Hamilton Engineering DCH-6000, DCH-2000, DCH-1500, DCH-5000, DCH-7000 Installation, Operation And Maintenance Manual

SOLSTREAM™ Complete Thermal Exchange Gas Fired Water Heater

Installation, Operation, and Maintenance Manual

Certified to

5

Hamilton Engineering Company, Inc.
34000 Autry Street, Livonia, MI 48150 | hamiltonengineering.com
Ph. 734.419.0200 | Toll Free 800.968.5530 | Fax [phone]

U.S. patent 5,924,391

Keep this manual with

heater for future reference.

Contents

Safety ......................................................................................1

The SOLSTREAM™ System .............................................2

Typical System .............................................................2

Specifications ..............................................................4

Heater ..........................................................................4

Materials of Construction .........................................4

Operational Specifications .......................................4

Technical Specifications ..........................................4

Dimensions ..............................................................5

Orientation ...............................................................6

Transfer Pump Assembly ..............................................8

Materials of Construction .........................................8

Dimensions and Operational Specifications .............8

Orientation ...............................................................8

Storage Tank ................................................................9

Materials of Construction .........................................9

General Specifications .............................................9

Specifications by Model ...........................................9

Orientation .............................................................10

Assembly and Installation ................................................ 11

Unpacking ...................................................................11

Installing Large Heaters ..............................................11

Installing Small Heaters .............................................13

Installing Exhaust Ducting .........................................15

Installing Intake Air Ducting .......................................16

Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fuel Connection .........................................................18

Electrical Panels ................................................................ 19

Control Panel ..............................................................19

Disconnect Panel ......................................................20

Upper to Lower Canister .............................................22

Transfer Pump ............................................................23

Storage Tank ..............................................................23

Main Power Connection ............................................. 24

Operation .............................................................................25

Description of Operation ............................................25

Sequence of Operation ...............................................26

Pre-Start-Up Checklist ...............................................27

Commissioning ...................................................................28

Inspecting Installation ............................................... 28

Inspecting Water System .......................................... 28

Commissioning .......................................................... 28

Periodic Maintenance ......................................................30

Maintenance Schedule .............................................. 30

High Temperature Switch Check ................................31

Troubleshooting ................................................................32

Troubleshooting Table ...............................................32

PLC I/Os .....................................................................33

Parts Lists ............................................................................34

Top Plate ................................................................... 34

Water Train ................................................................35

Control Box ................................................................36

Disconnect Box ..........................................................37

Fuel Train ...................................................................38

Lower Canister ...........................................................39

Storage Tank .............................................................40

Appendix: Modulating Burner........................................41

Descriptions of the major modulation

components ...............................................................41

Operation: ................................................................. 42

Heater Label .............................................................. 20

Electrical Connections ................................................21

Top Plate to Upper Canister ........................................21

Hamilton Engineering Company, Inc.
34000 Autry Street, Livonia, MI 48150 | hamiltonengineering.com
Ph. 734.419.0200 | Toll Free 800.968.5530 | Fax [phone]

Limited Warranty and Remedy..................................... 44

Notes ....................................................................................45

Safety

Icon Legend

If instructions are not followed:

— injury or death and property damage are imminent

— injury or death and property damage are possible

— potential property damage, expensive repairs, and/or voiding the warranty may result

Warning: If the information in these instructions is not followed
exactly, a fire or explosion may result causing property damage,
personal injury, or death.

· Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.

· What to do if you smell gas

– Do not try to light any appliance.
– Do not touch any electrical switch; do not use any phone in your building.
– Immediately call your gas supplier from a neighbor's phone. Follow the gas

supplier's instructions.

– If you cannot reach your gas supplier, call the fire department.

· Installation and service must be performed by a qualified installer, service
agency, or gas supplier.

Solstream™ Installation, Operation, and Maintenance Manual

Note: Operating with any safety device bypassed will void the warranty.

� Applicable codes must be followed

and supersede any other instructions.
Generally applicable codes in the US
include:

· NEC

· NFPA #86

� Hot water or metal may cause scald burns.

Skin exposure to 140° water or metal for
only five seconds may cause a second
degree burn.

� Read this manual.
� Improper installation or operation may cause a

fire or explosion resulting in property damage,
personal injury, or death. Hamilton Engineering
strongly recommends that a qualified installer be
used.

� Service must be performed by a qualified person.
� Improper installation, start-up, operation,

maintenance, or service may void the warranty.

� Do not attempt to use the heater if it has

been submerged in water. Contact a
qualified service technician to inspect it
and replace compromised parts.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 1 of 49

The Solstream™ System

Hamilton's Solstream™ water heaters:

� Are designed for industrial applications
� Use complete thermal exchange technology
� Come in sizes from 1 to 16 million Btu/hr
� Heat water up to 185°F maximum

Typical System

Solstream™ Installation, Operation, and Maintenance Manual

Heater Transfer

Pump

Storage Tank

Hamilton Engineering reserves the
right to make design or specification
changes without notification.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 2 of 49

Typical System

Solstream™ Installation, Operation, and Maintenance Manual

Solstream™ water heaters are highly efficient, low maintenance systems.

� Complete thermal exchange technology means no fuel is used for warm-up

or idle time and no energy is lost through conversion or exchange.

� Without internal moving parts, there is very little to maintain.
� Water conditioning is not required.

Solstream™ systems are highly customizable at both a system
and component level. The information in this manual

generally uses a 5 million Btu/hr unit and is intended to
be typical. Illustrations are not intended to be complete or
correct in every detail. System-specific drawings, including
wiring schematics, are provided with each unit and should
be referred to when installing and operating your system.

Common options:

� Gravity drain (without a transfer pump)
� Standard (consistent incoming water temperature) or

modulating burner actuator

� Natural gas or propane fuel
� Remote or integral tank

Other available options include:

� Skid-packaged heaters
� Performance matched components
� Ultra-low NOx emissions
� Non-standard fuels
� Storage tank heating element

Peripheral components:

� Digital mixing valves
� Variable frequency drive pump
� Hose stations

Optional services:

� Turn-key installation
� Installation project management
� System assessment and optimization
� Energy conservation measures (ECM)

For further information, visit http://www.hamiltonengineering.com
or contact Hamilton Engineering.

Note: Hamilton provides separate IOMs for the burner, blower, and for optional
components. Consult the appropriate document for more information.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 3 of 49

Typical System

Solstream™ Installation, Operation, and Maintenance Manual

Specifications

Heater

Materials of Construction

Component Material

Canister 304 SS (10 ga. ≤ DCH-9000; 3/16 > DCH-9000)

Canister gasket WARCO white (food grade buna rubber)

Flame tube 304 SS

Gas piping Malleable iron with standard yellow finish

Water piping Welded stainless steel (304)

Spray ring 304/316 SS

Pall ring 304 SS

Operational Specifications

Spec English Units SI Units

Gas supply pressure 2–6 psig (optimum 4–5.5 psig) 0.14–0.41 bar (optimum 0.28–0.38 bar)

Water supply pressure 30–100 psig with ± 5 psig variation 2.07–6.84 bar with ± 0.34 bar variation

Inlet water temperature 32 °F to 120 °F 0 °C to 49 °C

Outlet water temperature 185 °F 85 °C

Water temperature differential 10 °F to 140 °F 5.6 °C to 77.8 °C

NOx emission 30–60 ppm

Thermal efficiency 99.7%

Technical Specifications

· Solstream™ water heaters are built to UL standard 795

· May be manufactured to comply with various other electrical or water quality standards

· Three-phase power is required; most available voltages may be accommodated

*Consult factory for additional information.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 4 of 49

Specifications — Heater

D

A

E

B

C

Dimensions

Solstream™ Installation, Operation, and Maintenance Manual

Solstream™ Dimensions and Weights

Connections Dimensions

Model

DCH-1000 1 25 1 25 95 2413 71 1803 39 991 24 610 8 203 825 375 1,000,000 292

DCH-1500 1 25 1 25 97 2464 73 1854 41 1041 26 660 8 203 850 386 1,500,000 439

DCH-2000 1-1/2 40 1-1/2 40 100 2540 76 1930 44 1118 30 762 10-3/4 273 1500 680 2,000,000 585

DCH-3000 2 50 1-1/2 40 100 2540 76 1930 44 1118 36 914 12 305 1600 725 3,000,000 878

DCH-5000 2-1/2 65 2 50 127 3226 97 2464 65 1651 44 1118 16 406 2500 1136 5,000,000 1464

DCH-6000 3 80 2 50 132 3353 100 2540 70 1778 47 1194 18 457 2900 1316 6,000,000 1757

DCH-7000 3 80 2 50 139 3531 107 2718 77 1956 50 1270 18 457 3200 1455 7,000,000 2050

DCH-9000 3 80 2 50 169 4293 139 3531 107 2718 60 1524 20 508 5000 2273 9,000,000 2635

DCH-10000 3 80 2 50 181 4597 151 3835 119 3023 61 1549 20 508 5200 2405 10,000,000 2928

DCH-12000 4 100 3 80 181 4597 151 3835 119 3023 61 1549 22 559 5500 2495 12,000,000 3514

DCH-15000 4 100 3 80 192 4877 161 4089 129 3277 70 1778 24 610 7000 3175 15,000,000 4392

*Connections may be NPT, flanged, or use a sanitary ferrule as required.

*DCH capacity ratings are subject to a +/- 5% total output variance based on supply conditions variables and combustion requirements. If actual
installation conditions differ from those listed in the product IOM then the 5% variance may be additionally impacted.

in mm in mm in mm in mm in mm in mm in mm lb kg

Weight

btu/hr kW1 2 A B C D E

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 5 of 49

Specifications — Heater

Orientation

Solstream™ Installation, Operation, and Maintenance Manual

UV scanner

Top Plate

Upper
Canister

Blower

Water
pressure
switch

Water flow
volume
adjust valve

Water inlet
valve

Control Panel

Exhaust vent

Burner actuator

Burner

See next page
for Fuel Train
components

Disconnect
panel

Gas inlet (behind
pipe)

Water
inlet

High temp
shut-off
switch

Lower
Canister

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Level
switches

Drain plug

Page 6 of 49

Hot water outlet

Anchoring tab

Specifications — Heater

Fuel Train Components

High gas
pressure
switch

Low gas
pressure
switch

Solstream™ Installation, Operation, and Maintenance Manual

Regulated
pressure
display

Proof of
Closure (POC)
switch

Dual blocking
valves

Visual display of
valve state
(white = closed
red = open)

Regulator

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 7 of 49

Specifications — Heater

Transfer Pump Assembly

Materials of Construction

Component Material

Piping 304 OR 316 stainless steel

Braided flex hose Stainless steel

Pump Stainless steel (TEFC motor)

Bypass valve Stainless steel motorized butterfly valve

Globe valve Stainless steel

Stand Carbon steel (painted)

Dimensions and Operational Specifications

Solstream™ Installation, Operation, and Maintenance Manual

Maximum

Model

TP-50 50 11.4 1-1/2 40 1-1/2 40 1 25 1 25 2 1.49

TP-90 90 20.4 1-1/2 40 2 50 1-1/2 40 1-1/2 40 3 2.24

TP-135 135 30.7 2 50 2-1/2 65 2 50 1-1/2 40 5 3.73

TP-200 200 45.4 2-1/2 65 3 80 2 50 2 50 7-1/2 5.59

TP-275 275 62.5 2-1/2 65 4 100 2-1/2 65 2 50 10 7.46

TP-350 350 79.5 3 80 4 100 3 80 2 50 10 7.46

Flow Rate

GPM m3/hr in. mm in. mm in. mm in. mm HP kW

Inlet

Connection

Outlet

Connection

Flow

Control

Valve

Bypass

Valve

Pump

Power

Orientation

Water outlet

Throttling valve

Bypass

Actuated valve

Water inlet

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 8 of 49

Pump

Specifications — Transfer Pump Assembly

Storage Tank

Materials of Construction

Component Material

Structural layer Fiber-reinforced plastic

Structural and liner resin DerakaneTM 441-400

Exterior layer resin Isophthalic polyester

Tank finish Gel coat with UV inhibitor

Color Gray (AT071)

Tank fittings Fiber-reinforced plastic

Vent Fiber-reinforced plastic

Manhole and cover Fiber-reinforced plastic

Manhole cover bolts Stainless steel

Manhole gasket EPDM

Hold down and lifting lugs Powder-coated carbon steel

Solstream™ Installation, Operation, and Maintenance Manual

General Specifications

Design standard ASTM D49097-00

Maximum pressure Atmospheric

Vacuum None

Maximum temperature 180°F (82.2 °C)

Specific gravity 1.2

Seismic code/design None

Wind load 0 mph/kph

Immersion heater port 4" NPT

Sight glass port 1" NPT

Insulation thickness 2" (50 mm)

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 9 of 49

Specifications — Storage Tank

Solstream™ Installation, Operation, and Maintenance Manual

Orientation

Upper sight
glass mount
(1" NPT)

Water inlet

Recirculation
return

Float switch mount
for heater stop

Screened vent

Manway

Float switch mount
for heater start

Lower sight glass
mount (1" NPT)
(optional tank
level sensor)

Outlet for immersion
heater (4" NPT)

Thermometer
mount

Float switch mount
for low water to pump
cutoff (if used)

Outlet

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 10 of 49

Specifications — Storage Tank

Assembly and Installation

Unpacking

Note:

· Obvious damage should be noted on delivery paperwork.
Hidden damage must be reported to carrier within ten days.

· Cleaning heater using local plant standard is recommended
prior to installation.

· Storage tanks are typically shipped directly from vendor.

Depending on heater size and mode of shipping, one of two
scenarios may apply.

Small heaters (approximately DCH-5000 and under) when
shipped with adequate height clearance in vehicle:

· Top plate and upper canister will be attached and upright.

· A fork lift will usually be adequate for moving. Use of a
strap or chain is recommended.

Large heaters:

· Top plate will be bolted to lower canister.

· Upper canister will be on its side with top covered.

· A crane or hoist of some kind will be needed for moving.
At least two, preferably four straps or chains will be
needed.

Solstream™ Installation, Operation, and Maintenance Manual

Installing Large Heaters

1

Stand upper canister upright and position near final

heater location.

Note: Remove cover and, if necessary, rearrange

palls until they are approximately level and do not
interfere with spray nozzles.

2

Wipe off flange and place gasket on it

with holes aligned.

3

Remove cable ties from wiring and unbolt

top plate from lower canister.

Note: Long bolt in blower motor bracket

must be reinstalled in that hole.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 11 of 49

Unpacking | Installing Large Heaters

4

Remove top plate from

lower canister.

5

Position top plate on

top of upper canister
with holes aligned.

Solstream™ Installation, Operation, and Maintenance Manual

Attach as shown
to keep plate
approximately level.

Note: Top plates on largest

heaters have lifting lugs.

6

Install all bolts and start

nuts. Liberal use of an anti­sieze compound is strongly
recommended.

7

Tighten all bolts using

pattern shown or similar.

Note: This pattern is for
heaters with 16 bolts.
24-bolt patterns should
be tightened similarly.

Orient so union in fuel line
can be connected.

Note: "Gas" and "fuel" are
used interchangeably in this
document.

9

1

16

8

12 11

5

13

3

4

14

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

8

7

Attach canister sections

as for a small heater

15

6

2

10

Page 12 of 49

below.

Installing Large Heaters

Installing Small Heaters

1

Place lower canister in final heater position:

· On level surface

· With adequate clearances

· With adequate support for operating
weight

· With outlet facing transfer pump location

· Not near flammable or combustible
materials

Solstream™ Installation, Operation, and Maintenance Manual

To transfer
pump

2

Wipe flange and gasket to remove

any dirt or debris and place gasket on
flange of canister with holes aligned.

3

Move upper canister

into position over lower
canister using lift lugs.

4

Lower carefully until a few bolts can be inserted.

Tip: Using several tapered pry bars or long

screwdrivers will aid in aligning.

18"

(sides and back)

Wall

48"

(front)

Note: Control panels are typically above

standpipe (see approval drawing for actual
orientation). If slight indexing is required to align
outlet, some rewiring may be necessary between
canister sections.

5

Lower upper canister completely, insert all bolts,

and start nuts. Liberal application of an anti-sieze
compound is strongly recommended.

6

Raise entire heater slightly above floor to

allow self-aligning.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 13 of 49

Installing Small Heaters

7

Snug all bolts using pattern

shown or similar.

1

16

Solstream™ Installation, Operation, and Maintenance Manual

9

5

13

8

12 11

4

14

6

10

8

Lower onto floor and tighten all bolts

15

2

using pattern shown or similar.

Note: Leakage is normal pending

stress relief. Tighten applicable bolts
as required when leaks appear.

9

Hamilton Engineering recommends

anchoring heater in place.

10

Repeat tightening sequence after

several hours and after a few days
of operation or as leaks occur.

3

7

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 14 of 49

Installing Small Heaters

Installing Exhaust Ducting

Note:

· Roof installation preferred.

· Solstream™ heater is not naturally
drafting; exhaust is under slight pressure.

· Insulation is not required because exhaust
temperature is only a few degrees above
incoming water temperature.

Solstream™ Installation, Operation, and Maintenance Manual

Cover external
termination with rain
guard and bird screen.

Exterior opening
must be at least equal
to cross section of
exhaust duct.

Roof

Connect exhaust
ducting using either
CPVC or single wall,
welded stainless
steel. Snap-together
ducting is not
recommended.

Duct must be same size
or larger than heater's
exhaust outlet.

Provide independent
support for duct. Do not
rest weight on heater.

Hamilton
Engineering
recommends no
bend sharper
than 45°

Install horizontal exhaust
duct sloping upward to drain
condensate in duct (1/4" per
foot is recommended).

Bird screen
installation is
recommended.

Condensate will drip
from end of horizontal
ducting. Install where
dripping will not be a
nuisance or ice a hazard.

Models DCH-1000 and
DCH-1500 require a rubber
sewer connection boot to
connect. All other models
have a flange (shown).
Joint should be sealed
with RTV (clear silicone).

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Heater
stack

Page 15 of 49

Wall

Installing Exhaust Ducting

Installing Intake Air Ducting

Note:
Do not use manifold connected to other appliances.
Do not run heater under negative air pressure.

Top must be
solid metal.

Provide
independent
support for duct.
Do not rest weight
on blower
inlet.

Solstream™ Installation, Operation, and Maintenance Manual

Typical enclosure
in sheet metal box
with screen.

Roof

Using outside air is recommended, especially:

· When inside air is not dust free

· When inside air is under positive or negative pressure

Alternatively, filtration may be used.

Bird screen
required.

Wall

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Duct diameter must be at
least as large as intake
diameter on blower. 15%
diameter increase is
recommended every 10 feet
removed from heater.

Page 16 of 49

Material can be:

· CPVC

· Galvanized sheet metal

· Single wall stainless steel

Installing Intake Air Ducting

Flexible
connector
required.

Water Connections

Warranty is void unless clean,
potable water is used.

Solstream™ Installation, Operation, and Maintenance Manual

If large pressure
swings occur, install
pressure regulating
valve in inlet water line.

Inlet water pipe must
be at least as large as
heater's water inlet piping.
Maximum recommended
water velocity is 9 ft/sec in
inlet piping.

Note: Incoming water must not

contain any chloride compounds
above 100 ppm or salts. These
will destroy 304 stainless steel.
(Alternative metals are available.)

Line from transfer
pipe must be at least
as large as transfer
pump pipe.

Line from transfer
pump must be
routed to top of
storage tank to
prevent backflow.

Check valve
recommended.

Storage tank

Suction hose between
heater and transfer
pump must be flexible
to isolate vibration.

Lower canister

Transfer pump assembly
must be installed on level
surface and at or below
heater level to maintain
pump's prime.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 17 of 49

Water Connections

Fuel Connection

1

Connect union in line between top plate

and upper canister.

Note: Local codes may require routing

regulator vent outside.

2

Connect gas supply (applicable codes

may govern connection type). Provide
adequate support.

Note: Do not put excess weight on

heater connection.

Note: If codes require pressure test
of fuel line, close ball valve entering
fuel train to heater. Failure to do so
may damage fuel regulator.

3

With ball valve entering fuel train

closed, purge air from fuel line.

Solstream™ Installation, Operation, and Maintenance Manual

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 18 of 49

Fuel Connection

Electrical Panels

Solstream™ Installation, Operation, and Maintenance Manual

Control Panel

Spark generator

Power supply
24 VDC

Ethernet switch

Veri-Flame control

Fuse 2 (3A—PLC)

Hour meter

Programmable
logic controller
(PLC)

Control relay

Fuse 1 (5A)

Control Panel Cover

Terminal block

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 19 of 49

Control Panel

Disconnect Panel

Control
transformer (3
phase to 120V)

Solstream™ Installation, Operation, and Maintenance Manual

Main fused
disconnect

Grounding lug

Motor fuse
blocks

Terminal block

Grounding lug

Motor
overloads

Heater Label

Note: This is a sample

label. All electrical work

must conform to the

specifications on this label

as found on your heater.

Motor starters

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 20 of 49

Heater Label

Electrical Connections

Top Plate to Upper Canister

Note:

· Consult wiring schematic provided with your heater for exact details.

· Remove all cable ties, bubble wrap, and tape from wiring.

5

Reconnect threaded

fitting to burner
flame sensor port.

Solstream™ Installation, Operation, and Maintenance Manual

Modulating burner
wiring (may not be
present)

1

Route blower

motor wiring
through conduit
and into
disconnect panel.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

2

4

Reconnect spark rod wire

to spark rod in burner.

In disconnect panel, connect

wires to motor overload
connection terminals below
motor starter.

Page 21 of 49

3

Route switch group

wiring through
conduit and into
control panel.

Electrical Connections

6

Reconnect water pressure switch

wiring on top plate to water
pressure switch on upper canister.

Solstream™ Installation, Operation, and Maintenance Manual

Upper to Lower Canister

Note: Depending on how canister sections were oriented
during installation, wires and conduit for these connections
may not be the correct length. Rewire if necessary.

1

Thread high

temperature
switch wiring into
control panel.

2

Reconnect

conduit.

3

Connect wires to

corresponding
number locations
in terminal block.

RTD wiring for
modulating burner
(if required.)

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

4

Repeat for float

switch wiring from
standpipe.

Page 22 of 49

Electrical Connections

Transfer Pump

1

Thread wires into control box and

reattach conduit.

2

Connect motor wires to overload terminal

below motor starter with wire colors
opposite same color on input side.

3

Connect numbered wires to corresponding

terminals on terminal strip.

4

If modulating burner, connect second

wire for RTD to control panel.

Solstream™ Installation, Operation, and Maintenance Manual

Storage Tank

1

Install float switches from

Hamilton Engineering in
tank oriented as shown.

2

Using additional

wire and conduit as
necessary, thread
wires into control
panel on heater.

3

Connect numbered wires

to corresponding terminals
on terminal block.

Cycle Stop

Cycle Start

*Float
switches

1/2" half
coupling

Power

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 23 of 49

* For float orientation consult wiring
diagram supplied with unit.

Electrical Connections

Main Power Connection

Note: If facility does not have surge and lightning protection,
Hamilton Engineering recommends both for heater.

1

Connect supply voltage to top

terminals of main fuse disconnect
inside disconnect panel.

2

Manually test each starter ("bump the

starter") to check for correct motor rotation,
as indicated on motor housing.

Note: If rotation is incorrect, change any

two phases on input side of applicable
starter and recheck.

3

Connect supply ground to

grounding lug at top right of
disconnect panel.

Solstream™ Installation, Operation, and Maintenance Manual

4

Tighten all conduit connections.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 24 of 49

Electrical Connections

Operation

Solstream™ Installation, Operation, and Maintenance Manual

Description of Operation

Water is dispersed
into upper canister
and is broken
into ever smaller
droplets by passing
down through palls.

Very efficient heat
exchange keeps
exhaust within a few
degrees of incoming
water temperature.

Air and gas combine in
burner and enter dry flame
tube, which enables complete
combustion producing no
undesirable gases.

System operation is
controlled by float
switches in remote storage
tank (not shown).

Water is heated as
combustion gases
pass up through palls
and out of heater.

Hot water
collects
in lower
canister.

Temperature of
outgoing water
must be adjusted
by manually
changing volume
of incoming water.

Pump runs
continuously
during heating
cycle.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Water level is controlled
by four float switches in
standpipe connected to
bypass loop.

Page 25 of 49

Solstream™ Installation, Operation, and Maintenance Manual

Sequence of Operation

Note: The description in this section assumes that the heater is in automatic mode

When low level float switch in remote storage tank calls for water, PLC will

1

confirm that top float switch in lower canister is not in a fault condition and
burner is in low fire position, then energize control relay A.

Note: PLC is preset. Re-progamming it without written permission will void
the warranty and absolve Hamilton Engineering of all service commitments.

If low gas pressure, high gas pressure, and high temperature switches are all

2

closed (no fault conditions), power will be supplied to Veri-Flame controller.
(Any fault condition will cause Veri-Flame control to shut down heater.).

If air pressure switch is open and fuel valve is closed, blower will start.

3

Within a few seconds, air pressure switch must indicate adequate pressure,

4

then blower will initiate a 30-second purge (time is adjustable using DIP
settings on Veri-Flame).

Veri-Flame control allows fuel into burner and the spark rod to ignite it .

5

Simultaneously water valve opens.

When UV scanner confirms flame, Veri-Flame control energizes actuator:

6

· Non-modulating burner opens air and fuel dampers, and burner enters high-
fire setting.

· Modulating burner control changes from manual to auto mode allowing
control to track set point.

Veri-Flame control de-energizes spark rod.

7

Pump will start when water in lower canister reaches second float switch.

8

During operation when correctly set, transfer pump bypass will cycle on and off

9

keeping water level in lower canister between middle float switches.

Once upper level switch in remote storage tank closes, PLC will de-energize

10

CR-A causing Veri-Flame control will turn off fuel valves. Blower will run for
several seconds to purge any remaining fuel.

If POC switch senses that fuel valve did not close completely, lockout valve will

11

close and blower will come on to purge any fuel.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 26 of 49

Solstream™ Installation, Operation, and Maintenance Manual

Pre-Start-Up Checklist

Note: This section to be performed by installer. Consult other information, such as schematics, as necessary.

 Heater in permanent location on level surface sufficient for load and anchored

 Heater assembled

 Transfer pump (if used) in place with flexible water pipe connected

 Wiring reconnected

· Water pressure switch

· Blower motor

· UV scanner

· Spark rod

· Burner modulation, if used

· Lower canister float switches

· High temperature switch

· Transfer pump

· Remote storage tank switches or field-supplied relay coil in control panel

 Fuel line connected

· Adequately sized

· Adequately supported

· Pressure checked if required

· Purged

 Water piping connected

· Sufficient inlet flow and pressure

· Adequately supported

· PRV if large pressure swings

 Exhaust piping connected

· CPVC welded or stainless steel

· No unsealed joints

· No bends sharper than 45°

· Properly sized (no back pressure)

· Adequately supported

· Properly terminated

 Intake air piping connected or filters installed if necessary

· CPVC, stainless steel, or galvanized

· Adequately sized

· Adequately supported

· Proper termination

 Storage tank

· Properly piped

· Float switches installed correctly

· Float switches correctly wired to heater

 Main power supply properly connected

· Three phase

· Voltage as specified on nameplate and connections

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 27 of 49

Commissioning

Inspecting Installation

Confirm all checks in start-up checklist above.

1

Check all field connections in control panels.

2

Identify any additional wiring in panels.

3

Confirm rotation of blower and pump motors.

4

Confirm what fuel is supplied and note label on fuel train.

5

Inspecting Water System

Run cold water first to prevent damage in

1

lower canister.

Press "MANUAL START".

2

Solstream™ Installation, Operation, and Maintenance Manual

Set water inlet pressure to about 20 psi.

3

Set outlet pressure at pump to 40 psi, with bypass off.

4

Visually confirm proper flow.

5

Check for leaks.

6

Confirm adequate pressure.

7

Confirm pump operation.

8

Close water valve.

9

10

Set main water valve to normal operation.

Commissioning

Turn on fuel.

1

· Check for leaks in piping

· Verify that gas pressure is between 2 and 6 psi

Note: Start-up process requires running heater in "MANUAL"

mode, which overrides all automation and produces hot water
continuously until heater is manually turned off.

Never leave heater unattended in "MANUAL" mode.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 28 of 49

Commissioning

Solstream™ Installation, Operation, and Maintenance Manual

Press "MANUAL START."

2

Note: During initial start-up, low gas pressure fault light may come on.

Once pressure is established, reset pressure switch. Several attempts
to start may be required until fuel enters burner.

Confirm that Veri-Flame controller has a solid green light.

3

Verify that burner goes to high fire after flame is established and

4

Veri-Flame indicates flame.

Check temperature on gauge above transfer pump. Adjust incoming

5

water pressure to obtain target output temperature if necessary.

Adjust throttling valve above transfer pump to cycle bypass valve and

6

maintain water level in heater.

Note: Level should fluctuate slowly between second and third float

switches without seeing a tank-full fault or pump turning off.

Check exhaust piping for leaks.

7

Insert combustion analyzer in port in exhaust stack and tune heater.

8

· Oxygen reading must be 3.5–6%

· Adjust for minimum carbon monoxide (CO)

Note: Low efficiency may be due to back pressure in exhaust piping if

opening at cap is too small.

Record regulator pressure on fuel train label.

9

Confirm operation of all safety features:

10

· Low gas pressure switch

· High gas pressure switch

· Proof of closure switch

· Low water pressure

· High temperature

· Flame failure (UV scanner)

· False flame

Perform at least ten start cycles in "MANUAL" mode, allowing heater to reach

11

high fire condition each time, to ensure reliable starting and operation.

Run heater in "AUTOMATIC" mode to confirm proper operation in that mode.

12

Allow heater to sit and cool for several hours, then check for cold start.

13

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 29 of 49

Inspecting Installation

Solstream™ Installation, Operation, and Maintenance Manual

Periodic Maintenance

Maintenance Schedule

Note: Periodic maintenance for blower and burner is not shown below. See those IOMs for required
maintenance. The Solstream™ heater is designed to require very little maintenance. The list below is
recommended, but only safety items (*) are required.

Frequency Task

Check output temperature (non-modulated). (To change, adjust water flow valve slowly and

Daily

Weekly

Monthly

Annually

As Needed
(Typically
done not
less than
when
warmer is
cleaned)

in small increments allowing time for change to take effect. Increase water flow to decrease
temperature and vice versa).

Check air filters if present. Clean or replace as necessary (see manufacturer's information).

Check for water leaks.

Check fuel train for leaks.

Remove and wipe off quartz lens below flame sensor.

*Check water pressure switch:

· Turn off water supply while heater is in operation

· Confirm that heater shuts down within 10 seconds and "WATER PRESSURE FAULT" light
comes on

*Check low gas pressure switch:

· Turn off the fuel supply while heater is in operation

· Confirm that heater shuts down and "LOW GAS PRESSURE" fault light comes on

*Check high temperature switch (see instructions below).

Inspect burner’s air damper linkage (use a borescope through burner’s window).

Check spark rod connection and wire.

*Check the Veri-Flame controller:
With heater running, close ball valve in fuel train just upstream of burner.

· Burner should go out

· Veri-Flame control should show no indication of flame

· Control should de-energize safety shut-off valves (there will be a "clunk" sound as valves close;
some models also have indicator lights)

If results are not as described, a hazard condition exists. Shut down heater and contact
Hamilton.

Check all electrical connections.

Check all nuts and bolts.

Check float switches for proper operation.

Check all fuel train connections and fittings.

Check all water train connections and fittings.

If in a bottling warming application—Perform a Unit Clean In Place (CIP)

· Dump all bad/dirty water (including in the DCH basin)

· Heat up and run Clean in Place

o Up to facility on chemical additives and duration

· Dump all water again (including in the DCH basin)

· Fill with fresh clean water

· Run unit

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 30 of 49

High Temperature Switch Check

Solstream™ Installation, Operation, and Maintenance Manual

Caution: Wiring is live! Avoid
touching connections!

With heater on but not running, unscrew

1

cover on switch (shown removed below).

Confirm that heater

3

shuts down and high
temperature fault
light comes on. If not,
contact Hamilton.

Compress spring to

2

trip switch.

Press reset button

4

and replace cover.

Caution: Wiring is live! Avoid
touching connections!

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 31 of 49

Troubleshooting

Troubleshooting Table

Note: Turn off power to heater prior to beginning. During troubleshooting, turn it on only when and only for as
long as required for specific steps below.

Problem Probable Cause Correction

Transitory alarm or to confirm fault Press "FAULT RESET" on HMI.

Solstream™ Installation, Operation, and Maintenance Manual

Troubleshooting

Actuator Fault

Flame Safety Fault

Start attempt without actuator in low
fire position

Heater with modulating burner not in
"MANUAL" state at start-up attempt

Transitory alarm or to confirm fault Press reset button twice on Veri-Flame controller

Flame failure Check spark rod wiring and connection for breaks,

Air failure Check air flow switch:

System error Check adjustment of POC switch.

Confirm that switch on burner arm is in contact and
closed.

Press "FAULT RESET" on HMI.

inside control panel (button must be out). If fault
recurs, continue.

arcing, or carbon fouling.
Check UV scanner for dirt and reaction to flame.

· Disconnection

· Plugged sensor tube

· Defective

Check blower overloads:

· Electric current setting. Adjust or reset.

· If fault recurs, check 3-phase wiring.

· If fault persists, check blower motor coil
impedance.

Check gas valve for proper operation.

Transitory alarm or to confirm fault Press red reset button on low gas pressure switch

Low Gas Pressure

High Gas Pressure

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Upstream fuel valve closed Open all upstream valves.

Defective pressure regulator spring Replace spring.

Defective pressure regulator Replace regulator.

Transitory alarm or to confirm fault Press red reset button on high gas pressure switch

Regulator pressure set too high Turn regulator adjustment screw CCW to reduce

Defective pressure regulator spring Replace spring.

Defective pressure regulator Replace regulator.

Page 32 of 49

on fuel train.

on fuel train.

pressure.

Troubleshooting Table

Solstream™ Installation, Operation, and Maintenance Manual

Troubleshooting

Problem Probable Cause Correction

High Temperature Fault

Contact Hamilton!
Do not operate
heater!

Tank Full Fault:
Pump not keeping up
with water production

Water Pressure Fault

Modulating burner
does not enter
automatic mode
and track set-point
("MANUAL" stays
lit after flame is
established)

Water pressure switch failed and "dry
fire" start-up attempted

Check water pressure. If correct, replace pressure
switch. If not, continue.

Nozzles clogged Remove top plate and clean nozzles.

Transfer pump throttling valve out of

Readjust valve.

adjustment

Transfer pump and/or bypass

Check and repair or replace.

inoperable

Downstream valves closed or restricted Confirm that all downstream valves are fully open.

Press "FAULT RESET" on HMI.

Flow control valve restricted Open flow control valve.

Shut-off valve defective Repair or replace valve.

Restriction in inlet line Check filters and piping for obstructions.

Low system pressure Correct system pressure.

Press "FAULT RESET" on HMI.

Reset button on Veri-Flame control
is pressed in

Press reset button on Veri-Flame control (button
must be in up position.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 33 of 49

Troubleshooting Table

Solstream™ Installation, Operation, and Maintenance Manual

PLC I/Os

The following PLC inputs and outputs are shown to facilitate more advanced troubleshooting.

Inputs Outputs

Start Input IN 0
Stop Input IN 1 Water On Relay OUT 1

Low FIre Limit IN 2 Transfer Pump On OUT 2

Water Pressure Sw. IN 3 Transfer Pump Bypass Open Relay OUT 3

Bottom Float Sw. IN 4

2nd Float Sw. IN 5

3rd Float Sw. IN 6

Top Float Sw. IN 7

Main Fuel IN 8

Ignition IN 9

HIgh Fire/Modulate

Blower On

Flame Safety Alarm IN 12

Low Gas Alarm IN 13
HIgh Gas Alarm IN 14

High Temp Alarm IN 15

E-Stop - Run Relay Chain IN 16

Interlocks Closed IN 17

AIr Flow IN 18

Main Fuel P.O.C. IN 19

IN 10
IN 11

Heater Run Permissive

General Fault

OUT 0

OUT 4

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 34 of 49

PLC I/Os

Parts Lists

Top Plate

Note: Some wiring in this drawing has been removed for clarity.

Solstream™ Installation, Operation, and Maintenance Manual

7 & 8 installed in union

8

9

7

6

10

5

1

2

3

4

11

Ref

Description Part

No.

—

Spark Plug Wire, 7 mm, SCS7­100

1 Spark Rod, #47232 D19194

DCH Spark Plug Wire Kit.

2 3

Includes Pug End Connector,
Spark Plug Boot, 15’ Spark
Plug Wire and Terminal Ring.
Cord grip, ½", Appleton

4

CG1850
5 Low Fire Limit Switch D19195 DCH-4000 D7568
6 Veri-Flame, UV Scanner, 90 D16915 DCH-5000 D7569

O-Ring, Viton, 7/8" x 1" D17086 DCH-6000 D7570

7
8 Quartz lens, 1" Dia x 1/16" D17085 DCH-7000 D7571
9 Air Pressure Switch, 1950-5-2F D16919 DCH-9000 to 12000 D7576

Burner Actuator

10

For burner parts, contact MAXON Corp., 765-284-3304 (fax: [phone])
For blower assembly parts, contact Cincinnati Corp.,
513-573-0600 (fax: [phone])

Actuator, Standard D16978

Actuator, Modulating 4-20 MA D94741

12

Ref No. Description Part

No.

D17513

Flange Gasket – WARCO White

No.

DCH-1000 D7564

D9821 DCH-1500 D7565

D16992 DCH-2000 D7566

11

DCH-3000 D7567

DCH-13000 to 15000 D7579

Flame Shield

DCH-1000 & 1500 D27182
DCH-2000 D27183

12

DCH-3000 & 4000 D27184

DCH-5000 to15000 D26712

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 35 of 49

Water Train

Solstream™ Installation, Operation, and Maintenance Manual

Ref
No.

1 Water Pressure Switch D16905
2 Pressure Gauge; 0-110 psi D11554

1" D14596
1-1/2" D14597
2" D14598

2

1

Welded
Stainless Steel

3

3

2-1/2" (flanged) D14599
3" (flanged) D14600
4" (flanged) D14601

1-1/2" D53229
2" D30041
2-1/2" D76536

4

3" D76537
4" D76750
VB030 Electric Actuator D76170
VB060 Electric Actuator D70728

Description Part

No.

Globe Valve, Stainless Steel

Actuacted Valve Assembly

4

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 36 of 49

Control Panel

Solstream™ Installation, Operation, and Maintenance Manual

Ref No. Description Part No.

1 HMI Panelview Plus 7 9 Inch D106961
2 Emergency Stop Button D106011
3 Ignition Transformer D19185
4 Elipse Veriflame 5602-22 (US) D19186

Elipse Veriflame 5605-22AA (CAN) D19187
5 Elipse Veriflame Base Terminal D16866
6 PLC Micrologix 1400 D60067
7 PLC Analog Module 2 IN 2 OUT D90858
8 Relay Base 14 Blade D16866
9 Relay 4PDT 120VAC Coil D16903

Relay 4PDT 24VDC Coil D56376

10 Relay Slim 2PDT 120VAC Coil D30776
11 Power Supply 24VDC 90W D34094
12 Ethernet Switch Unmanaged 5 Port D60074

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 37 of 49

Disconnect Panel

Solstream™ Installation, Operation, and Maintenance Manual

1

8

9

11

10

6

5

3

13

2

12

1

4

7

Ref No. Description Part No. Ref No. Description Part No.

Fuse, Low Peak, Class J Motor Overload

3A D19610
5A D17885 3.2–16A D7663
7A D19611 5.4–27A D7664

1.6–5A D17910

4

10A D19612 9–45A D7665
12A D19613 5 Relay, 4 Pole, Double Throw D16903
15A D19614 6 Base Socket, Mini, 14 Blade D16886
17 1/2A D19615 Fuse Cover, Bus, Indicating
20A D19616

1

25A D19617 60A D22629

30A D19762

7
30A D19618 100A D21900
35A D19619 8 Fuse Cover, Bus, Non-Indicating D17413
40A D19620 Disconnect Handle
50A D19621
60A D19622 100A D21901

30A & 60A D15638

9

70A D19623 Connecting Rod, Disconnect
80A D19624
100A D19625 100A D21902

10

30A & 60A D17218

Fuse, Class CC, FNQ-R 11 Circuit Block, IEC, Single Feed D10789

6A D21849 Fused Disconnect

2

8A D19763
15A D18692 60A D19671

12

30A D17179

Motor Starter 100A D21903
5 HP D7655 Control Voltage Transformer
7 1/2 HP D7656
10 HP D7657 750VA 575/380 – 115 D13662

3

15 HP D7658

13

750VA 480 x 240 – 120 D17409

20 HP D7659
25 HP D7660
30 HP D7661

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 38 of 49

Fuel Train

Solstream™ Installation, Operation, and Maintenance Manual

DCH-5000 to
DCH-15000

Ref
No.

DCH-1000 and DCH-1500 (1" NPT) D15432
DCH-2000 and DCH-3000 (1-1/2" NPT) D15433

1

DCH-4000 to DCH-10000 (2" NPT) D15434
DCH-11000 to DCH-15000 (3" NPT) D15435

2 Pressure Gauge, 0–15 psi D14800

DCH-1000 to DCH-4000 (FRI 710/6) D14806

3

DCH-5000 to DCH-10000 (FRS 720/6) D14807
DCH-11000 to DCH-15000 (FRS 730/6) D14808

DCH-1000 to DCH-4000 Yellow 12"–28" w.c. D11555
DCH-1000 to DCH-4000 Black 24"–44" w.c. D14809
DCH-5000 to DCH-10000 Yellow 12"–28" w.c. D19189
DCH-5000 to DCH-10000 Black 24"–44" w.c. D14810
DCH-5000 to DCH-10000 Pink 40"–60" w.c. D12543

4

DCH-11000 to DCH-15000 Yellow 12"–28" w.c. D11559
DCH-11000 to DCH-15000 Black 24"–44" w.c. D14811
DCH-11000 to DCH-15000 Pink 40"–60" w.c. D12336
DCH-11000 to DCH-15000 Gray 56"–80" w.c. D12142

DCH-1000 to DCH-4000 (DMV-D 703/11) D14823

5

DCH-5000 to DCH-10000 (DMV-D 525/11) D14824
DCH-11000 to DCH-15000 (DMV-D 5080/11) D14825
Low Gas Pressure Switch 12"–60" w.c.

6

(GMH-A2-4-6)

DCH-1000 to DCH-14000 12"–60" w.c.
(GMH-A2-4-6)

7

DCH-15000 40"–200" w.c. (GMH-A2-4-8) D12335
8 Visual Proof of Closure Indicator D11573
9 Electrical Proof of Closure Indicator (CPI-400) D14826

10 DIN Connector (D210319) D14827
11 Pressure Gauge, 1"–100" w.c. D14828

Description Part

No.

Gas Rated Ball Valve

Gas Pressure Regulator

Gas Regulator Spring

Dual Blocking Valve Assembly

D11538

High Gas Pressure Switch

D14829

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

DCH-1000 to
DCH-4000

Page 39 of 49

Lower Canister

Note: This drawing is a composite.

Not all parts are present in every
heater configuration.

Solstream™ Installation, Operation, and Maintenance Manual

All 4 float
switches swing
downward

Ref No. Description Part No.

1 Float Switch, Polypropylene D16907
2 High Temp Shutoff Switch, 600 °F D16916
3 Standpipe Cap D18110

RTD Temp Sensor
1-1/2", 100 D13273
2", 100 D10210

4

3", 100 D17584
5", 100 D27358

5 Drain Plug, 1" NPT, 304 SS D16918
6 Plug, ½" NPT, 304 SS D11018
7 Wiring Trough Drilled for Standpipe D17265

SS Braided Flex Hose, Clamp Ends
1-1/2" Dia x 36" long D15722
2" Dia x 36" long D15723

8

3" Dia x 36" long D15724
4" Dia x 36" long D15725

Flange Gasket – WARCO White
DCH-1000 D7564
DCH-1500 D7565
DCH-2000 D7566
DCH-3000 D7567
DCH-4000 D7568

9

DCH-5000 D7569
DCH-6000 D7570
DCH-7000 & 8000 D7571
DCH-9000 to DCH-12000 D7576
DCH-13000 to DCH-15000 D7579

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 40 of 49

Secured to
float switches
(pumped only)

Gravity drain

For pumped
units only

Modulating burner with
gravity drain only. If
pumped, RTD is installed in
transfer pump package.

Storage Tank

Solstream™ Installation, Operation, and Maintenance Manual

Float switch*

Float switch*

Float switch*

*For float orientation,
consult wiring diagram
supplied with unit.

Ref No. Description Part No.

1 Bushing, CPVC 4" x 1/2" NPT D18785
2 Float Switch, Polypropylene D16907
3 Thermometer, Back Mount, 4" Stem D8969
4 Plug, 2" NPT, 304 SS D18789
5 Plug, 1" NPT, 304 SS D16918

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 41 of 49

Solstream™ Installation, Operation, and Maintenance Manual

Appendix: HMI Interface

This water heater package includes an HMI (Human-Machine Interface) terminal with displays and controls
for heater status and operation along with related system information.

NOTE: BLUE denotes a user selection, button or input.

Main Screen

Below is the default display on machine start-up and contains general information on the heater run status and
functions in the form of simulated pilots lights, a unified fault display and several buttons for control functions.
These are arranged into panels where the indicators and buttons have related functions.

COMBUSTION AIR STATUS
Blower On: The combustion air blower has been energized.
Air On: The combustion air proving switch has been made.

BURNER AND FUEL STATUS
Low Fire Limit Switch Made: Conformation that the burner has actuated to low fire mode.
Spark On: The burner spark igniter has been energized.
Fuel On: The main fuel valves have been energized.

WATER CONTROL STATUS
Water On: The inlet water valve is energized.
Pump On: The transfer pump is energized.
Bypass Open: The transfer pump bypass is energized.
Basin Level: The level of water in the lower basin based on the number of float switches triggered. (0-4)

FAULT STATUS
This display scrolls through heater faults (detailed elsewhere) or displays NO FAULTS if none are present.

MANUAL RUN CONTROL
When the heater is in manual run mode use the START and STOP buttons to control the heater.

RUN MODE
The Solstream™ has two run modes: MANUAL and AUTO. This panel is used to switch between them. In MANUAL
mode the heater is started and stopped by the buttons on the panel above (manual run control). Pressing the AUTO
RUN button will switch to auto run mode and the heater will start and stop via an external input. This can be float
switches in a storage tank, a remote run control relay or a remote run bit via Ethernet connection.

Hamilton Engineering Company, Inc.
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and Maintenance Manual Water Heater

Page 42 of 49

Solstream™ Installation, Operation, and Maintenance Manual

This controller has three “dry” contacts and a 4-20 mA DC output, two of the “dry” contacts are to drive the actuator
one way or the other, a spare “dry” contact is available for use as an alarm, etc. A 4-20 mA DC output is available to
transmit various analog values such as set point, process variable, etc.

The input is set via internal jumpers for an RTD. In addition, there are five special contacts that can cause the controller
to perform various functions. The designated output (“d-out”) function is always used. When this “dry” contact is
closed, the controller will go to manual mode and 0% output. The controller must be in this mode and output in order
for the Solstream™ to start. Other special functions are possibly as a second set-point and possibly the ability to
accept a remote set-point. Please refer to the specific program listing, electrical schematic, and the Powers manual for
more detail.

The text at the top of the run mode panel indicates which mode is presently active.

In auto run mode the manual run control panel will be replaced by a remote start input
indicator which will light when a remote start input is present.

To switch between modes simply press the appropriate button. When switching modes with
the heater running the heater will not stop without a stop input from either the stop button in
manual mode, or removal of the remote start signal in auto run mode

Depending on the project and heater options, other panels and data will be present.
These typically are placed under the fault display panel and may include items such as
burner modulation controls, temperature readings and storage tank level.

In this example below the heater is running and several of the indicators are lit. Additional information about the storage
tank water level and temperature would displayed below the fault status indicator.

In this example the heater is stopped because of a water pressure fault. The E-Stop is also pressed in. When a non­critical fault (actuator, water pressure or high heater basin) occurs then a fault reset button will appear and pressing it
will reset the fault if the condition has been rectified. Gas system faults must be reset manually at the switch which is
faulted (see troubleshooting section).

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 43 of 49

Solstream™ Installation, Operation, and Maintenance Manual

Modulating Control Option

In the example below, the heater is in modulating mode. In modulating mode the HMI will modulate the burner to
satisfy the setpoint. The setpoint can be local or remote. The display also shows the burner position and outlet water
temperature.

Local Setpoint Control

Press the setpoint button to bring up the local setpoint menu shown below. Use this menu to increase or decrease
the local setpoint. Press the MOD/POS button to toggle between modulating temperature mode and direct positon
control.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 44 of 49

Solstream™ Installation, Operation, and Maintenance Manual

Menu Screen

Pressing the MENU button on the main screen will bring up this display below.

Depending on the options installed additional selections may be available here.
The base selections are shown at left.

Pressing MAIN SCREEN returns to the main heater screen.

Pressing I/O LIST brings up a list of all PLC Inputs and Outputs and their status.
This is detailed below.

The LOGIN button will bring up a user login menu where an
authorized user can enter their User Name and Password to
access additional functions. Pressing the User Name or Password
button will bring up screen keyboard.

Press the Login button on the menu to Log into the system.
Press Cancel to exit.

The User Name MAINT has been created for use by plant
maintenance personnel.
The password has been left blank and can be changed on the
Configuration screen detailed below.

When logged in additional menu options will appear on screen.
The CONFIGURATION selection will always be present. Others
may be available based on the heater options set.

Pressing the LOGOUT button will log out the current user and
return the HMI to the basic access state. Additionally, if there
is no activity at the HMI for ten minutes the current user will be
automatically logged out and the HMI will return to the main
display screen.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 45 of 49

Solstream™ Installation, Operation, and Maintenance Manual

I/O List Screen

This screen displays all PLC inputs and outputs with an indicator denoting their status. The indicator will be lit when that
input or output is on.

Additional inputs and outputs may be present depending on the heater options set.

Pressing the BACK button will return the Menu screen.

This screen is useful for troubleshooting wiring issues and to help determine the heater run state as it progresses through
its sequence of operation.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 46 of 49

Configuration Screen

Advanced configuration options will be displayed here and will depend
on the heater options.

Pressing the Goto Config Screen button will exit the run environment
on the HMI and bring up the terminal configuration screen detailed
below. This should only be done by a user familiar with PanelView Plus
terminals!

The CHANGE PASSWORD button will bring up a menu where the
current user’s password can be changed. Any of the Password
buttons on the left bring up an HMI keypad for entering the password
in the corresponding box.

Enter the old password and the new password (twice). Press the
Change Password button to accept the new password for the current
user. The Cancel button to exit.

NOTE THIS CHANGE! If the password is not known then the HMI
terminal will have to be reset in order to access the advanced user
functions.

Solstream™ Installation, Operation, and Maintenance Manual

The default password for the MAINT login is blank so the old
password box should be left blank.

Pressing the BACK button will return to the Menu Screen.

HMI Terminal Errors

In the course of operation it is possible that the HMI will generate notifications and alarms when certain values go out of
range, communications are lost or from other causes. These will be displayed in a display that overlays the current page:

In this example communications with the PLC have been lost and then re-established. Once this or another error has
been rectified the notifications can be cleared individually by pressing the Clear button, or all at once by pressing the Clear
All button. Then the display can be dismissed by pressing the Close button.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 47 of 49

Solstream™ Installation, Operation, and Maintenance Manual

Limited Warranty and Remedy

Hamilton Engineering warrants to the original user of those products supplied by it and used in the service and in the
manner for which they are intended, that such products shall be free from defects in material and workmanship for a
period of one (1) year from the date of installation, but not longer than 15 months from the date of shipment from the
factory [unless a special warranty period applies, as listed below]. This warranty does not extend to any product that has
been subject to misuse, neglect, or alteration after shipment from the Hamilton Engineering factory. Except as may be
expressly provided in a written agreement between Hamilton Engineering and the user, which is signed by both parties,
Hamilton Engineering DOES NOT MAKE ANY OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE. The sole and exclusive remedy with respect to the above limited warranty
or with respect to any other claim relating to the products or to defects or any condition or use of the products supplied
by Hamilton Engineering, however caused, and whether such claim is based upon warranty, contract, negligence, strict
liability, or any other basis or theory, is limited to Hamilton Engineering's repair or replacement of the part or product,
excluding any labor or any other cost to remove or install said part or product, or, at Hamilton Engineering's option, to
repayment of the purchase price. As a condition of enforcing any rights or remedies relating to Hamilton Engineering
products, notice of any warranty or other claim relating to the products must be given in writing to Hamilton Engineering:
(i) within 30 days of last day of the applicable warranty period, or (ii) within 30 days of the date of the manifestation of
the condition or occurrence giving rise to the claim, whichever is earlier. IN NO EVENT SHALL Hamilton Engineering BE
LIABLE FOR SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT
LIMITED TO, LOSS OF USE OR PROFITS OR INTERRUPTION OF BUSINESS. The Limited Warranty and Remedy
terms herein apply notwithstanding any contrary terms in any purchase order or form submitted or issued by any user,
purchaser, or third party and all such contrary terms shall be deemed rejected by Hamilton Engineering.

Special Warranty Periods are as follows:

· The stainless steel structure and stainless steel internals (flame tube, pall rings, supports, etc.): Seven (7) years from
the date of installation, but not longer than eighty seven (87) months from the date of shipment, provided only clean
potable water is heated and commercially available fuel is used as well as clean air.

· In applications such as bottle or can warming, special consideration must be placed on routine and preventative
maintenance to ensure clean water is used throughout the operation of the unit. Any failures as a result of dirty water
will void the warranty.

· The other components on the Solstream™, such as valves, combustion equipment, electrical controls, and the burner:
Two (2) years from the date of installation, but not longer than twenty-six (26) months from the date of shipment.

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 48 of 49

Notes

Solstream™ Installation, Operation, and Maintenance Manual

Hamilton Engineering Company, Inc.
LIT97000 | Solstream™ Installation, Operation,
and Maintenance Manual Water Heater

Page 49 of 49