318281

318281
Instruction Manual
RESIDENTIAL SOLAR WATER HEATING SYSTEMS
DELUXE SYSTEMS
WITH SINGLE WALL HEAT EXCHANGER
FOR POTABLE WATER HEATING ONLY
C
US
LISTED
Solar Water Heater
™
Solar Collector
SRCC OG-100
™
Solar Water Heating System
SRCC OG-300
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 0311
1
318281-002
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use, and servicing of this water
heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to
warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this
manual. It is very important that the meaning of each safety message is understood by you and others who install,
use, or service this water heater.
This is the safety alert symbol. It is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or injury.
CAUTION
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, could result in property
damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety
message, and how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed in the act.
Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To prevent
the possibility of injury under these conditions, we recommend the hot water faucet be opened for several minutes at
the kitchen sink before using any electrical appliance which is connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water begins to flow. Do not
smoke or have any open flame near the faucet at the time it is open.
IMPORTANT DEFINITIONS
• Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of
plumbing and electrical installation of these appliances. This would include a thorough understanding of the
requirements of the National Electrical Code and applicable local electrical and plumbing codes (and tools
necessary to confirm proper installation and operation of the water heater) as they relate to the installation
of electric water heaters. The qualified installer must have a thorough understanding of the water heater
Instruction Manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of
plumbing and electrical installation of these appliances. This would include a thorough understanding of the
requirements of the National Electrical Code and applicable local electrical and plumbing codes (and tools
necessary to confirm proper installation and operation of the water heater) as they relate to the installation
of electric water heaters. The service agency must have a thorough understanding of the water heater
Instruction Manual.
2
GENERAL SAFETY
3
INTRODUCTION
Thank You for purchasing this water heating system.
Properly installed and maintained, it should give you years
of trouble free service.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section of this manual first and
then the entire manual carefully. If you don’t follow the
safety rules, the water heater will not operate properly. It
could cause DEATH, SERIOUS BODILY INJURY, AND/
OR PROPERTY DAMAGE.
Abbreviations Found In This Instruction Manual:
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturers Association
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratories Inc.
• SRCC - Solar Rating and Certification Corp.
This manual contains instructions for the installation,
operation, and maintenance of the solar water heater.
It also contains warnings throughout the manual that
you must read and understand. All warnings and all
instructions are essential to the proper operation of
the water heater and your safety. READ THE ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
SYSTEM DESCRIPTION
This Solar Water Heating System consists of four main
parts — the solar collectors, the solar pump station, the
solar storage tank, and the plumbing for the heat transfer
fluid.
2. The installation must conform with these instructions
and the local code authority having jurisdiction and the
requirements of the power company. In the absence of
local code requirements follow NFPA-70, the National
Electrical Code (current edition), which may be
ordered from: National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02169.
The solar pump station uses a pump to circulate a heattransfer fluid through the “collector loop”. This collector
loop includes the solar collectors, the fluid lines or “lineset” and a heat exchanger. The collector loop is a “closed
loop”, meaning there is no contact of the heat transfer fluid
with your potable water or with the atmosphere. The collector loop contains only a small volume of heat-transfer fluid
which is non-toxic and freeze-protected to -30°F (Freeze
tolerance limits are based upon an assumed set of environmental conditions). Though freeze protection may not be
necessary in all areas, the heat-transfer fluid also contains
corrosion inhibitors which protect the system components,
has an elevated boiling point, and is suitable throughout
North America.
3. If after reading this manual you have any questions or
do not understand any portion of the instructions, call the
local utility or the manufacturer whose name appears on
the rating plate.
4. Carefully plan your intended placement of the water heater
and collectors. INSTALLATION OR SERVICE OF THIS
WATER HEATER REQUIRES ABILITY EQUIVALENT
TO THAT OF A LICENSED TRADESMAN IN THE FIELD
INVOLVED. PLUMBING AND ELECTRICAL WORK ARE
REQUIRED.
When exposed to sunlight, the solar collectors get hot.
As the heat-transfer fluid passes through the collectors,
it absorbs the heat and then travels down the line-set to
the tank. The hot fluid passes through the heat exchanger
and heat is transferred to the potable water. After giving up
its heat to the potable water, the cool heat-transfer fluid is
pumped back to the solar collectors to be heated again.
Hot potable water is stored in the solar storage tank.
Examine the location to ensure the water heater complies
with the “Facts to Consider About the Location” section
in this manual.
5. For California installation this water heater must be
braced, anchored, or strapped to avoid falling or moving
during an earthquake. See instructions for correct
installation procedures. Instructions may be obtained
from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.
The auxiliary or back-up electric-heating guarantees hot
water even under poor solar conditions (at night or when
very cloudy). The minimum acceptable temperature setpoint is specified in local plumbing codes.
6. Massachusetts Code requires this water heater to be
installed in accordance with Massachusetts 248-CMR
2.00: State Plumbing Code and 248-CMR 5.00.
You can save the most money on your water-heating bills
by using the backup heater on your system as little as possible. If the sun shines brightly between 10 am and 3 pm,
enough heat will normally be generated to keep the water
hot throughout the rest of the day and night.
7. The solar energy system described by this manual, when
properly installed and maintained, meets the minimum
standards established by the SRCC. This certification
does not imply endorsement or warranty of this product
by SRCC.
However, on days when the sky is cloudy or when large
quantities of hot water are being used, we recommend
leaving the backup heater turned on and set to 120° F to
provide adequate hot water.
4
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE............................ 2
Important Definitions ................................................. 2
GENERAL SAFETY ................................................................. 3
INTRODUCTION ..................................................................... 4
System Description ................................................... 4
Preparing for Installation ............................................ 4
TABLE OF CONTENTS ........................................................... 5
SYSTEM DIAGRAM/TYPICAL INSTALLATION ...................... 6
SYSTEM COMPONENT PART ............................................... 7
STORAGE TANK INSTALLATION ........................................... 7
Local Codes .............................................................. 7
Temperature-Pressure Relief Valve .......................7-8
Closed System/Thermal Expansion ........................... 8
Locating the Solar Water Heater ............................... 8
Water Piping ...........................................................8-9
Installation in Residential Garages............................. 9
Filling the Solar Water Heater with Water .................. 9
Wiring of Element .................................................9-10
Thermostat .............................................................. 10
Temperature Regulation .......................................... 10
Temperature Settings ......................................... 10-11
Temperature Adjustment ......................................... 11
Tank Sensor ............................................................ 11
Draining .............................................................. 11-12
Element ................................................................... 12
Element Replacement ............................................. 12
Anode ...................................................................... 12
Water Heater Sounds .............................................. 12
SOLAR COLLECTOR INSTALLATION ................................. 13
Collector Location ................................................... 13
General Considerations .......................................... 13
Collector Orientation ..........................................14-15
Spanner Mounting ..............................................15-17
Attaching Collector to Mounting Brackets ............... 18
Collector Piping ....................................................... 19
Collector Piping Detail ............................................. 20
Sensor Mounting at Collector .................................. 20
Piping Through the Roof ......................................... 20
Piping Insulation ...................................................... 20
PUMP STATION INSTALLATION .......................................... 21
Pump Station ........................................................... 21
Safety Instructions ................................................... 21
Safety Equipment .................................................... 22
Wall Mounting the Solar Pump Station ................... 22
Plumbing Configuration ........................................... 23
Function .................................................................. 23
Flowmeter ............................................................... 24
Start-up and Operation of the Solar Pump Station .. 24
Leak Detection ........................................................ 24
Flushing ................................................................... 25
Preparation of the Heat Transfer Fluid ...............24-25
Filling ....................................................................... 25
Draining .................................................................... 25
PUMP STATION CONTROL INSTRUCTIONS ...................... 26
Control Instructions ................................................. 26
Operation and Function ......................................26-31
TROUBLESHOOTING .....................................................32-34
SYSTEM MAINTENANCE ..................................................... 35
REPAIR PARTS ..................................................................... 36
HEAT TRANSFER FLUID PROPERTIES ............................. 37
SOLAR RATING / MODELS / WARRANTY.......INSERT SHEET
5
SYSTEM DIAGRAM/TYPICAL INSTALLATION
6
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A CLOSED
WATER SYSTEM
8
10
VACUUM RELIEF
VALVE
INSTALL PER
LOCAL CODES
1
1
11
5
Flow Direction
4
Discharge Pipe
(DO NOT CAP
OR PLUG)
2
9
Metal
Drain
Pan
3
10
7
6” Maximum Air Gap
Piped To An
Adequate Drain
At Least 2” Greater Than The
Diameter Of The Water Heater.
I N S TA L L VA C U U M
RELIEF IN COLD
WATER INLET LINE AS
REQUIRED BY LOCAL
CODES.
NOTE: SEE SYSTEM COMPONENT
TABLE FOR DESCRIPTIONS
INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER HEATER
IS INSTALLED IN A CLOSED WATER
SYSTEM.
Figure 1.
6
INSTALL SUITABLE METAL DRAIN
PANS UNDER HEATERS TO PREVENT
DAMAGE DUE TO LEAKAGE. REFER
TO WATER HEATER LOCATION, SEE
“ L O C AT I N G T H E S O L A R WAT E R
HEATER” SECTION.
SYSTEM COMPONENT PART
Item
Component
Function
1
Solar collector
Absorbs the sun’s heat energy and transfers this to the heat transfer
fluid circulating through the collector.
2
Solar storage tank
Stores potable water heated by solar generated heat or installed
back-up electric resistance element.
3
Heat exchanger (Not Shown)
Transfers the heat from the collector loop to the potable water in the
solar storage tank.
4
Expansion tank
Allows for the expansion and contraction of the heat transfer fluid as
it heat and cools.
5
Temperature and Pressure relief
valve
Required by plumbing code to automatically open and dump water if
the storage tank exceeds 150 PSI of pressure or 210° F in temperature.
6
Air vent
Purges air from the collector loop fluid during the installation.
7
Drain valve
Used to drain the heat transfer fluid from the collector loop.
8
Mixing valve
Used to temper hot water from the solar storage tank with cold inlet
water to maintain appropriate temperature hot water delivered from
the system.
9
Solar pump station
Controls the flow of heat transfer fluid from the collectors to the tank/
heat exchanger. For a detailed description of the solar pump station
see page 20.
10
Temperature sensor
Tank and collector sensor work together to turn the circulating
pump(s) on and off at preset temperature differentials.
11
Cold Water Cut-Off Valve
Isolates the tank from incoming water supply.
STORAGE TANK INSTALLATION
Never operate the electrical heating element without being
certain the solar water heater is completely filled with water.
If any air is left in the top of the tank, the heating element
will burn out.
be terminated at an adequate drain inside the building. Be
certain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in size
under any circumstances. Excessive length, over 15 feet, or
use of more than two elbows can cause restriction and reduce
the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
temperature-pressure relief valve and the tank. Do not
connect tubing directly to discharge drain unless a 6” air
gap is provided. To prevent bodily injury, hazard to life
or damage to property, the temperature-pressure relief
valve must be allowed to discharge water in quantities
should circumstances demand. If the discharge pipe is not
connected to a drain or other suitable means, the water flow
may cause property damage.
LOCAL CODES
The installation of this solar water heater must be in
accordance with these instructions and all applicable local
codes and electric utility requirements. In the absence of
local codes, install in accordance with the latest edition of the
National Electrical Code (NFPA-70).
TEMPERATURE-PRESSURE RELIEF VALVE
For protection against excessive pressures and temperatures
in this water heater, install temperature-pressure protective
equipment required by local codes, but not less than a
combination temperature-pressure relief valve certified by
a nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment or
materials, as meeting the requirements for Relief Valves for
Hot Water Supply Systems, the latest edition of ANSI Z21.22.
This valve must be marked with a maximum set pressure not
to exceed the marked hydrostatic working pressure of the
water heater (150 lbs./sq. in.).
Install the temperature-pressure relief valve directly into the
fitting of the water heater. Position the valve downward and
provide a discharge pipe that must terminate a maximum
of six inches above a floor drain or external to the building.
In cold climates, it is recommended that the discharge pipe
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the
temperature-pressure relief valve, or have any reducing
couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain
or external to the building. In cold climates, it is recommended
that the discharge pipe be terminated at an adequate drain
inside the building.
7
• Shall not have any valve between the relief valve and tank.
When installing the temperature-pressure relief valve, use
two or three turns of Teflon® tape or other suitable thread
sealer around the threaded end of the valve.
heater. It is also a good place to end the drain line of
the temperature-pressure relief (T & P) valve.
3. The solar water heater or the pipes and the connections
may, in time, leak. Put the solar water heater in a place
where a water leak will not damage anything.
4. You must not put the water heater in an area where
it might freeze You must turn off the electricity to the
water heater before you drain it, to protect the heating
elements.
5. Make sure that you are able to reach the drain valve
and all access panels when the water heater is in place.
This will make it easy to service the water heater.
6. The water heater must be level before you begin the
piping.
WATER HEATERS EVENTUALLY LEAK. The installation
of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow
of water will not cause damage to the area adjoining the
water heater or to lower floors of the structure. When such
locations can’t be avoided, a suitable metal drain pan should
be installed under the water heater. Such a pan should be
no greater than 1 1/2 inches deep, have a minimum length
and width of at least two inches greater than the heater
dimensions and must be piped to an adequate drain.
Figure 2.
The temperature-pressure relief valve should be manually
opened once a year. Caution should be taken to ensure that
(1) no one is in front of or around the outlet of the
temperature-pressure relief valve discharge line, and (2)
the water manually discharged will not cause any bodily
injury or property damage because the water may be
extremely hot.
If after manually operating the valve, it fails to completely
reset and continues to release water, immediately close
the cold water inlet to the water heater, follow the draining
instructions, and replace the temperature-pressure relief
valve with a new one.
If the temperature-pressure relief valve on the appliance
This solar water heater, as all water heaters, will eventually
leak. Do not install without adequate drainage provisions
where water flow will cause damage. Note: normal
condensation from a solar water heater may appear to be
a leaking tank.
weeps this may be due to thermal expansion. The water
supply serving this solar water heater may have a check
valve installed. Contact the water supplier or local plumbing
contractor on how to control this situation. Do not plug the
temperature-pressure relief valve.
WATER PIPING
CLOSED SYSTEM/THERMAL EXPANSION
This solar water heater is design certified to be used with a
potable water system. When connecting water piping with
solder joints use only lead free solder.
As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will grow. As the volume
of water grows, there will be a corresponding increase
in water pressure due to thermal expansion. Thermal
expansion can cause premature tank failure (leakage). This
type of failure is not covered under the limited warranty.
Thermal expansion can also cause intermittent temperaturepressure relief valve operation: water discharged from the
valve due to excessive pressure build up. The temperaturepressure relief valve is not intended for the constant relief
of thermal expansion. This condition is not covered under
the limited warranty.
A properly-sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of
thermal expansion. Contact a plumbing service agency or
your retail supplier regarding the installation of a thermal
expansion tank..
The indirect coil in this unit is a single wall and may only be
used in a closed loop - fill only with a mixture of propylene
glycol containing corrosion inhibitors (such as Dowfrost™)
(50% by volume maximum) and distilled or de-mineralized
water. Never fill with a toxic liquid. Use of any heat transfer
fluid other than that specified or failure to operate the heat
exchanger in a closed loop will void the warranty, and may
result in poor performance, equipment damage, or risk to
health and safety.
This solar water heater shall not be connected to any
heating systems or component(s) previously used with a
non-potable water heating appliance.
LOCATING THE SOLAR WATER HEATER
If you have a choice of where to install the solar water heater,
these ideas may help you decide.
1. Put the solar water heater indoors as close as possible
to where you use the most hot water. This water heater
is not intended for outdoor installation.
2. It is handy to have a floor drain, tub or sink nearby.
That will make it easy to drain water from the water
8
If this solar water heater is also used for space heating
applications, all piping and components connected to the
solar water heater shall be suitable for use with potable
water.
This appliance has been design certified as a solar water
heater complying with Standards for Safety - UL174 for
the U.S. and can/csa-c22.2 No 110 F379.1 and F379.2
for Canada. The particular application of this appliance
described (above paragraph) may be subject to review and
approval by local code officials.
Toxic chemicals such as used for treatment of boilers or nonpotable water heating appliances shall never be introduced
into a potable water space heating system.
a. Look at the top cover of the solar water heater. The
hot and cold connections are marked there.
b. A non-metallic dip tube is supplied to carry cold water
from the tank top to the bottom. Be sure that it is in
the cold water inlet.
c. If using copper tubing, solder tubing to an adapter
BEFORE you attach the adapter to the cold water
inlet. DO NOT solder the cold water supply pipe
directly to the cold water inlet connection. It might
harm the dip tube.
d. The cold water supply line must have a shut-off valve
and union.
4. Use a union to connect the hot water supply pipe to the
solar water heater’s hot water outlet.
Operating an empty or partially filled solar water heater will
result in damage to the tank.
If a solar water heater is installed in a closed water system;
such as one having a back flow preventer, check valve or
water meter with check valve in the cold water supply line,
means shall be provided to control thermal expansion.
Contact the water supplier or local plumbing contractor on
how to control this situation.
INSTALLATION IN RESIDENTIAL GARAGES
The solar water heater must be located and/or protected so
it is not subject to physical damage by a moving vehicle.
FILLING THE SOLAR WATER
HEATER WITH WATER
1. Close the solar water heater drain valve. The drain valve
is on the lower front of the solar water heater.
2. Open the cold water supply to the solar water heater.
NOTE: THIS VALVE MUST BE LEFT OPEN WHEN THE
SOLAR WATER HEATER IS IN USE.
3. Fill the solar water heater until a constant flow of water
runs out an opened hot water faucet. This will let out
air in the solar water heater and the piping. Close the
faucet after all air has been purged and the water comes
out with constant flow.. You must not turn the electricity
on until the solar water heater is full of water. IF ANY
AIR IS LEFT IN THE TOP OF THE SOLAR WATER
HEATER THE TOP HEATING ELEMENT WILL BURN
OUT IMMEDIATELY.
4. Check all the new water piping for leaks. Fix as
needed.
Figure 3.
The solar water heater will work better if you keep the hot
water runs short. You will also get hot water faster and with
less heat loss.
The illustration shows the correct valves and fittings that you
will need to install the solar water heater. Threaded (3/4”)
water connections are supplied through the tank top.
WIRING OF ELEMENT
Determine voltage and wattage from the rating plate
attached to the solar water heater. All external wiring,
connection, and overcurrent protective devices must be
provided and installed in accordance with the latest edition
of the National Electrical Code, local codes, and local utility
requirements. The solar water heater must be electrically
“grounded” by the installer. A green ground screw has been
provided on the solar water heater’s junction box.
The grounding electrode conductor shall be of copper,
aluminum, or copper clad aluminum. The material shall
be resistant to corrosion, and shall be of one continuous
length without a splice or joint.
Rigid metal conduit, intermediate metal conduit, or electrical
metallic tubing may be used for the grounding means
if conduit or tubing is terminated in fittings approved for
grounding.
Figure 4.
1. Buy the fittings that you need to connect the pipes.
Remember that you have to connect both the hot and
cold water pipes.
2. Apply a light covering of pipe joint compound to each
outside thread before making connection.
3. Connect the cold water supply pipe to the cold water inlet
of your solar water heater as follows:
9
THERMOSTAT
Each thermostat is factory preset at 120°F to reduce the
risk of scald injury. This setting has proven by experience
to be most satisfactory from the standpoint of operational
costs and household needs.
Solar water heaters installed in Florida require the
thermostat(s) to be set at 125°F. If you wish to adjust the
settings, see the “Temperature Adjustment” section of this
installation manual on page 11.
Figure 5.
TEMPERATURE REGULATION
Flexible metal conduit or flexible metallic tubing shall be
permitted for grounding if all the following conditions are
met:
1. The length in any ground return path does not exceed
6 feet.
2. The circuit conductors contained therein are protected
by overcurrent devices rated at 20 amperes or less.
3. The conduit or tubing is terminated in fittings approved
for grounding.
Never use this solar water heater unless it is completely
full of water.
SOLAR WATER HEATERS EQUIPPED FOR ONE TYPE
VOLTAGE ONLY. This solar water heater is equipped
for one type of voltage only. Check the rating plate near
the bottom access panel for the correct voltage. DO NOT
USE THIS SOLAR WATER HEATER WITH ANY VOLTAGE
OTHER THAN THE ONE SHOWN ON THE MODEL
RATING PLATE. Failure to use the correct voltage can
cause problems which can result in DEATH, SERIOUS
BODILY INJURY OR PROPERTY DAMAGE. If you have
any questions or doubts consult your electric company.
HOTTER WATER CAN SCALD: Solar water heaters are
intended to produce hot water. Water heated to a temperature
which will satisfy clothes washing, dish washing, and other
sanitizing needs can cause scalds resulting in serious
personal injury and/or death. Some people are more likely
to be permanently injured by hot water than others. These
include the elderly, children, the infirmed, or physically
handicapped. If anyone using hot water in your home fits
into one of these groups or if there is a local code or state
law requiring a certain temperature water at the hot water
tap, then you must take special precautions. Please see
Figure 7 and Table 2 for information regarding thermostat
settings. In addition to using the lowest possible temperature
setting that satisfies your hot water needs, some type of
mixing device, such as a mixing valve should be used at the
hot water taps used by these people or at the solar water
heater. Mixing valves are available at plumbing supply or
hardware stores. Follow manufacturers instructions for
installation of the valves. Before changing the factory
setting of the thermostat, read the Temperature Adjustment
section. KEEPING THE THERMOSTAT SETTING AT 120°F
WILL REDUCE THE RISK OF SCALDS. Never allow
small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person
unattended in a bathtub or shower.
If wiring from the fuse box or circuit breaker box was aluminum for the old tank, replace it with copper wire. If you wish
to reuse the existing aluminum wire, have the connection
at the solar water heater made by a competent electrician.
BLACK
RED
F
BLACK
F (60 C)
RED
(49 C)
F
(66 C)
TEMPERATURE SETTINGS
NOTE: This residential solar water heater will not supply
sanitizing hot water for dishwashers.
ELEMENT
The thermostat is factory set at its lowest position which
approximates 120°F and is adjustable if a different water
temperature is desired. For best system savings this
temperature should not be changed. Read all warnings in this
manual and on the solar water heater before proceeding.
Figure 6.
Contact your local utility to arrange for a professional
electrician.
10
HIGH LIMIT
CONTROL
RESET
BUTTON
RESET
BUTTON
ADJUSTABLE
THERMOSTAT
WITH
HIGH LIMIT
Figure 8.
A non-adjustable high temperature limit control operates
before steam temperatures are reached. The high limit is
in the same area as the upper thermostat and must be reset
manually when it activates. BECAUSE THE HIGH LIMIT
ACTIVATES ONLY WHEN ABNORMALLY HIGH WATER
TEMPERATURES ARE PRESENT, IT IS IMPORTANT
THAT A QUALIFIED SERVICE AGENT BE CONTACTED
TO DETERMINE THE REASON FOR OPERATION
BEFORE RESETTING.
Figure 7.
Water
Temperature °F
Time for 1st Degree
Burn
(Less Severe Burns)
110
116
116
122
131
140
149
154
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
TANK SENSOR
Time for Permanent Burns 2nd &
3rd Degree (Most
Severe Burns)
The surface mount tank sensor should be attached to the
sensor stud behind the lower door by placing the hole in
the sensor over the stud provided and securing in place
with a nut. The end of the tank sensor shall be connected
to the red wires in the opening with wire nuts (with no
regard for polarity). The other ends of the red temperature
sensor extension extend from the top of the tank and shall
be connected to the controller in the tank sensor position.
DRAINING
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 seconds
It is recommended that the storage tank be drained and
flushed every 6 months to remove sediment which may
build up during operation. The water heater should be
drained if being shut down during freezing temperatures.
To drain the tank, perform the following steps:
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
TABLE 2.
TEMPERATURE ADJUSTMENT
1. Turn off power to the water heater.
2. Open a nearby hot water faucet until the water is no
longer hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to
an adequate drain or external to the building.
5. Open the water heater drain valve and allow all of the
water to drain from the tank. Flush the tank with water
as needed to remove sediment.
6. Close the drain valve, refill the tank, and restart the
heater as directed in this manual.
If the water heater is going to be shut down for an extended period, the drain valve should be left open.
To adjust the temperature setting:
1. Turn “OFF” the electrical power to the water heater, at
the junction box.
HAZARD OF ELECTRICAL SHOCK! Failure to turn
“OFF” electric power to the solar water heater will result
in the possibility of DEATH, SERIOUS BODILY INJURY
OR PROPERTY DAMAGE.
2. Take off the access panel and fold away the insulation.
3. Turn the water temperature dial clockwise (
) to
increase the temperature, or counterclockwise (
) to
decrease the temperature.
4. Fold the insulation back in place and replace the access
panel.
5. Turn “ON” the power supply.
IMPORTANT: Condensation may occur when refilling the
tank and should not be confused with a tank leak.
If the solar water heater is to be shut off and exposed to
freezing temperatures, it must be drained. Water, if left in
the tank and allowed to freeze, will expand and damage
the solar water heater.
11
1. Turn “OFF” the electrical supply to the solar water heater.
Make sure the electrical supply to the solar water heater
is turned OFF. Failure to heed this will result in the
possibility of DEATH, SERIOUS BODILY INJURY OR
PROPERTY DAMAGE.
2. Open a nearby hot water faucet until the water is no
longer hot, then turn off the cold water supply and open
the drain valve, leaving the hot water faucet open.
3. The drain valve must be left open during the shut-down
period. Once the solar water heater is drained close the
hot water faucet.
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease
the life of the water heater tank.
The anode rod should be inspected after a maximum of
three years and annually thereafter until the condition of
the anode rod dictates its replacement. NOTE: artificially
softened water requires the anode rod to be inspected
annually.
The following are typical (but not all) signs of a depleted
anode rod:
• The majority of the rod’s diameter is less than 3/8”.
• Significant sections of the support wire (approx. 1/3 or
more of the anode rod’s length) are visible.
ELEMENT
In some water areas, scale or mineral deposits will build up
on heating elements. This build up may cause a rumbling
noise. Follow the element replacement directions to remove
the elements from the tank. Soaking in vinegar and scraping
will remove the mineral deposit. Be careful not to bend the
element.
If the anode rod shows signs of either
or both it should be replaced. NOTE:
Whether re-installing or replacing the
anode rod, check for any leaks and
immediately correct if found.
In replacing the anode:
ELEMENT REPLACEMENT
1. Turn off power supply to the water
heater.
Replacement elements must (1) be the same voltage and
(2) no greater wattage than listed on the model and rating
plate affixed to the solar water heater.
1. Turn OFF the electrical supply to the solar water heater.
Make sure the electrical supply to the solar water heater
is turned OFF. Failure to heed this will result in the
possibility of DEATH, SERIOUS BODILY INJURY OR
PROPERTY DAMAGE.
2. Drain the solar water heater. Follow the directions for
draining.
3. Take off the access panel and take off the access panel
and remove the insulation. Disconnect the wires from the
heating element terminals.
4. Use an element wrench to remove the element and gasket.
You should always use a new gasket when you replace the
element.
5. Install new element.
6. Reconnect the wires as they were.
7. Fill the tank , following the filling directions on page 9. Fill
the tank completely with water, BEFORE you turn on the
electric supply.
2. Shut off the water supply and
open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons
of water from tank. (Refer to
“Draining and Flushing” for proper
procedures). Close drain valve.
Figure 9.
4. Remove old anode rod.
5. Use Teflon® tape or approved pipe sealant on threads
and install new anode rod.
6. Turn on water supply and open a nearby hot water
faucet to purge air from water system. Check for any
leaks and immediately correct any if found.
7. Restart the water heater as directed in this manual.
See the Storage Tank Repair Parts section for anode
rod location.
TEFLON® is a registered trademark of E.I. Du Pont De
Nemours and Company.
ANODE
Hydrogen gas can be produced in a hot water system that
has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of bodily injury under
these conditions, open the hot water faucet for several
minutes at the kitchen sink before any electrical appliances
which are connected to the hot water system are used (such
as a dishwasher or washing machine). If hydrogen gas is
present, there will probably be an unusual sound similar
to air escaping through the pipe as the hot water faucet is
opened. There must be no smoking or open flame near
the faucet at the time it is opened.
Each water heater contains at least one anode rod, which
will slowly deplete (due to electrolysis) prolonging the life
of the water heater by protecting the glass-lined tank from
corrosion. Adverse water quality, hotter water temperatures,
high hot water usage, hydronic heating devices, and water
softening methods can increase the rate of anode rod
depletion. Once the anode rod is depleted, the tank will
start to corrode, eventually developing a leak.
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water. IMPORTANT: Do not remove this rod
permanently as it may void any warranties. A special anode
rod may be available if water odor or discoloration occurs.
NOTE: This rod may reduce but not eliminate water odor
problems. The water supply system may require special
filtration equipment from a water conditioning company to
successfully eliminate all water odor problems.
Artificially softened water is exceedingly corrosive because
WATER HEATER SOUNDS
1. The solar water heater is equipped with an immersion
heating element for fastest recovery. If the solar water
heater occasionally makes noises this is not a defect or a
safety hazard.
2. Lime or scale has accumulated on the heating element
causing a hissing sound. Element scale removal can be
accomplished by using vinegar or by scraping.
12
SOLAR COLLECTOR INSTALLATION
COLLECTOR LOCATION
Proper location and orientation of the solar collectors is
important for maximum system efficiency. The collectors
should be unshaded from 10:00 am through 3:00 pm each
day in every month of the year and should be located as
close to the storage tank as possible to minimize heat loss
in the piping runs. The best orientation is achieved when
the collectors are facing due south +/- 45° and tilted at
an angle from the horizontal equal to the latitude of the
location + 15°. A steeper angle provides better winter performance as the sun is lower in the sky. The collectors
will also shed snow more effectively at the steeper angle.
Figure 10 below shows many alternatives for collector
mounting. Placing the collectors as close as possible to
the peak of the roof will make installation easier by providing increased attic access.
Figure 10.
GENERAL CONSIDERATIONS
The contractor shall obtain all required permits and
approvals.
Before the installation the contractor shall inspect the condition of the roof and notify the homeowner of any existing
roof damage or necessary repairs.
The installation shall conform to all federal, state and local
regulations, codes, ordinances and standards governing
solar water heating system installations and the contractor
shall adhere to sound building safety and trade practices.
Special consideration must be given to building code
requirements for the penetration of structural members
and fire rated assemblies.
COLLECTOR ORIENTATION
Proper tilt angle for solar collectors is latitude plus 15°.
This 15° additional tilt improves performance in the
winter, when the sun is weaker and at a lower angle.
The cost in performance in the summer when the sun is
high is overcome by the hours of sunlight and strength
of irradiation that occurs in the summer. Tilt mounting
accessory kits are available to set the proper collector
angle. Please call your local dealer for more information.
Ensure the mounting surface is solid and able to withstand in excess of 330lbs / 150kg of pull force that
may be encountered during high winds. Consult a
structural engineer if in doubt.
When the collectors are mounted one behind the other,
they should be spaced sufficiently apart so that when the
sun is at its lowest altitude, the collectors will not shade
each other and cause efficiency loss. See Figure 11 and
Table 3. If a collector must be installed horizontally, replace
the upper vent with a rubber plug in order to prevent rain
penetration. See Figures 12 & 13.
The solar collector must be located in a structurally sound
area of the roof that will be unshaded for the majority of the
day all year round. Adjacent buildings and trees should be
checked for possible winter shading. An instrument such
as the Solar Pathfinder (www.solarpathfinder.com) can be
used for solar site analysis.
13
COLLECTOR TILT
48”
A”
Figure 11.
LATITUDE
COLLECTOR TILT
ROOF
ANGLE
&
PITCH
25° N
30° N
35° N
40° N
45° N
50° N
55° N
60° N
65° N
35°
40°
45°
50°
55°
60°
65°
70°
75°
ANGLE
PITCH
A” SPACING IN INCHES
0°
FLAT
87
103
127
159
213
260
330
446
661
5°
1/12
76
87
103
122
151
174
204
244
295
9°
2/12
69
78
90
104
123
139
157
180
205
14°
3/12
63
69
78
88
101
111
123
136
149
18°
4/12
59
64
71
78
88
96
105
115
123
23°
5/12
54
59
64
70
77
83
89
96
102
27°
6/12
52
55
59
64
70
75
80
86
90
30°
7/12
50
53
57
61
66
70
75
79
83
34°
8/12
48
51
54
57
61
65
69
72
75
37°
9/12
N/A
49
52
55
59
62
65
68
70
40°
10/12
N/A
48
50
53
56
59
62
65
66
43°
11/12
N/A
N/A
49
51
54
56
59
62
63
45°
12/12
N/A
N/A
48
50
53
55
57
60
61
Table 3. (For All Horizontally Mounted Collectors)
Figure 12.
Figure 13.
14
The most important structural consideration is to securely
anchor the solar collector and the mounting hardware to the
structural members of the roof with the stainless steel hardware
provided. The solar collector must be attached to the mounting
hardware as detailed in Figure 18.
CAUTION
ALL PERSONS WORKING ON ROOFS SHOULD
HAVE SUCCESSFULLY COMPLETED A FALL SAFETY
COURSE AND SHOULD BE PROPERLY EQUIPPED
WITH THE APPROPRIATE SAFETY EQUIPMENT
Preserving the integrity of the roof membrane is the
most important roofing consideration. Ensure that all roof
penetrations required to plumb and mount the solar collector
are properly flashed and sealed in accordance with standard
roofing practices.
WARNING
AFTER COMPLETION OF THE COLLECTOR
MOUNTING AND PRIOR TO SYSTEM CHARGING THE
COLLECTORS MUST BE COVERED BY A BLANKET OR
OTHER MEANS TO AVOID SOLAR RADIATION FROM
HEATING THE COLLECTORS. THE SURFACES OF THE
COLLECTOR CAN BECOME EXTREMELY HOT AND
COULD POSE A BURN HAZARD.
If the region is subject to hurricane conditions, additional
steps may be required to secure the collector and mounting
hardware to the structural members. In certain areas of the
country, local building codes may require collector wind load
testing or prescribe specific mounting procedures. Consult
your local building department.
Install the collectors as described in the Spanner Mounting
instructions.
SPANNER MOUNTING
Although there are other installation methods for mounting
solar collectors, it has been determined that the spanner
mounting method is the most suitable for this application.
Consult with your installer if other mounting means are
required for your installation.
extend about 4” below the roof rafters.
6. Fabricate spanners, one for each mounting bracket,
using a 2” x 4” or similar lumber. Spanners must be
long enough to span at least two rafters. In the attic or
crawl space drill a 5/16” hole through each spanner and
insert the all-thread through it. Secure each spanner to
the rafters with decking or wood screws. See Figure 17.
1. After locating the mounting points from Figure 14 for
vertical collector mounting, Figure 15 for horizontal
collector mounting, and Table 4, layout the roof as
specified and drill 5/16” holes between the rafters
where indicated.
7. Fabricate spacer blocks, one for each mounting bracket,
using a 2” x 4” or similar lumber the same width of the
rafter next to each all-thread. Place spacer blocks next
to the all-thread between the spanner and roof. Secure
each spacer block to the spanners with decking or
wood screws. Spacer blocks are necessary to avoid
deformation of the roof. See Figure 17.
2. Insert the flashing so the top part is under the next row
of shingles and the flashing hole/grommet aligns with
the mounting hole. See Figure 16.
3. The compression bracket washer is positioned over the
flashing seal with the concave side towards the seal.
See Figure 17.
8. With a stainless steel nut, lock washer and fender
washer secure the all-thread to each spanner. Tighten
down until the mounting bracket is tightly secured to
the roof (approx. 97 inch pounds). Be careful not to
overtighten and dish out the roof tiles underneath the
mounting bracket.
4. The mounting bracket is then placed on the compression
bracket washer.
5. A 12” length of stainless steel 5/16” all-thread is then
inserted through the hole and a stainless steel nut, lock
washer, and EPDM bonded washer secures the allthread to the mounting bracket. The all-thread should
Repeat steps 2-8 for the remainder of the mounting
bracket locations.
15
DRILL POINTS
(CLEARANCE HOLE
for 5/16” BOLT)
B”
C”
B”
MOUNTING
BRACKETS
C”
A”
RAFTER
D”
RAFTER
BASED ON 16” CENTER RAFTERS
VERTICAL MOUNTING
Figure 14.
DRILL POINTS
(CLEARANCE HOLE
for 5/16” BOLT)
B”
C”
A”
B”
C”
RAFTER
D”
BASED ON 16” CENTER RAFTERS
MOUNTING
BRACKET
RAFTER
RAFTER
HORIZONTAL MOUNTING
Figure 15.
16
NOTICE
Flashing
Bushing
* IF MOUNTING WITH AN OPTIONAL TILT MOUNT
KIT, FOR OPTIMAL COLLECTOR ANGLE REFER TO
ITS INSTRUCTION SHEET FOR THE APPLICABLE “A”
DIMENSION.
COLLECTOR
A
Vert. 3.5’ X 7’
86*
Vert. 4’ X 8’
97*
Vert. 4’ X 10’
121*
Horiz. 3.5’ X 7’ 42.25*
Horiz. 4’ X 8’
47*
Horiz. 4’ X 10’
47*
B
32
35
35
62
72
94
C
14
16
16
28
28
30
D
7-1/4
11-3/4
11-3/4
13-1/2
12
9
Figure 16.
Table 4.
STAINLESS STEEL NUT, ALL THREAD ROD
LOCK WASHER, & EPDM BONDED WASHER
4” MOUNTING BRACKET
CP COMPRESSION
BRACKET WASHER
SHINGLES
FLASHING
PLYWOOD
SHEETING
ROOF
RAFTER
DECKING/WOOD
SCREWS
Flashing
ROOF
RAFTER
SPACER
BLOCK
FENDER WASHER
LOCK WASHER
NUT
WOOD SPANNER
(2” x 4” or 2” x 6” LUMBER)
Figure 17.
17
ATTACHING COLLECTOR TO MOUNTING BRACKETS
Once all of the mounting brackets have been secured to
the roof the solar collector(s) can be installed. Refer to
Figure 18 for these instructions.
collector can then be set on the lower mounting brackets while the top clips are fastened over the lip on the
collector frame.
1. Insert the stainless steel channel nut w/spring inside
of the mounting bracket.
4. After the solar collector is in position, locate the upper
mounting clip so that its lip over-hangs the lip of the
solar collector frame as shown. Tighten the mounting
clip to the solar collector frame securely. Repeat for
the other upper mounting clips.
2. Fasten the solar collector mounting clip to the channel
nut with the stainless steel bolt, lock-washer, and flat
washer as shown. Do not tighten. Repeat step for the
other mounting bracket locations.
5. Once the upper mounting clips are secured, the bottom mounting clips can be loosened and retightened
over the collector lip as directed in step 4.
3. The solar collector can now be set on the mounting brackets. To aid in handling the collectors on the
roof the mounting clips may be tightened to the lower
mounting brackets prior to raising the collectors. The
6. Repeat steps as needed for other solar collectors.
SOLAR COLLECTOR FRAME
STAINLESS STEEL BOLT,
LOCK WASHER,
& FLAT WASHER
STAINLESS STEEL
NUT, ALL THREAD ROD
with LOCK WASHER, &
EPDM BONDED WASHER
MOUNTING CLIP
CHANNEL NUT with SPRING
(One Piece Part)
MOUNTING
BRACKET
ROOF
CP COMPRESSION
BRACKET WASHER
FLASHING
Figure 18.
18
COLLECTOR PIPING
Care should be taken in the spacing of collectors as
attachment of piping is easiest with properly aligned
collectors. The connection between the collector panels is
made with copper unions or couplings. To aid in installation
the collector array layout should be planned on the ground
and the unions or couplings soldered to the adjoining
headers prior to lifting the collectors to the roof. Similarly
the top and bottom outside header that will not be used
for the inlet or outlet (should be on opposite sides) should
be capped with the 1” copper cap provided while on the
ground. See Figure 19.
The piping of the system should be considered before a final
decision is made on how the collectors are mounted. Piping
should be made of copper tube of the type meeting local
codes, insulated with Armacell UT Solaflex or equivalent.
The maximum total piping length allowed in this system is
200 equivalent ft.
Use only lead-free solder. Use of 50/50 lead solder is
expressly prohibited. Use only type “L” or “M” copper
tubing in the collector loop plumbing. Use of galvanized
steel, CPVC, PVC, PEX or any other type of plastic pipe
is prohibited.
VERTICAL MOUNT
HORIZONTAL MOUNT
OUTLET
OUTLET
1” COPPER
CAPS
INLET
INLET
1” COPPER
CAPS
Figure 19.
1” COPPER
PIPE
HEADER
TEMPERATURE
SENSOR
PIPE
AIR VENT
ADAPTER
SOLAR COLLECTOR
COLLECTOR
(OUTLET)
COLLECTOR
(INLET)
Figure 20.
19
COLLECTOR PIPING DETAIL
The outlets of the collector are 1” copper pipe nipples See
Figure 20. They should be piped as shown with provisions
for an air vent. The air vent must be oriented vertically as
this must be the highest point in the system in order for air
to escape. This will prevent air lock and subsequent loss of
system efficiency. Teflon® tape or high temperature, high
quality pipe sealant should be used when making threaded
connections.
procedure is then repeated for the return line and flashing.
The sensor wire should also be run through the gooseneck
of the return flashing. The copper lines should be soldered
to the flashings coolie cap to a ensure proper seal. The
return and supply lines should be supported under the
roof to prevent undue stress on the piping assemblies at
the collector. Hangers shall provide adequate support and
correct pitch of pipes. Hangers or supports for insulated
pipes or components shall avoid compressing or damaging
the insulation material. Piping should be sloped toward drain
ports with a drainage slope of no less than 2 cm vertical
drop for each meter of horizontal length (1/4 inch per foot).
The collector inlets should be piped similarly but without
the air vent.
SENSOR MOUNTING AT COLLECTOR
The angled collector heat sensor is mounted to the outlet of
the collector. See Figure 21. The stainless steel screw clamp
should be used. The entire sensor should be wrapped
thoroughly with insulating stretch tape so that the sensor
is isolated from the outside air. If possible route the sensor
wire through the roof flashing and connect the sensor wire
to the sensor extension wire provided with wire nuts.
SENSOR WIRE
(to COLLECTOR)
Figure 22.
PIPE INSULATION
The collector loop piping (exterior and interior) must be
well insulated with a high quality flexible EPDM closed
cell insulation to minimize heat loss. The wall thickness
of the pipe insulation should not be less than ¾”. A 1” wall
thickness is required in all areas prone to annual hard
freeze conditions. When it comes to pipe insulation the
rule is simple: thicker is better. The specified insulation
material is Armacell UT Solaflex or equivalent. As part of
the insulation requirements the final 5 ft of the cold water
inlet to the storage tank must be insulated.
To the extent possible, slide the insulation material over
the pipe without cutting or taping. All butt joints must be
sealed with high temperature contact adhesive. The use
of rigid polyethylene pipe insulation is prohibited. All
outdoor insulation should be protected from moisture
and Ultraviolet deterioration by either paint or foil tape.
Insulation to complete the outdoor portion of the installation
has been provided.
Figure 21.
PIPING THROUGH THE ROOF
Piping through the roof should be weatherproofed as shown
in Figure 22. Three-quarter inch holes are drilled through
the roof on the same plane as the supply and return header
pipes. Do not drill the hole above the supply header of
the collector. This will prevent the collector from draining.
Placing the hole below the supply header is acceptable,
but it is more aesthetic if it is located on the same plane.
The flashing plate is placed over the hole with its base
cemented to the roof and its upper edges slid under the
adjoining shingle. The copper tube supply line is then
pushed up through the hole in the flashing. The same
20
PUMP STATION INSTALLATION
PUMP STATION
SAFETY INSTRUCTIONS
The following instructions describe the installation, startup, function and operation of the solar pump station. The
solar pump station may only be used in the collector circuit
of a solar thermal installation. The technical data specified
in these instructions must be observed. Improper usage
excludes any liability claims.
The wrapping materials that form the outer shell of the
pump station are made of recyclable materials and can be
disposed of with recyclable materials.
The solar station is a premounted valves and fittings group
checked for leakage used to circulate the solar fluid in the
solar circuit.
The installation and start-up of the solar station as well as
the connection of electrical components require technical
knowledge commensurate with a recognized vocational
qualification such as a fitter for plumbing, heating and air
conditioning technology, or a profession requiring a comparable level of knowledge [specialist]. The following must
be observed during installation and start-up:
• Relevant local and national codes
• Accident prevention regulations of the professional
association
• Instructions and safety instructions mentioned in this
manual
L
D
M
K
N
J
C
O
P
E
I
Q
R
B
S
F
A
T
H
U
V
G
W
Components:
A
Controller cover
M
Pressure relief valve
B
Differential temperature controller
N
Connection for expansion tank
C
Temperature gauge (red) with immersion sleeve for insertion into
the return ball valve
O
Pressure gauge
D
Front cover
P
Fill valve
E
Temperature gauge (blue) with immersion sleeve for insertion into
the supply ball valve
Q
Supply isolation ball valve with integrated check valve
F
Circulation pump
R
Pump speed selector
G
Flow meter access door
S
Flow restrictor
H
Supply (storage tank)
T
Drain valve
I
Air Scoop
U
Flowmeter
J
K
Return isolation ball valve with integrated check valve
V
Return (storage tank)
Return (collector loop)
W
Power Cord
L
Supply (collector loop)
Figure 23.
21
PUMP STATION INSTALLATION
SAFETY EQUIPMENT
the solar pump station back cover, insert the retaining
clips half way onto the mounting retaining stud (see
Figure 25) behind the isolation ball valves (J, Q), push
the assembly onto the bracket mounting stud and push
the clip down into place. Ensure assembly is properly
locked into place.
For protection against excessive pressures in the collector
loop a pressure relief valve is integrated into the solar
pump station. Drain tubing must be installed in the valve
outlet so that any discharge will exit only within 6 inches
above, or at any distance below the structural floor. Be
certain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in
size under any circumstances. Excessive length, over 15
feet, or use of more than two elbows can cause restriction
and reduce the discharge capacity of the valve.
Do not connect tubing directly to discharge drain unless a
6” air gap is provided. To prevent bodily injury, hazard to
life, or damage to property, the relief valve must be allowed
to discharge fluid in quantities should circumstances
demand. If the discharge pipe is not connected to a drain
or other suitable means, the fluid may cause property
damage.
Figure 25.
WALL MOUNTING THE SOLAR PUMP STATION
7. Connect the stainless steel corrugated hose to the
safety group (N). Do not forget to insert the seal.
ATTENTION: TO PREVENT DAMAGE TO PROPERTY,
THE LOCATION OF INSTALLATION MUST BE DRY,
LOAD-CARRYING AND FROST-PROOF TO PREVENT
MATERIAL DAMAGE TO THE INSTALLATION.
8. Choose the position for the expansion tank bracket
on the wall beside the solar pump station. Fasten the
bracket to the wall with the enclosed hardware (masonry
or drywall).
1. Choose the position to install the solar pump station
next to the storage tank (noting that the tank solar loop
inlet (from collector) and outlet (to pump) are on the
right side of the tank)
2. Remove the temperature gauges (C,E) by grasping the
frame and pulling straight forward.
3. Remove the front cover (D) of the solar station.
4. Remove the retainer clips behind the isolation ball
valves (J, Q) with a flat head screw driver to free the
mounting plate from the station (see Figure 24).
9. Unscrew the tank connector to separate the two halves.
The top half should be pushed onto the mounting
bracket and the lock ring tightened. The bottom half
should be attached to the ¾” threads on the expansion
tank. Do not forget to insert the seal.
10. Make sure that you are able to reach the drain valve
and all access panels when the solar station is in place.
This will make it easy to service the solar station.
NOTE: The tank connector allows you to isolate the
expansion tank from the solar circuit (Figure 26). When
the nut is unscrewed the valves in each half of the tank
connector are automatically closed tightly by the integrated
springs. Each side remains closed until the two halves are
screwed back together and the valves are forced open.
The expansion tank should not be connected to the system
until it has been flushed and charged.
Figure 24.
Note: To aid in later assembly, while each leg of the station
assembly is removed from the bracket, an extension leg of
¾” copper tubing can be attached to the bottom threaded
connector using the ¾” female NPT sweat adaptor provided.
5. Line the mounting plate up level on the wall and mark
the drill holes. (Holes will be 5 ¾” (146 mm) apart). Drill
the two holes with a 3/8” drill bit and mount the plate
with either the masonry mounting hardware or drywall
hardware provided.
FLOW
CLOSED
Figure 26.
11. Check and set the pressure of the air bladder in the
6. After the mounting plate is secured to the wall replace
22
expansion tank to 25 psi. If the pressure is higher bleed
pressure out until it is correct. If the pressure is too low
add air by use of a compressor or bicycle pump until
the pressure is correct.
12. Plumb the solar pump station to the storage tank
and to the collector: The tank connections should
use ¾” copper pipe and can be connected using
the threaded adaptors provided. The collector
connections should use ½” copper pipe and can be
connected with the compression fittings provided.
The total piping run in the solar loop should not exceed
200 equivalent feet. Failure to limit the line length may
cause poor system performance and lead to premature
pump failure.
13. Add the supplied copper drain valve to the lowest point
in the collector loop (near the tank by the bottom coil
outlet labeled “to pump” in most cases)
14. Install a discharge pipe to the pump station relief valve
that must terminate a maximum of six inches above a
floor drain or external to the building.
Installing the ½” copper to and from the collector using
the compression fittings.
PLUMBING CONFIGURATION
1
2
1.
L
K
2.
3.
H
4.
V
3
4
½” copper tube - from
the collector outlet
(top) to the collector
return compression
fitting (K)
½” copper tube – from
the collector inlet
(bottom) to the collector
supply compression
fitting (L)
¾” copper tube – from
the upper tank coil
inlet marked “from
collector” to the tank
supply threaded fitting
(H)
¾” copper tube –
from the lower tank
coil outlet marked
“to pump” to the tank
return threaded fitting
(V)
Figure 28.
1. Push the union nut  and
the cutting ring  onto the
copper pipe  . The pipe
must protrude at least 3/8”
(3 mm) from the cutting ring
in order to ensure the force
transmission and the sealing.
2. Insert the support sleeve  into
the copper pipe.
3. Insert the copper pipe with the
plugged-on individual parts (,
 and ) all the way into the
housing of the compression
fitting .
4. First screw the union nut 
manually.
5. Tighten the union nut  by
rotating one full turn. Hold the
housing of the compression
fitting  to avoid rotation in order
to avoid damaging the sealing
ring.
FUNCTION
Check valves
The solar station is equipped with check valves in the supply
and the return ball valve (J, Q).
For filling, venting and flushing of the installation the check
valves must be turned to the correct position. To set the
proper position for the check valves take off the temperature
gauges (C, E), remove the top cover (D) and turn the ball
valves into the proper position using a wrench. See Figure
29. In the 45° position the balls in the ball valves push the
check valves open.
During operation the ball valves must be in 0° position.
0°
45°
90°
Figure 27.
Check valve is
operating, flow
only in flow
direction
Check valve is not
operating, flow in
both directions.
Figure 29.
23
Ball valve
closed,
no flow.
FLOWMETER
6. Connect an air pressure hose to the fill valve (P) below
the pressure gauge (O) and open this valve.
The flowmeter (U) serves to measure and display flow
volume of the system in a range of 0.5-3.5 US gpm.
It has an integrated restrictor (S) with adjustment valve
which allows fine adjustment of the flow volume of the solar
installation.
In order to guarantee the flawless function of the measuring
device the installation must be flushed and free from foreign
substances.
The flowmeter MUST be mounted vertically.
7. Using an air compressor or pressurized air tank fill the
system with pressurized air until the pressure gauge
(O) reads 40 psi then close the fill valve (P).
8. The pressure should hold steady for 15 minutes. If
the pressure falls it is an indication of a leak. Find and
repair the leak then repeat steps 6 and 7 watching
for the pressure to hold at least 15 minutes. After the
pressure test slowly open the drain valve (T) to release
the air pressure on the system.
FLOW RESTRICTOR
FLUSHING
CAUTION
DRAIN VALVE (OPEN)
SOLAR THERMAL INSTALLATIONS CANNOT BE COMPLETELY EMPTIED
AFTER FLUSHING. THERE IS A DANGER OF FROST DAMAGE IF WATER
IS USED FOR FLUSHING. THERE IS A DANGER OF FROST DAMAGE IF
WATER IS USED FOR FLUSHING. ONLY USE WATER TO FLUS THE SYSTEM
WHEN THE OUTSIDE TEMPERATURE IS ABOVE 32° F, OTHERWISE USE
THE SOLAR FLUID TO FLUSH MAKING SURE TO FILTER ANY DEBRIS
BEFORE FINAL FILLING.
USE A WATER / PROPYLENE GLYCOL MIXTURE AS A SOLAR FLUID
(MAXIMUM 50% PROPYLENE GLYCOL).
SCALE
Figure 30.
Figure 31.
Always use a flat head screwdriver to adjust the flowmeter.
Read the flow rate from the upper edge of the floating body.
9. Disconnect the air pressure hose from the fill valve
(P).
10. Connect a water hose from a water source with at least
40 PSI supply pressure to the fill valve (P).
11. Connect a discharge hose to the drain valve (T) and
open this valve. Place the other end of the discharge
hose into an appropriate drain.
12. Turn the supply ball valve (Q) to 90° (horizontal) so that
the valve is closed.
Figure 32.
START-UP AND OPERATION OF THE SOLAR
PUMP STATION
13. Turn the slot of the flow restrictor (S) to the horizontal
position using a flat head screwdriver. The integrated
ball valve is now closed and will prevent debris from
entering the pump.
Observe the following safety instructions when starting up
the solar thermal installation:
14. Turn on the supply water and open the fill valve (P)
then leave running for 15 minutes to flush debris out
of the solar loop
15. After the 15 minute flush turn off the supply water at the
source and allow the system to drain. When water stops
flowing out of the discharge hose close the fill valve (P)
16. Close the drain valve (T) on the pump station and
move this hose to the drain valve that was installed at
the lowest point of the solar loop (near the bottom of
the tank)
17. Open this drain valve with a flat head screw driver
and open the fill valve (P) slowly to vent the system
and allow the remaining water to drain out. In order
to vent the system completely it is necessary to open
the flow restrictor (S) - turn with flat head screwdriver
until vertical.
LEAK DETECTION
1. Disconnect the expansion tank from the solar system by
unscrewing the nut on the tank connector. This prevents
the access of dirt particles present in the pipes from
entering the expansion tank.
PREPARATION OF THE HEAT TRANSFER FLUID
2. Remove the temperature gauges (C, E) and the front
cover (D) of the solar pump station.
18. Pour 100% Propylene Glycol into a large clean bucket.
Add an equivalent amount of distilled or de-mineralized
water for a 50/50 solution by volume.
The use of regular tap water as a mixing agent is
prohibited. Distilled or de-mineralized water is often
available from grocery stores and drugstores. This
3. Turn the two isolation ball valves (J, Q) to 45° using
an appropriate wrench to allow flow in both directions.
4. Close the drain valve (T).
5. Be sure the air vent at the collector array is closed.
24
solution provides freeze protection down to -30° F and
burst protection down to -60° F.
rate. If the flow rate is higher than necessary turn the
flow restrictor (S) on the flowmeter with a flat head
screwdriver to reduce the flow to the actual required.
See Table 5.
Use of heat-transfer fluid other than a maximum 50/50
mix by volume of Propylene Glycol and distilled or demineralized water is not permitted. Use of any heattransfer fluid other than that specified by the appliance
manufacturer will void warranty, and may result in poor
performance, equipment damage, or risk to health and
safety.
COLLECTOR
SIZE
NUMBER OF COLLECTORS
FILLING
19. Close the lower loop drain valve with a flat head screw
driver and move the discharge hose from the lower
valve to the drain valve (T) on the pump station and
open this valve. The other end of the discharge hose
will be placed into the glycol solution container.
20. Turn the return ball valve (J) to 0° (vertical) so that flow
is only allowed in the proper direction.
21. Connect a fill hose from the glycol container to a 1/2
HP transfer pump and another hose from the transfer
pump to the fill valve (P) then open this valve.
22. In order to flush as much air as possible from the system,
turn on the transfer pump to fill the system with the glycol
solution and allow to circulate for 15 minutes or until no
bubbles are returning to the collector.
23. Open the air vent at the top of the collector array until
all of the air has been dispersed then close the air vent.
24. Remove the cap from the front of the Air Scoop (I)
and open the vent with a flat head screwdriver. This
will release air that has been captured by the system
during circulation. Cover small outlet port with a rag
as fluid will be ejected after the air is evacuated. After
all air has been evacuated, close the vent with a flat
head screwdriver and replace the cap on the front of
the Air Scoop (I).
25. Turn the supply ball valve (Q) to 0° (vertical) so that
flow is only allowed in the proper direction and ensure
that the flow restrictor (S) is completely open (vertical)
26. With the transfer pump still running close the drain valve
and allow to system to rise to an operating pressure of
30 psi on the pressure gauge then close the fill valve
and turn off the pump. If the pressure has exceeded
30 psi after the pump is off then slowly open the drain
valve and relieve pressure until the pressure gauge
reads 30 psi, then close the drain valve.
27. Connect the expansion tank and verify the system
pressure. If it has dropped, open the fill valve (P) and
turn on the transfer pump. Repeat system pressure
setting in step 26.
28. Remove the fill and drain hoses and close the fill and
drain valves (P,T) with the caps provided. The caps
only serve to protect the valves against dirt. They are
not designed to withstand high system pressures, the
valves must be closed.
29. Plug in the solar pump station to a 115V outlet and turn
the pump on using the HND mode (see Pump Station
Control Instruction section). HND setting should be
set to “ON”.
30. Adjust the pump speed using the pump speed selector
(R) to the lowest setting possible to set the system
flow rate equal to or higher than the final system flow
1
2
3
4
3.5’ x 7’
0.7
1.4
2.1
2.8
4’ x 8’
1.0
2.0
3.0
4.0
4’ x 10’
1.3
2.6
3.8
5.0
FLOW RATE IN GPM
Table 5.
Cycle the pump on and off in manual mode to check
whether the starting torque is sufficient with the pump
speed selected. If flow does not start properly a higher
speed may need to be selected and the flow reset to
the proper level with the flow restrictor (S) Again check
the installation for leaks and ensure both ball valves are
open completely.
31. Replace the front cover (D) and re-insert the red
temperature gauge (C) in the return ball valve (J) and
the blue temperature gauge (E) in the supply ball valve
(Q).
32. Set the controller to operate in automatic mode (see
Pump Station Control Instruction section).
33. After the system has been running for several days
open the air vent at the top of the collector array until
all of the air has been dispersed then close the air vent.
DRAINING
1. Open the check valves in the supply and the return ball
valves (J,Q) by turning the ball valves to position 45°
with an appropriate wrench
2. Place a temperature-resistant container under the drain
valve at the lowest point of the solar thermal installation
(usually near heat exchange coil at the bottom of the
tank).
3. Open the drain valve at the lowest point of the solar
thermal installation.
4. Open the air vent at the top of the collector array. This
will serve as a vacuum break to aid in draining.
5. Dispose of the solar fluid observing any local code.
ATTENTION: Upon completion of the pump station
installation and prior to the pump station start-up the
included pump station valve diagram label must be attached
to the pump station piping so that it is in plain view.
25
PUMP STATION CONTROL INSTRUCTIONS
The power supply is connected to the following terminals:
CONTROL INSTRUCTIONS
19 = Neutral - N
20 = Line power - L
12 = Ground
The control is equipped with two relays, one for the
integrated pump in the solar pump station and one for use
in specialty custom applications requiring a second pump:
• Relay 1 (primary pump)
18 = Line power - R1
17 = Neutral - N
13 = Ground
• Relay 2 (secondary pump – optional, not included)
16 = Line power - R2
15 = Neutral - N
14 = Ground
Prior to operation of the control on the solar pump station
the collector and tank temperature sensors must be properly connected. Remove the control cover and connect
the sensors to the proper terminals.
OPERATION AND FUNCTION
DISPLAY
COVER
OPERATION
CONTROL LAMP
BACKWARDS
FORWARDS
2
PUSHBUTTONS
3
1
CABLE CONDUITS
WITH STRAIN RELIEF
CAN FUSE 4A
Figure 33.
SET
(SELECTION / ADJUSTMENT MODE)
Figure 35.
The controller is operated by 3 push buttons below the
display. The forward key (1) is used for scrolling forward
through the indication menu or to increase the adjustment
values. The backwards key (2) is used for scrolling
backward through the indication menu or to decrease the
adjustment values.
For system settings adjustment press the forward key to
reach the last display channel. Then hold the forward
button down for 2 seconds and the system setting screens
can then be shown. If an adjustable value is shown on the
display
is indicated. To change the set value press the
Set button (3) so that
flashes. Adjust the value using
button 1 or 2 until the desired value is shown then press
button 3 so that
permanently appears. The adjusted
value is now saved.
Figure 34.
The temperature sensors should be connected to the
following terminals with no dependence on polarity:
1 / 2 = sensor 1 (collector outlet)
3 / 4 = sensor 2 (tank bottom)
5 / 6 = sensor 3 (tank top – optional, not included)
7 / 8 = sensor 4 (return flow temperature – optional, not
included)
26
System Monitoring Display
The system monitoring display consists of 3 blocks: channel indication, the tool bar, and
system screen.
Complete monitoring display
Channel indication
The channel indication consists of two lines. The upper line is an alphanumeric 16
segment indication in which the channel name or menu item is shown. The lower 7
segment indication shows the channel value and the adjustment parameters are
indicated.
Temperatures are indicated in °F / °C, Temperature differences are indicated in °F / K
Toolbar
The symbols in the tool bar indicate the current system status
SYMBOL
STANDARD
FLASHING
Relay 1 active
Relay 2 active
Maximum tank limit reached / maximum tank
temperature exceeded.
Collector cooling function active
Antifreeze – function activated
Collector minimum temperature reached
Collector security shutdown or tank security
shutdown active (max temperature reached).
Sensor error
Manual operation active
Displayed channel indication is adjustable
Adjustment mode for displayed channel
System Screen
The system screen (active system scheme) shows the scheme selected on the controller.
It consists of several component symbols, which are – depending on the current status
of the system – either flashing, permanently shown or hidden.
Blinking control symbols
• Pump is blinking while running
• Sensors are blinking if the respective sensor
indication channel is selected
• Sensors are quickly blinking if there is a sensor error
Operation control lamp indication
Constantly green:
system operation normal
Red/green blinking: initialization phase, manual
operation
Red blinking:
27
sensor error
STARTUP / SYSTEM SETTINGS
The AC power cord should be plugged in to an appropriate 115V outlet. The controller will enter an initialization phase in
which the operating control lamp will flash red and green. After the initialization period the controller will be in automatic
operation with the default settings active.
The pre-adjusted system scheme is ARR 1. Other system settings are available, but this setting should not be changed
for the system included in this package.
The controller is now ready for operation. The following system settings should be made as indicated. The operational
system channels are listed in order of appearance by pressing the forward (1) button.
COL:
Collector Temperature
Display range: -40 to +482 °F
Shows the current collector temperature.
TST:
Tank temperature
Display range: -40 to +482 °F
Shows the current tank temperature (from tank bottom sensor).
S3, S4:
Additional sensor temperature
Display range -40 to +482 °F
Shows the current temperature of the corresponding optional
sensor (without control function).
TRF:
Temperature return flow
Display range -40 to +482 °F
Shows the current temperature of the optional temperature
return flow sensor (S4) when the heat quantity measurement
option is activated.
hP:
Operating hours counter
Display channel
The operating hours counter adds up the solar operating hours
of the pump. Full hours are shown on the display.
S3 and S4 are only indicated if the temperature sensors are
connected.
The total operating hours can be reset. When the operating
hours channel is selected the symbol
is permanently
shown in the display. The set button (3) must be pressed for
approximately 2 seconds in order to go into the reset mode
for the counter. The display symbol
will be flashing and
the operating hours will be set to 0. In order to finish the reset
procedure the set button (3) must be pressed in order to
confirm.
In order to interrupt the reset procedure no button should be
pressed for about 5 seconds. The controller will automatically
return to the indication mode with the previous total.
Once the final display channel is reached the remaining system setting channels may only be accessed by holding the forward (2)
button down for approximately 2 seconds. The following setting channels will then be shown:
ARR:
System arrangement setting
Shows the current system configuration setting. Arrangement
1 should be used for the system in this package and this setting
should not be changed.
DTO:
Switch-on temperature diff.
Adjustment range
2.0 to 40.0 °F
Recommended setting: 10.0
Primarily the controller works in the same way as a standard
differential controller. If the switch-on difference, DT O (collector
temperature sensor reading minus the tank sensor reading), is
reached the pump is activated.
DTF:
Switch-off temperature diff.
Adjustment range
1.0 to 38.0 °F
Recommended setting: 4.0
If the switch-off temperature, DT F, is reached the pump is deactivated.
Note: the switch-off temperature must be at least 2 degrees
lower than the switch-on temperature.
28
SMX:
Maximum tank temperature
Adjustment range:
40 to 205 °F
Recommended setting: 160 °F
If the maximum tank temperature is reached the control will
prevent the pump from operating and heating the tank any further.
Note: The controller will only allow the tank temperature to exceed the maximum tank temperature setting when the optional
system cooling function (OCX) is active and the maximum collector temp (CMX) has been exceeded. In this case the pump
will run to transfer heat from the collector to the tank to prevent
prolonged overheating of the collector. In this case the tank
may be heated until it reaches the emergency shutoff point of
190 °F and no further heating will be done.
If the maximum tank temperature setting is exceeded the
symbol will be shown on the display.
If the collector temperature limit is reached the solar pump (R1)
is deactivated in order to avoid damaging overheating of the
solar components (collector emergency shutdown).
EM:
Collector temperature limit
Adjustment range:
If the collector temperature limit setting is exceeded the
symbol will be shown flashing on the display.
230 to 400 °F
Recommended setting: 285 °F
OCX:
Collector cooling
Adjustment: OFF / ON
Recommended setting: ON
This function is used to avoid prolonged periods of excessive
collector temperatures. If the maximum tank temperature is
reached, the solar system will shut off. After this point if the
collector temperature reaches the maximum collector temperature (CMX), the solar pump will activate until the collector temperature drops below the set point. The tank temperature may
continue to rise, overriding the maximum tank temperature, but
only until it reached the emergency tank shutoff point of 190 °F.
CMX:
Maximum collector temp.
Adjustment range:
210 to 380 °F
Recommended setting: 250 °F
Channel only available when
OCX is active
When the system is actively cooling the collectors (CMX exceeded) the symbol will be shown flashing on the display.
OCN:
Minimum collector limit
Adjustment: OFF / ON
Recommended setting: OFF
The minimum collector temperature is a minimum switching
temperature, which must be exceeded before the solar pump
(R1) is switched on. The minimum temperature will avoid short
cycling of the solar pump at low collector temperatures. If the
collector temperature is lower than the minimum collector temperature set point the
symbol will be shown flashing on the
display.
CMN:
Minimum collector temp.
Adjustment range:
50 to 195 °F
Recommended setting: 50 °F
Channel only available when
OCN is active
This function is unnecessary if the system backup heating element has a set point maintained at 120 °F.
OCF:
Antifreeze function
Adjustment: OFF / ON
Recommended setting: OFF
This function is used to transfer heat from the storage tank to
the collector in order to avoid freezing of the heat transfer medium is some system types.
This system uses a solution of propylene glycol and water and
is freeze resistant to -30 °F; therefore, this function is not necessary.
CFR:
Antifreeze temperature
Adjustment range:
15 to 50 °F
Recommended setting: 40 °F
Channel only available when
OCF is active
Channel only available when OCF is active
29
OREC:
Recooling function
Adjustment: OFF / ON
Recommended setting: ON
The recooling function is used to cool the tank when the
maximum tank temperature (S MX) is exceeded, such as when
the collector cooling function (OCX) is activated and the tank
may reach 190 °F (emergency shut down of the tank).
OTC:
Tube collector function
Adjustment: OFF / ON
Recommended setting: OFF
When the collector is 5° cooler than the tank the pump will run
to dump excess heat from the tank in the piping and at the
solar collector until the tank is cooled to the maximum tank
temperature setting.
The tube collector function is only needed for systems that use
vacuum tube solar collectors.
This function is not necessary for this system.
OHQM:
Heat quantity measurement
Adjustment: OFF / ON
Recommended setting: OFF
A Heat quantity measurement is possible for this system
in conjunction with the flow meter. In order for this function
measure the heat gain of the system the optional temperature
sensor 4 (return flow sensor) must be added and connected to
the copper pipe between the coil outlet on the tank (marked “to
pump”) and the solar pump station.
FMAX:
Volume flow in gal/min
Adjustment range:
0.0 to 20.0 in steps of 0.1
Recommended setting: pump
station flow meter reading
converted to (l/min).
For OHQM to give an accurate reading the volume flow readable
at the flowmeter (l/min) must be adjusted in the channel FMAX.
Channel only available when OHQM is active
MEDT:
Type of antifreeze
Adjustment range: 0 to 3
Recommended setting: 1
Channel only available when
OHQM is active.
For OHQM to give an accurate reading the type of heat transfer
fluid type(antifreeze) must be set in the channel MEDT:
0: water
1: propylene glycol
2: ethylene glycol
3: Tyfocor ® LS / G – LS
Caution: for this system type only type 1: propylene glycol
should be selected. Use of any other type of heat transfer fluid
in this system may cause damage to the system or present a
health hazard
MED%:
Concentration of antifreeze by
volume %
Adjustment range: 20 to 70%
Recommended setting: 50
The antifreeze concentration by % volume should be entered in
this channel for OHQM to give an accurate reading.
Standard system concentration should be a 50% propylene
glycol and 50% distilled or de-mineralized water.
Channel only available when OHQM is active.
The total heat quantity value can be reset. When one of the
heat quantity display channels is selected the symbol
is
permanently shown in the display. The set button (3) must be
pressed for approximately 2 seconds in order to go into the
reset mode for the counter. The display symbol
will be
flashing and the value for heat quantity will be set to 0. In order
to finish the reset procedure the set button (3) must be pressed
in order to confirm.
kWh/MWh:
Heat quantity value shown
in the kWh and MWh display
channels. The sum of both
channels form the total heat
output.
Channel only available when
OHQM is active
In order to interrupt the reset procedure no button should be
pressed for about 5 seconds. The controller will automatically
return to the indication mode with the previous total.
30
HND 1, HND 2:
Pump operating mode
Adjustment range:
OFF / AUTO / ON
Recommended setting:
AUTO
For system setup and service work the operating mode of the
pump can be manually adjusted by selecting the adjustment
value for HND 1 (primary pump) or HND 2 (optional secondary
pump, not included).
Operating mode:
OFF:
relay off
(flashing) +
AUTO: relay in automatic operation
ON:
relay on
(flashing) +
The menu language can be adjusted in this channel:
LANG:
Controller language
Adjustment range:
De, En, It, Fr
Recommended setting: En
De: German
En: English
It:
Italian
Fr: French
The temperature unit can be adjusted in this channel:
UNIT:
Temperature units
Adjustment: FAH, CEL
Recommended setting: FAH
FAH:
°Fahrenheit
CEL:
°Celsius
The final two channels indicate the current program and version number for the controller. To exit out of the system setting mode
press the backward button (2) repeatedly until you reach the first display channel (COL).
31
TROUBLESHOOTING
PROBLEM
No hot water
Not enough hot water
CHECK THIS
POSSIBLE CAUSE
CORRECTIVE ACTION
Storage water heater
No power to auxiliary back-up
heating element
Check high temperature
protection and push reset
button on the heater
thermostat. (Use caution when
dealing with electricity.)
Storage water heater
thermostat
Thermostat defective
Replace
Thermostatic mixing valve
Improper adjustment
Check water temperature at
house faucet and adjust valve
setting
Valve defective
Replace. System must not
be run without thermostatic
mixing valve due to scald risk.
Undersized for hot water
demand load
Replace
Thermostat set too low
Increase set point temperature
Element failure
Replace element
Thermostat failure
Replace thermostat
Element disconnected
Reconnect element and set
thermostat to 120°F
Check valve
Heat loss due to defective
check valve in solar pump
station
Inspect valve and repair or
replace
Cold water supply dip tube
Missing or defective
Replace dip tube
Collectors
Absorber coating degradation
Replace collector
Collector panel area
undersized
Increase collector area
Excessive condensation
Inspect and clean weep holes
and vents at bottom.
Glazing dirty
Clean as required
Storage water heater
Differential Controller
Leaks
Repair
Orientation
Check orientation. Face
collector within 45° of due
South
Shaded by tree(s) or other
obstructions
Remove obstacle and shading
or relocate collectors
Improper tilt
Check tilt for geographic area.
Ensure tilt is equal to latitude
plus 15°
Improperly plumbed
Compare with system
schematic and correct.
Improper operation (cycling,
late turn on)
Check sensor placement
and insulation from ambient
conditions
Faulty sensor
Sensor line break. Check the
line and repair or replace
is shown and control
reads 888.8 instead of
temperature
Faulty sensor
is shown and control
reads -88.8 instead of
temperature
32
Short circuit. Check the line
for breaks, metal contact,
water exposure and corrosion.
PROBLEM
Not enough hot water (cont.)
CHECK THIS
Compare with system
schematic. Check for proper
connections. Seal all splices
against moisture
Isolation valves
Closed
Open
Thermostatic mixing valve
Improper adjustment
Check water temperature at
house faucet and adjust valve
setting
Valve defective
Replace. System must not
be run without thermostatic
mixing valve due to scald risk.
Insufficient Insulation
Add insulation where required
High heat losses
Check insulation for splits,
deterioration, absence
Nighttime thermosyphoning
Check for pump operation at
night
Improperly plumbed
Compare with system
schematic. Check flow
direction
Flow blockage
Flush system. Check effluent
for debris.
Low system pressure
Check pressure gauge. Set
system pressure to correct
setting, check for leaks.
No power
Check breaker, pump cord,
and controller fuse. Repair or
replace
Flow rated too high or too low
Adjust flow rate
Faulty pump
Listen for irregular noises
in pump operation. Feel
collector feed and return line
for temperature difference.
Ensure all air is purged from
system.
Runs continuously
Check sensors for shorts
Storage water heater
Circuit breaker shut off
Turn breaker on
Differential controller
Sensor wires reversed
Ensure the collector and
tanks sensors are wired to
the correct position on the
controller
Thermostatic mixing valve
Improper adjustment
Check water temperature at
house faucet and adjust valve
setting
Valve defective
Replace. System must not
be run without thermostatic
mixing valve due to scald risk.
Pump
Water too hot
CORRECTIVE ACTION
Improper wiring or loose
connections)
Piping
No hot water in the morning
POSSIBLE CAUSE
Differential Controller
No water
Cold-water supply valve
Valve closed
Open valve
Pump does not start
Differential controller
Controller set to “off” position
Set system operation to
“Auto”
Unplugged
Return power to controller
On and/or off temperature
differential set points too high
Reset on and off
differentials according to
recommendations
Loose contacts
Clean contacts and tighten
connections or replace
Blown fuse
Replace fuse
33
PROBLEM
Pump does not start
Pump starts, but cycles
continuously
Pump cycles after dark
Pump runs continuously
Pump operated but no fluid
flows from collectors
Noisy system
CHECK THIS
Electrical power supply
POSSIBLE CAUSE
CORRECTIVE ACTION
Controller plug disconnected
Reconnect control plug to
power outlet
Blown fuse or breaker tripped
on overload
Determine cause and replace
fuse or reset breaker
Pump
Motor failure
Replace pump
Sensors
Defective sensors, sensor
error
Check wiring continuity.
Repair or replace
Differential controller
On and/or off temperature
differential set points too low
Reset on and off
differentials according to
recommendations
Piping
Reversed connections to
collectors
Compare with system
schematic and reconnect
properly
Sensors
Improper location
Compare with system
schematic and reconnect
properly
Differential controller
Recooling function active
and max temperature setting
exceeded
Controller operating properly.
No fault.
Sensors
Defective sensors, sensor
error
Check wiring continuity.
Repair or replace
Differential controller
Off temperature differential set
too low
Reset off differential according
to recommendation
Controller set to “on” position
Set system operation to
“Auto”
Air Scoop
System air-locked
Purge air from air scoop in
solar pump station by opening
valve slowly. Caution: after air
is evacuated fluid will flow out
in a small stream and may be
hot. Cover port with a rag to
catch any fluid.
Air vent
System air-locked
Open air vent on the top of the
system and purge excess air.
Close after purging.
Fluid
Loss of fluid from system
Locate leak and repair
Isolation valves
Valves in closed position
Open valves
Piping
Clogged or damaged piping
Unblock piping or repair
damaged piping
Pump
Broken impeller shaft
Replace shaft
Not vented properly
Install in correct orientation
Undersized
System piping run too long.
Refer to maximum piping
lengths and adjust
Air vents
Air trapped in system
Open air vent and purge air
scoop in solar pump station
by opening the valve slowly.
Caution: after air is evacuated
fluid will flow out in a small
stream and may be hot.
Cover port with a rag to catch
any fluid.
Pump
Bearings are dry or have
excessive wear
Lubricate or replace
Impeller loose
Tighten or replace impeller
34
SYSTEM MAINTENANCE
HEAT TRANSFER FLUID (HTF) QUALITY
SOLAR PANEL CLARITY
The chemical composition of the HTF may change over
time. The HTF quality should be monitored on a periodic
basis – at least annually. After summer and before any
chance of the first freeze is an ideal time. A drop in ph can
indicate the system has been stagnating frequently. The
cause should be determined and corrected.
If you live in a dusty climate, once a month wash off dirt that
settles on the solar panel glass. Clean glass allows the solar
panel to maintain a high level of thermal performance.
EXPANSION TANK
Annually check condition of the solar expansion tank. Check
to see if it is waterlogged by quickly pressing Schrader valve
stem at bottom of the tank. You should get a quick burst of
air. If fluid is discharged, the tank may be waterlogged and
need replacement. Contact a qualified solar installer if the
tank needs replacement.
To test the pH level, use a digital ph tester or tight range
litmus paper. Remove a small sample of the fluid from the
air scoop on the pump station. The pH should be between
8.1 and 12.0. Fluid with pH between 7.5 and 8.1 can be
conditioned by your contractor using an inhibitor boost. Fluid
with pH above 12.0 or that is dark, dirty or has an acidic
smell should be replaced.
VACATION
For extended periods with no hot water usage such
as vacation it is recommend that the maximum tank
temperature (S MX) in the solar control be set to 120°F.
This maximizes the storage capacity of heat build-up during
the day using the CMX function for maximum collector
temperature and will aid in preventing breakdown of the
heat transfer fluid due to overheating.
PIPING AND EXTERNAL INSULATION
On an annual basis, all piping should be checked for leakage
at joints, and unions. Any damaged external insulation
should be repaired or replaced.
WIRING AND CONNECTIONS
On an annual basis, check wiring and connections, including
sensor wiring and splices. Look for signs of overheating,
discoloration, corrosion or loose connections. Any damaged
wiring should be repaired or replaced.
EMERGENCY SHUTDOWN
For a Emergency system shut down both the power to the
unit and the pump station shall be disconnected. In addition
the pump station has two ball valves located as shown below
that must be turned to the 90° position to shut off the flow
through the collector. See Figure 36. The inlet water shut-off
to the unit itself shall also be closed. This will isolate any
electricity or fluids from entering the unit.
FLUID LEAKS
If you detect a glycol or water leak, or the glycol loop
pressure drops unexpectedly, contact your installation
contractor immediately to diagnose the problem and
recharge the system.
Figure 36.
35
REPAIR PARTS
REPAIR PARTS SCHEDULE
ORDERING REPAIR PARTS
The following parts may be ordered through the store or dealer from whom you purchased the solar water heater, or direct
from the factory listed on the model & rating plate located on the lower front of the solar water heater and by phone at
1-800-433-2545. Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be
billed accordingly. When ordering repair parts always give the following information: (1) Part description, (2) Model serial
number, (3) Element wattage, (4) Voltage, (5) Part number.
ITEM
PART DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
Primary Anode
Element w/Gasket
Thermostat Bracket
Thermostat w/Hi Limit
Terminal Cover
Access Panel
Sensor Mounting Plug
Dip Tube with Diffuser
T&P Valve
Heat Trap Nipple
Drain Valve
Tank Temperature Sensor (Not Pictured)
Water Tempering (Mixing) Valve (Not
Pictured)
Temperature Sensor Control Wire Assy
75’ Roll (Not Pictured)
Propylene Glycol HTF (DOWFROST)
5 Gallon (Not Pictured)
Air Vent (Not Pictured)
Solar Loop Expansion Tank (Not Pictured)
13
14
15
16
17
SERVICE
PART #
ITEM
9006914005
9003950115
9003898215
9007623015
9003914015
9003900005
9007309005
9002549005
9000728015
9003915015
9003906015
9007462015
18
19
20
21
22
23
24
25
26
27
28
9007448005
29
9007449005
30
9007645005
31
9007451005
9007456005
36
PART DESCRIPTION
Roof Flashing w/Cap (Not Pictured)
Roof Flashing w/Cap and Gooseneck
(Not Pictured)
Temperature Gauge-Supply (Red)
Temperature Gauge-Return (Blue)
Pressure Gauge
Resol BS3 Controller
Flowmeter
Wilo Star S 16-U-15 Pump w/Seal Kit
Pressure Relief Valve
Sealing Cap
Collector Temperature Sensor (Not
Pictured)
Chromagen CR110 AP Solar Collector
(Not Pictured)
Chromagen CR130 AP Solar Collector
(Not Pictured)
Chromagen CR140 AP Solar Collector
(Not Pictured)
SERVICE
PART #
9007646005
9007647005
9007452005
9007453005
9007454005
9007458005
9007459005
9007455005
9007460005
9007792015
9007461015
9007447005
9007712005
9007724005
DOWFROST HEAT TRANSFER FLUID
Potential Health Effects
Eye Contact: May cause slight temporary eye irritation. Corneal injury is unlikely.
Skin Contact: Prolonged contact is essentially nonirritating to skin. Repeated contact may cause flaking and softening of skin.
Skin Absorption: Prolonged skin contact is unlikely to result in absorption of harmful amounts.
Inhalation: At room temperature, exposure to vapor is minimal due to low volatility. Mist may cause irritation of upper respiratory tract (nose and throat).
Ingestion: Very low toxicity if swallowed. Harmful effects not anticipated from swallowing small amounts.
Effects of Repeated Exposure: In rare cases, repeated excessive exposure to propylene glycol may cause central nervous system effects.
Component
Propylene glycol
Dipotassium hydrogen phosphate
Deionized water
CAS
57-55-6
7758-11-4
7732-18-5
# Amount
> 95.0 %
< 3.0 %
< 3.0 %
First-aid measures
Eye Contact: Flush eyes thoroughly with water for several minutes. Remove contact lenses after the initial 1-2 minutes and continue flushing for several additional minutes. If effects occur, consult a physician, preferably an ophthalmologist.
Skin Contact: Wash skin with plenty of water.
Inhalation: Move person to fresh air; if effects occur, consult a physician.
Ingestion: No emergency medical treatment necessary.
Notes to Physician: No specific antidote. Treatment of exposure should be directed at the control of symptoms and the clinical condition of the patient.
Accidental Release Measures
Steps to be Taken if Material is Released or Spilled: Small spills: Absorb with materials such as: Cat litter. Sawdust. Vermiculite. Zorb-all®. Collect in suitable and properly labeled containers. Large spills: Dike area to contain spill. Recover spilled material if possible.
Handling and Storage
Handling
General Handling: No special precautions required. Keep container closed. Spills of these organic materials on hot fibrous insulations may lead to lowering of the autoignition temperatures possibly resulting in spontaneous combustion. See Section 8, EXPOSURE CONTROLS AND PERSONAL PROTECTION.
Storage
Do not store in: Galvanized steel. Opened or unlabeled containers. Store in original unopened container.
Exposure Controls / Personal Protection
Exposure Limits
Component List Type Value
Propylene glycol
Personal Protection
Eye/Face Protection: Use safety glasses.
Skin Protection: Wear clean, body-covering clothing.
Hand protection: Use gloves chemically resistant to this material when prolonged or frequently repeated contact could occur. Examples of preferred glove barrier materials include: Butyl rubber. Natural rubber ("latex"). Neoprene. Nitrile/butadiene rubber ("nitrile" or "NBR").
Respiratory Protection: Respiratory protection should be worn when there is a potential to exceed the exposure limit requirements or guidelines. If there are no applicable exposure limit requirements or guidelines, wear respiratory protection when adverse effects, such as respiratory irritation or discomfort have been experienced, or
where indicated by your risk assessment process.
Physical and Chemical Properties
Physical State Liquid
Color Colorless
Odor Characteristic
Flash Point - Closed Cup 104 °C (219 °F) Pensky-Martens Closed Cup ASTM D 93 (based on major component), Propylene glycol
Flammable Limits In Air Lower: 2.6 %(V) Literature Propylene glycol
Upper: 12.5 %(V) Literature Propylene glycol
Autoignition Temperature 371 °C (700 °F) Literature Propylene glycol
Vapor Pressure 2.2 mmHg Literature
Boiling Point (760 mmHg) 152 °C (306 °F) Literature .
Vapor Density (air = 1) >1.0 Literature
Specific Gravity (H2O = 1) 1.05 20 °C/20 °C Literature
Freezing Point supercools
Melting Point Not applicable to liquids
Solubility in Water (by weight)
100 % Literature
pH 10.0 Literature
Kinematic Viscosity 43.4 cSt @ 20 °C Literature
Disposal Considerations
DO NOT DUMP INTO ANY SEWERS, ON THE GROUND, OR INTO ANY BODY OF WATER. All disposal practices must be in compliance with all Federal, State/Provincial and local laws and regulations. Regulations may vary in different locations. Waste characterizations and compliance with applicable laws are the responsibility solely
of the waste generator.
Regulatory Information
OSHA Hazard Communication Standard
This product is not a "Hazardous Chemical" as defined by the OSHA Hazard Communication Standard, 29
CFR 1910.1200.
Superfund Amendments and Reauthorization Act of 1986 Title III (Emergency Planning and Community Right-to-Know Act of 1986) Sections 311 and 312
Immediate (Acute) Health Hazard
No
Delayed (Chronic) Health Hazard
No
Fire Hazard
No
Reactive Hazard
No
Sudden Release of Pressure Hazard
No
37
NOTES
38
NOTES
39
40
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