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Alpha SolarSmart 100 - Component Replacement
8 COMPONENT REPLACEMENT
The data badge (serial number) for the cylinder and DBU are located on the lefthand side of the case. See Figs. 10 and 11.
Always carry out electrical system checks, i.e. earth continuity, resistance to earth, short circuit and polarity with a suitable
meter, after any electrical work has been carried out on the system.
Check the operation of the system before and after any servicing or replacement of parts.
Take care when removing items as they may still contain some water.
8.1 REMOVE THE CYLINDER CASE
Isolate the electrical supply before removing the case.
Remove the two screws (top of the control panel) as shown in Fig. 10 securing the cylinder case and carefully pull off the
case.
8.2 DRAIN THE CYLINDER
Isolate the mains water supply and open a hot tap to release the pressure in the cylinder. Attach a hose to the drain point
located at the bottom of the cylinder (see Fig. 27) and route the hose to a drain. Open the drain valve to drain the cylinder.
8.3 EXPANSION VESSEL
Drain the cylinder as described in Section 8.2.
Disconnect the union from the bottom of the expansion vessel and remove the locknut (see Fig. 27) then carefully lift the
vessel out.
Reassemble in reverse order with a new vessel and washer.
8.4 TEMPERATURE AND PRESSURE RELIEF VALVE
Drain the cylinder as described in Section 8.2.
Loosen and remove the copper pipe from the valve and release the ¾" nut and remove the valve from the cylinder (see Fig. 27).
Reassemble in reverse order.
8.5 CYLINDER PUMP
Drain the cylinder as described in Section 8.2.
Undo the two pump unions (see Fig. 27) cut the plastic tie securing the pump and lift out the pump from the supporting
bracket. Remove the two fixing screws and lift off the terminal block cover (see Fig. 27) and disconnect the pump lead from
terminals 10 and 11 of the control unit. Release the cable clamp and withdraw the lead.
Reassemble in reverse order using new pump washers. Refer to the wiring diagram, Section 9 when connecting the pump
lead and ensure it is secured by the cable clamp.
Fig. 27
Terminal block cover
Fixing screws
Pump union
(each side)
Pressure relief valve
Pressure relief valve
(safety manifold assy.)
Upper cylinder sensor
Lower cylinder sensor
Expansion vessel
union and locknut
Expansion vessel
Drain point
Control unit fixing screws
