of roof and its gutter be isolated from the rain water collection system. The gutter should be isolated to a width greater than the solar collector and pipe work and must have suitable drainage.
INSTALLATION – SOLAR STORAGE TANK HOT WATER DELIVERY This water heater can deliver water at temperatures which can cause scalding. It is necessary and we recommend that a temperature limiting device be fitted between the water heater and the hot water outlets in any ablution area such as a bathroom or ensuite, to reduce the risk of scalding. The installing plumber may have a legal obligation to ensure the installation of this water heater meets the delivery water temperature requirements of AS/NZS 3500.
INSTALLATION – SOLAR STORAGE TANK CIRCULATED HOT WATER FLOW AND RETURN SYSTEM Remote Gas Booster The solar storage tank of a solar water heater should not be installed as part of a circulated hot water flow and return system in a building. The benefits of solar gain will be significantly reduced and energy gained from the sun lost through the pipe work.
INSTALLATION – SOLAR STORAGE TANK Circulated Hot Water Flow and Return System In-series Gas Booster Remote of Storage Tank LEGEND REDUCING HEAT LOSSES The cold water line to and the hot water line from the water heater must be insulated in accordance with the requirements of AS/NZS 3500.4. The insulation must be weatherproof and UV resistant if exposed. The full length of the solar hot and solar cold pipes between the solar storage tank and the solar collector(s) MUST BE insulated.
DIMENSIONS AND TECHNICAL DATA 423 423 212 212 503 690 503 211 51 211 51 Solar Connections Solar Preheat Outlet Solar Connections Solar Preheat Outlet TPR Valve Sola Prehea Outle 408 TPR Valve 1858 1613 1206 805 1818 1858 1613 1213 Hot Water Outlet 1615 1818 Cold Water Inlet Col Wate Inle 402 Cold Water Inlet 402 PR alve INSTALLATION – SOLAR STORAGE TANK Storage storageTank tank with remote boost (Remote Boost) Storage Tank storage tankwith with tank Integrated mounted in-
INSTALLATION – SOLAR STORAGE TANK TYPICAL INSTALLATION – TANK MOUNTED GAS BOOSTER 20L SENSOR CONNECTION HOT SENSOR LEAD SOLAR COLD PIPE Insulated copper pipe.Use a compression nut and olive. CABLE TIE TO PIPE INSULATION SOLAR HOT PIPE Insulated copper pipe. Use a compression nut and olive.
INSTALLATION – SOLAR STORAGE TANK TYPICAL INSTALLATION – REMOTE GAS BOOSTER 20L SENSOR CONNECTION SENSOR HOT SENSOR LEAD CONNECTION HOT SENSOR LEAD CABLE TIE LEAD TO PIPE INSULATION CABLE TIE LEAD TO PIPE INSULATION SOLAR HOT PIPE Insulated copper pipe. use a compression nutHOT and PIPE olive SOLAR Insulated copper pipe. use SOLAR PREHEAT a compression nut and olive (HOT WATER) OUTLET SOLAR COLD PIPE Insulated copper pipe. Use a compression SOLAR COLD PIPE nut and olive. Insulated copper pipe.
INSTALLATION – SOLAR STORAGE TANK TYPICAL INSTALLATION – REMOTE GAS BOOSTER 27L SENSOR CONNECTION SENSOR CONNECTION HOT SENSOR LEAD HOT SENSOR LEAD CABLE TIE LEAD TO PIPE INSULATION CABLE TIE LEAD TO PIPE INSULATION SOLAR HOT PIPE Insulated copper pipe. use SOLAR HOT PIPE a compression nut and olive Insulated copper pipe. use SOLAR PREHEAT a compression nut and olive (HOT WATER) OUTLET SOLAR PREHEAT Use a union connection & (HOT WATER) OUTLET insulate hot water pipe.
INSTALLATION – SOLAR COLLECTOR SOLAR COLLECTOR LOCATION Consideration must be given to the position of the solar collector in relation to the solar storage tank. There are limitations on both the maximum length of the solar hot and solar cold pipes and the maximum height between the solar storage tank and the solar collector. Refer to “Solar Storage Tank Location” on page 22 and to “Pipe Lengths” on page 34. The solar collector must be installed in a shade free position.
INSTALLATION – SOLAR COLLECTOR LATITUDE OF SOME AUSTRALIAN CITIES Adelaide 35°S Cairns 17°S Hobart 42°S Port Hedland 20°S Alice Springs 24°S Canberra 35°S Mildura 34°S Rockhampton 24°S Brisbane 27°S Darwin 12°S Melbourne 38°S Sydney 34°S Broken Hill 31°S Geraldton 28°S Perth 32°S Townsville 19°S PIPE LENGTHS The solar hot and solar cold pipes between the solar storage tank and the solar collector shall: be of DN15 bendable grade or hard drawn copper tube.
INSTALLATION – SOLAR COLLECTOR WARNING: Plumber – Be Aware The solar hot and solar cold pipes between the solar storage tank and the solar collectors MUST BE of copper. All compression fittings must use brass or copper olives. The full length of the solar hot and solar cold pipes MUST BE insulated.
INSTALLATION – SOLAR COLLECTOR Maximum Height To Collector The solar collector(s) must be the highest point of the system. The maximum height of the solar installation, from the base of the solar storage tank to the top of the solar collector(s), is 7.5 m. The pump supplied with the solar storage tank will not circulate closed circuit fluid through heights greater than 7.5 m and solar gain will not be achieved.
INSTALLATION – SOLAR COLLECTOR Pressure Testing The solar water heater, including the collector circuit and solar collectors, is to be isolated during the testing and commissioning of the heated water reticulation system in a building, in accordance with Clause 11.1 and 11.3 (a) of AS/NZS 3500.4.
CONNECTIONS – PLUMBING All plumbing work must be carried out by a qualified person and in accordance with the requirements of the Standard AS/NZS 3500.4, and all local codes and regulatory authority requirements. In New Zealand, the installation must conform with Clause G12 of the New Zealand Building Code. All gas work must be carried out by a qualified person and in compliance with the Standard AS 5601 or AS/NZS 5601.
CONNECTIONS – PLUMBING PIPE SIZES To achieve true mains pressure operation, the cold water line to the water heater should be the same size or bigger than the hot water line from the water heater. The minimum recommended hot pipe size is DN20. The pipe sizing for hot water supply systems should be carried out by persons competent to do so, choosing the most suitable pipe size for each individual application.
CONNECTIONS – PLUMBING SUPPLIED WITH VSI160 SOLAR STORAGE TANK – KIT 299662 Item Part Description Number Item Part Description Number 1 088039 hex nipple ¾” x ½” 6 088144 fitting union ¾” F x ½” C 2 088150 elbow ½” F x ½” M Rye 2503 7 144704 panel mounting bracket 3 088152 braided flexible hose 262 mm long ½” x ½” female cone 8 080031 screw phillips pan HD No 8 x 13 (4 off) 4 088151 elbow fitting ½” M x ½” C Rye 4840 9 080187 screw HD bolt M6 x 12 5 088148 preformed pipe DN15,
CONNECTIONS – PLUMBING RELIEF VALVE DRAIN DN15 copper drain lines must be fitted to the temperature pressure relief valve, expansion control valve (if one is installed) and solar circuit relief valve to carry the discharge clear of the water heater. Connect the drain lines to the valves using disconnection unions.
CONNECTIONS – PLUMBING To connect the solar cold and solar hot pipes to the solar storage tank: Solar hot pipe connection Remove the plastic cap from the solar hot inlet pipe end at the top of the solar storage tank. Undo the compression nut and olive from the compression union and fit over the solar hot pipe connection. Fit the ½” x ½” nipple from the compression union supplied to the solar hot inlet pipe end.
CONNECTIONS – ELECTRICAL The power supply to the water heater must not be switched on until the solar storage tank is filled with water. MEGGER READING It is not mandatory to conduct a megger test on a plug in appliance, however if a megger test is conducted on this water heater, then the following should be noted. Warning: This water heater contains electronic equipment and 500 V insulation tests must only be conducted between either active and earth or neutral and earth.
CONNECTIONS – ELECTRICAL HOT SENSOR LEAD The plug on the hot sensor lead connected to the solar control board, located behind the front cover of the solar storage tank, is to be connected to the socket on the hot sensor from the solar collector.
CONNECTIONS – ELECTRICAL WIRING DIAGRAM Wiring Diagram Solar Drain Back Integrated Gas Boost & Storage Tank 45
COMMISSIONING TO FILL AND TURN ON THE WATER HEATER The power supply to the water heater must not be switched on until the solar storage tank is filled with water. To fill the solar storage tank with water and turn on the water heater: Open all of the hot water taps in the house (don‟t forget the shower). Open the cold water isolation valve fully on the cold water line to the water heater. Air will be forced out of the taps. Close each tap as water flows freely from it. Check the pipe work for leaks.
COMMISSIONING SOLAR CIRCUIT Commissioning of the Solar Circuit It is necessary to commission and check the operation of the solar circuit as part of the installation. The water heater is supplied charged with closed circuit fluid. The commissioning procedure includes checking the: circulation of closed circuit fluid through the solar circuit. drain back function of the solar circuit. solar circuit under circulation to ensure there are no leaks. level of the closed circuit fluid.
COMMISSIONING PRE-COMMISSIONING WARNINGS It is recommended to conduct the solar circuit commissioning procedure with the solar collector covered, otherwise during the commissioning and checking procedure of the solar circuit, the closed circuit fluid may experience solar gain as it passes through the solar collector. This will increase both the temperature and pressure of the closed circuit fluid and vapour inside of the solar circuit.
COMMISSIONING Commissioning the Solar Circuit To commission and check the solar circuit: 1. Switch off the electrical supply at the power outlets to the solar storage tank and in-series gas booster. If the pump has been operating, wait five minutes to allow the drain back of the closed circuit fluid in the solar circuit. 2. Cover the solar collector with an opaque material to prevent solar gain during the commissioning process. 3.
COMMISSIONING Solar Circuit Circulation 8. Disconnect the hot sensor lead from the solar control board inside of the lower front cover of the solar storage tank. It is important, at the end of this procedure when the commissioning and checking of the solar circuit is complete, to reconnect the hot sensor lead, otherwise when the electrical supply is switched on, the solar pump will deactivate after one hour and the solar control unit will then enter a fault mode and no solar gain will be achieved. 9.
COMMISSIONING 11. Mark the dynamic level of the closed circuit fluid in the hose on the side of the solar storage tank with a non permanent marker when satisfied the solar circuit circulation is operating satisfactorily. mark dynamic level on tank 12. If the procedure to check the solar circuit circulation is not complete before the pump has automatically turned off, then: switch off the electrical supply at the power outlet to the solar storage tank. recommence this procedure from step 9.
COMMISSIONING Closed Circuit Fluid Level 15. Measure the distance from the text marking “MINIMUM FLUID LEVEL WITH PUMP OPERATING” to the closed circuit fluid dynamic level marked on the side of the solar storage tank during step 11. The correct closed circuit fluid dynamic level for efficient operation of the system when the pump is operating, is between the “MINIMUM FLUID LEVEL WITH PUMP OPERATING” text marking on the side of the solar storage tank and 150 mm above this mark.
COMMISSIONING 16. Determine the correct amount of water to be added to or closed circuit fluid to be drained from the heat exchanger if the dynamic level is either below the text marking “MINIMUM FLUID LEVEL WITH PUMP OPERATING” or more than 150 mm above this mark. Each 100 mm of fluid level height is equivalent to 730 ml (0.73 litres) of closed circuit fluid. 50 mm 0.37 litres 250 mm 1.83 litres 450 mm 3.29 litres 100 mm 0.73 litres 300 mm 2.19 litres 500 mm 3.65 litres 150 mm 1.
COMMISSIONING 17. Measure into a container the amount of water to be added to top up the level of the closed circuit fluid in the heat exchanger if required. To add water to the closed circuit fluid: If not already removed, disconnect the drain line and remove the spring clip from the solar circuit relief valve at the top of the solar storage tank and remove the valve (refer to step 5). Warning: The solar circuit may be under pressure.
COMMISSIONING Checking the Solar Circuit for Leaks 20. Close the heat exchanger drain valve. 21. Refit the solar circuit relief valve, orientating the valve outlet to the rear of the solar storage tank. Secure with the spring clip. Reconnect the drain pipe to the valve. heat exchanger drain valve closed 22. Switch on the electrical supply at the power outlet to the solar storage tank.
COMMISSIONING Remove Closed Circuit Fluid Level Hose 28. Remove the clear hose from the solar storage tank when satisfied the commissioning procedure is complete. To remove the hose: Ensure the heat exchanger drain valve is closed. heat exchanger drain valve closed Remove the hose from the side of the storage tank and place the end into a container to collect the closed circuit fluid in the hose.
COMMISSIONING DIAGNOSTIC FEATURES OF THE SOLAR CONTROLLER The solar storage tank incorporates a solar monitor which is connected to the solar control module by a ribbon cable. The solar monitor is located above the lower front cover and houses both 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.
COMMISSIONING IN-SERIES BOOSTER Refer to the Owner‟s Guide and Installation Instructions supplied with the in-series booster for the commissioning procedure of the water heater. If a gas water heater has been installed as an in-series booster to the solar water heater, then to complete the installation, it is necessary to check the gas supply pressure at the inlet to the in-series gas booster, and also the minimum test point pressure and the maximum test point pressure of the in-series gas booster.
COMMISSIONING TO TURN OFF THE WATER HEATER If it is necessary to turn off the water heater on completion of the installation, such as on a building site or where the premises is vacant, then: Switch off the electrical supply at the power outlets to the solar storage tank and in-series gas booster (refer to note below). Close the gas isolation valve at the inlet to the water heater. Close the cold water isolation valve at the inlet to the water heater.
DRAINING THE WATER HEATER GAS BOOSTER WATER HEATER To drain the in-series gas booster: Turn off the water heater (refer to “To Turn Off The Water Heater” on page 59). Open a hot tap (preferably the shower outlet). Unscrew the two drain plugs, one each at the cold water inlet and hot water outlet, on the underside of the in-series gas booster. Water will drain from the in-series gas booster. When water stops flowing from the in-series gas booster, close the hot tap.
DRAINING THE WATER HEATER HEAT EXCHANGER Warning: Exercise care, as fluid discharged from the heat exchanger may be of a very high temperature. To drain the closed circuit heat exchanger: Switch off the electrical supply at the power outlet to the solar storage tank. Remove the lower front cover from the solar storage tank. Attach a 10 mm (3/8”) diameter clear hose to the heat exchanger drain valve hose tail connection (refer to step 4 of “Attach Closed Circuit Fluid Level Hose” on page 49).
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VULCAN SOLAR WATER HEATER WARRANTY – AUSTRALIA ONLY – SOLAR WATER HEATER MODEL 690160 1. THE VULCAN WARRANTY – GENERAL 1.1 This warranty is given by Rheem Australia Pty Limited ABN 21 098 823 511 of 1 Alan Street, Rydalmere New South Wales, the manufacturer of Vulcan mains pressure water heaters. 1.2 Rheem offer a trained and qualified national service network who will repair or replace components at the address of the water heater subject to the terms of the Vulcan warranty.
VULCAN SOLAR WATER HEATER WARRANTY – AUSTRALIA ONLY – SOLAR WATER HEATER MODEL 690160 3. WHAT IS COVERED BY THE VULCAN WARRANTY FOR THE WATER HEATERS DETAILED IN THIS DOCUMENT 3.
