322148

322148
Instruction Manual
SOLAR WATER HEATING SYSTEMS
WITH SINGLE WALL HEAT EXCHANGER
AND GAS BACKUP
FOR POTABLE WATER HEATING ONLY
Low Lead Content
Canadian Standards Association
1
®
Solar Collector
SRCC OG-100
®
Solar Water Heating System
SRCC OG-300
Read and understand this instruction
manual and safety messages before
installing, operating, or servicing this
pump station.
Failure to follow these instructions
and safety messages could result in
death or serious injury.
This manual must remain with the
pump station.
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.
1011322148-000
1
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 injury or death.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result
in minor or moderate injury.
CAUTION
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
CAUTION
Improper installation, use and service may result
in property damage.
Read and understand this instruction
manual and safety messages before
installing, operating, or servicing this
pump station.
Failure to follow these instructions
and safety messages could result in
death or serious injury.
This manual must remain with the
pump station.
•
•
•
•
•
Do not operate water heater if flood damaged.
Inspect the anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
WARNING
Electrical Shock Hazard
Explosion Hazard
Overheated water can cause
water tank explosion.
• Before removing any access panels or
servicing the water heater, make sure
the electrical supply to the water
heater is turned off.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
• Failure to do this could result in death,
serious bodily injury, or property
damage.
DANGER
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the physically
or mentally disabled are at highest risk
for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as
mixing valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
Fire Hazard / Electric Shock Hazard
• DO NOT USE THIS PUMP STATION
WITH ANY VOLTAGE OTHER THAN
SHOWN ON THE MODEL RATING
PLATE.
•
FAILURE TO USE THE CORRECT
VOLTAGE SHOWN ON THE MODEL
RATING PLATE COULD RESULT IN
DEATH, SERIOUS BODILY INJURY, OR
PROPERTY DAMAGE.
3
INTRODUCTION
Thank You for purchasing this water heating system.
Properly installed and maintained, it should give you years
of trouble free service.
2. 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.
Abbreviations Found In This Instruction Manual:
•
•
•
•
•
•
•
ANSI - American National Standards Institute
ASME - American Society of Mechanical Engineers
CSA - Canadian Standards Association
NEC - National Electrical Code
NFPA - National Fire Protection Association
SRCC - Solar Rating and Certification Corp.
UL - Underwriters Laboratories Inc.
3. The installation must conform to all instructions
contained in this manual and the local code authority
having jurisdiction. These shall be carefully followed
in all cases. Authorities having jurisdiction should be
consulted before installation begins if there are any
questions regarding compliance with local, state or
national codes.
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.
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.
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.
The auxiliary or back-up gas-heating guarantees hot water
even under poor solar conditions (at night or when very
cloudy). The minimum acceptable temperature set-point is
specified in local plumbing codes.
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.
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.
In the absence of local codes, the installation must
comply with the current editions of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and the National
Electrical Code, NFPA 70 or CAN/CSA-B149.1, the
Natural Gas and Propane Installation Code and CSA
C22.1, the Canadian Electrical Code. All documents
are available from CSA, 8501 East Pleasant Valley
Road, Cleveland, OH 44131. NFPA documents are also
available from the National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269.
4. 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.
5. 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.
6. Examine the location to ensure the water heater
complies with the “Facts to Consider About the
Location” section in this manual.
7. 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.
8. 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.
Preparing for the Installation
9. The solar energy system described by this manual,
when properly installed and maintained, meets the
OG-100 and OG-300 standards established by the
SRCC. This certification does not imply endorsement
or warranty of this product by SRCC.
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.
4
TABLE OF CONTENTS
Collector Piping��������������������������������������������������������� 20
Collector Piping Detail����������������������������������������������� 21
Sensor Mounting at Collector������������������������������������ 21
Piping through the Roof��������������������������������������������� 21
Pipe Insulation����������������������������������������������������������� 21
PUMP STATION INSTALLATION���������������������������������� 22
Pump Station������������������������������������������������������������� 22
Safety Instructions����������������������������������������������������� 22
Safety Equipment������������������������������������������������������ 23
Wall Mounting the Solar Pump Station���������������������� 23
Plumbing Configuration��������������������������������������������� 24
Function��������������������������������������������������������������������� 24
Flowmeter������������������������������������������������������������������ 25
Start-up & Operation - Solar Pump Station��������������� 25
Leak Detection����������������������������������������������������������� 25
Flushing��������������������������������������������������������������������� 25
Preparation of the Heat Transfer Fluid���������������������� 26
Filling the Solar Loop������������������������������������������������� 26
Draining the Solar Loop��������������������������������������������� 27
PUMP STATION CONTROL INSTRUCTIONS�������������� 28
Control Instructions���������������������������������������������������� 28
System Description���������������������������������������������������� 28
Operation and Function��������������������������������������������� 29
Start-UP / System Settings���������������������������������������� 30
TROUBLESHOOTING�������������������������������������������������� 35
SYSTEM MAINTENANCE��������������������������������������������� 38
System Checkpoint���������������������������������������������������� 38
Heat Transfer Fluid (HTF) Quality����������������������������� 38
Piping and External Insulation����������������������������������� 38
Wiring and Connections�������������������������������������������� 38
Fluid Leaks���������������������������������������������������������������� 38
Solar Panel Clarity����������������������������������������������������� 38
Expansion Tank��������������������������������������������������������� 38
Vacation��������������������������������������������������������������������� 38
Emergency Shutdown����������������������������������������������� 38
REPAIR PARTS������������������������������������������������������������� 39
Repair Parts Schedule����������������������������������������������� 39
Dowfrost Heat Transfer Fluid Properties������������������� 40
WARRANTY / MODELS / SOLAR RATING....Insert Sheet
SAFE INSTALLATION, USE AND SERVICE������������������ 2
IMPORTANT DEFINITIONS���������������������������������������� 2
GENERAL SAFETY�������������������������������������������������������� 3
INTRODUCTION������������������������������������������������������������� 4
System Description������������������������������������������������������ 4
Preparing for the Installation���������������������������������������� 4
TABLE OF CONTENTS��������������������������������������������������� 5
SYSTEM DIAGRAM / TYPICAL INSTALLATION������������ 6
SYSTEM COMPONENT PARTS������������������������������������� 7
STORAGE TANK INSTALLATION����������������������������������� 7
Local Codes����������������������������������������������������������������� 7
Temperature-Pressure Relief Valve����������������������������� 7
Closed System / thermal expansion���������������������������� 8
Locating the Solar Water Heater��������������������������������� 8
Water Piping���������������������������������������������������������������� 8
Mixing Valves��������������������������������������������������������������� 9
Installation in Residential Garages������������������������������ 9
Venting Installation ��������������������������������������������������� 10
Filling the Solar Water Heater with Water������������������ 10
Condensate Drain������������������������������������������������������ 10
Gas Supply���������������������������������������������������������������� 10
Electrical Wiring��������������������������������������������������������� 10
Power Supply������������������������������������������������������������ 10
Thermostat���������������������������������������������������������������� 10
Polarity Sensitive��������������������������������������������������������11
Temperature Regulation���������������������������������������������11
Temperature Settings�������������������������������������������������11
Temperature Adjustment���������������������������������������������11
High Temperature Limit Control (ECO)���������������������� 12
Tank Sensor��������������������������������������������������������������� 12
Draining and Flushing������������������������������������������������ 12
Powered Anode Rods������������������������������������������������ 13
SOLAR COLLECTOR INSTALLATION������������������������� 14
Collector Location������������������������������������������������������ 14
General considerations���������������������������������������������� 14
Collector Orientation�������������������������������������������������� 14
Spanner Mounting����������������������������������������������������� 16
Attaching collector to mounting brackets������������������� 19
5
SYSTEM DIAGRAM / TYPICAL INSTALLATION
10
6
1
1
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A CLOSED
WATER SYSTEM
VACUUM RELIEF
VALVE
INSTALL PER
LOCAL CODES
COLD
WATER
INLET
TEMPERED
WATER OUTLET
11
8
UNTEMPERED
WATER OUTLET
(OPTIONAL)
NOTE: SEE SYSTEM COMPONENT
TABLE FOR DESCRIPTIONS
SOLAR CONTROLLER
TEMPERATURE
WIRES
5
4
9
2
3
DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
10
7
6” (15 cm)
MAXIMUM
AIR GAP
METAL
DRAIN
PAN
INSTALL VACUUM RELIEF
IN COLD WATER INLET
LINE AS REQUIRED BY
LOCAL CODES.
12
INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER
HEATER IS INSTALLED IN A
CLOSED WATER SYSTEM.
Figure 1.
6
AT LEAST 2” (2.5 cm)
GREATER THAN THE
DIAMETER OF THE
WATER HEATER
6” (15 cm)
MAXIMUM
AIR GAP
PIPED TO AN
ADEQUATE
DRAIN
INSTALL SUITABLE METAL DRAIN
PANS UNDER HEATERS TO PREVENT
DAMAGE DUE TO LEAKAGE. REFER
TO WATER HEATER LOCATION, see
“Locating the Solar Water
Heater” on page 8.
SYSTEM COMPONENT PARTS
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 gas
back-up.
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 (REQUIRED)
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 the pump station installation section.
10
SOLAR TANK/COLLECTOR
TEMPERATURE SENSORS
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.
12
LOWER TANK TEMPERATURE
PROBE
1 of 2 temperature probes. The water heater’s direct control system
monitors this probe to detect water temperature in the lower portion
of the storage tank.
Table 1.
STORAGE TANK INSTALLATION
NOTE: Refer to the installation manual supplied with
the Solar Storage Tank for more detailed instructions
concerning its installation. This section is only meant to
provide a brief overview regarding its installation with the
solar system.
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
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 editions of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and
the National Electric Code NFPA 70 or CAN/CSA-B149.1.
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 PSI).
Install the temperature-pressure relief valve directly into the
fitting of the water heater. Position the valve downward and
The Discharge Pipe:
•
•
•
•
7
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.
• 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. The solar water heater must not be located in an area
where it will be subjected to freezing temperatures.
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.
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 water heater
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.
7. Locate the solar water heater close to a 120 VAC
power supply.
8. Locate the solar water heater where an adequate
supply of fresh air for combustion and ventilation can
be obtained.
9. Locate the solar water heater where the vent and air
intake piping, when installed, will remain within the
maximum equivalent lengths allowed.
10.Do not locate the solar water heater where noise (such
as the Combustion Blower) during normal operation
will objectionable in adjacent areas.
11.Do not locate the solar water heater where the
subsequent installation of the vent (exhaust) or intake
air terminations would be objectionable due to noise at
the termination(s). This includes locations close to or
across from windows and doors.
12.Combustible materials used in solar equipment and
adjacent structures shall not be exposed to an elevated
temperature that could cause ignition.
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.
Closed System / thermal expansion
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 in accordance with
ASHRAE recommendations 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.
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.
Locating the Solar Water Heater
Water Piping
If you have a choice of where to install the solar water heater,
these ideas may help you decide.
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.
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
DANGER
MIXED
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
HOT
Children, the elderly and the physically
or mentally disabled are at highest risk
for scald injury.
COLD
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.
Feel water before bathing or showering.
Temperature limiting devices such as
mixing valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
The illustration shows the correct valves and fittings that
you will need to install the solar water heater. Threaded (11/2 NPT) water connections are supplied through the tank.
The thermostatic mixing valve provided with the system
has 1” sweat (solder) connections.
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.
TEMPERED WATER
OUTLET
COLD WATER
INLET
UNTEMPERED
WATER
OUTLET
(OPTIONAL)
No other fluids shall be used that would change the original
classification of this system. Unauthorized alterations to
this system could result in a hazardous health condition.
This solar water heater shall not be connected to any
heating systems or component(s) previously used with a
non-potable water heating appliance.
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.
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.
This appliance has been design certified as a solar water
heater complying with the latest editions of the American
National Standard ANSI Z21.10.3 and CSA Standard CSA
4.3.
2. Apply a light covering of pipe joint compound to each
outside thread before making connection.
Toxic chemicals such as used for treatment of boilers
or non-potable water heating appliances shall never be
introduced into a potable water space heating system.
3. Connect the cold water supply pipe to the cold water
inlet of your solar water heater as follows:
• The cold water supply connection is located on the
lower front of the solar water heater and the hot water
outlet connection is located on the top cover.
• The cold water supply line must have a shut-off valve
and union. See Figure 4.
Operating an empty or partially filled solar water heater will
result in damage to the tank.
Mixing Valves
THE THERMOSTATIC MIXING
VALVE PROVIDED WITH THE
SYSTEM MUST BE INSTALLED
TO PREVENT SCALDING FROM
HIGH WATER TEMPERATURES
ACHIEVED BY SOLAR HEATING.
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 such as an expansion tank shall be provided to
control thermal expansion. Contact the water supplier or
local plumbing contractor on how to control this situation.
A mixing valve is supplied with this solar system. Water
temperature above 120°F(49°C) can cause serious
injury. The mixing valve should be installed and adjusted
by a licensed contractor in accordance with local codes
and ordinances. Follow mixing valve manufacturer’s
instructions for installation and use of the valves.
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.
9
Venting Installation
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
label.
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with codes.
• Do not operate water heater if flood damaged.
• Special consideration must be taken with installations
Excessive gas pressure to gas valve can
cause serious injury or death.
above 10,000 feet (3,048 m) refer to high altitude
section of this manual.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
• Do not operate if soot buildup.
• Do not obstruct water heater air intake with insulating
jacket or blanket.
• Do not place chemical vapor emitting products near
Make sure the gas supplied is the same type listed on the
solar water heater’s rating label.
The solar water heaters covered in this manual are not
intended for operation at higher than 10.5” W. C. (2.62 kPa)
for natural gas and 14.0” W. C. (3.49 kPa) for propane gas
supply pressure. Exposure to higher gas supply pressures
may cause damage to the gas controls which could result
in fire or explosion.
Refer to the Supply Gas Line and Installation sections of
the installation manual supplied with the solar water heater
for more details on the proper installation, sizing, and
operational requirements of the supply gas.
water heater.
• Gas and carbon monoxide detectors are available.
• Never operate the heater unless it is vented to the
outdoors and has adequate air supply to avoid risks
of improper operation, fire, explosion or asphyxiation.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand the instruction manual.
Electrical Wiring
Never operate the solar water heater unless it is vented
to the outdoors. For safe operation an adequate supply of
fresh uncontaminated air for combustion and ventilation
must be provided
Refer to the “Air Requirements” and “Venting Installation”
sections of the solar water heater installation manual for
the proper air and venting requirements of the solar water
heaters covered by this manual.
All electrical work must be installed in accordance with the
National Electrical Code, ANSI/NFPA 70 or the Canadian
Electrical Code, CSA C22.1 and local requirements.
When installed, the solar water heater must be electrically
grounded in accordance with local codes or, in the absence
of local codes, with the National Electrical Code, ANSI/NFPA
70 or the Canadian Electrical Code, CSA C22.1.
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.
4. Check all the new water piping for leaks. Fix as needed.
If any of the original wire as supplied with the water heater
must be replaced, it must be replaced with 105°C rated
wiring or its equivalent, except in the burner housing. In
this case use 200°C rated wire.
Power Supply
The solar water heater covered in this manual requires a
120VAC, single phase, 60Hz, 15 amp power supply and
must also be electrically grounded in accordance with local
codes or, in the absence of local codes, with the National
Electrical Code, ANSI/NFPA 70 or the Canadian Electrical
Code, CSA C22.1.
Condensate Drain
The solar water heaters covered in this manual are
condensing appliances and require a building drain to be
located in close proximity to allow the condensate to drain
freely. Installation must conform with these instructions
and local building codes. Ensure the condensate drain
is properly connected to the exhaust elbow on the water
heater and draining freely to a suitable floor drain. Refer
to the “Condensate Drain Installation” sections of the solar
water heater installation manual.
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.
Gas Supply
Contact your local gas utility company to ensure that
adequate gas service is available and to review applicable
installation codes for your area.
10
Polarity Sensitive
Temperature Settings
The solar water heater’s control system is polarity sensitive
and will lock out and disable the gas heating operation if the
polarity of the power supply is reversed. The control system
will display the “AC Reversed” Fault message on the LCD.
The 120 VAC hot wire from the power supply must connect
to the black wire in the solar water heater’s junction box
and 120 VAC neutral wire must connect to the white wire
in the junction box for correct polarity.
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 , the solar storage tank manual, and on the solar
water heater before proceeding.
Water
Temperature °F
NOTE: Do not apply power to the solar water heater before
installation is complete and the solar water heater is filled
with water.
Temperature Regulation
Time for
Time for 1st Degree
Permanent Burns
Burn
2nd & 3rd Degree
(Less Severe Burns)
(Most Severe Burns)
110
(normal shower temp.)
116
(pain threshold)
116
35 minutes
45 minutes
122
1 minute
5 minutes
131
5 seconds
25 seconds
140
2 seconds
5 seconds
149
1 second
2 seconds
154
instantaneous
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)
Table 2.
Temperature Adjustment
The solar water heater covered in this manual is equipped
with an electronic control system to regulate the water
temperature. The “Operating Set Point” is adjusted to
regulate the water temperature inside the storage tank.
This is an adjustable user setting in the control system’s
“Temperatures” Menu.: This and all control system menus
are accessed through the UIM (user interface module)
located on the front of the solar water heater.
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 5 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.
The Operating Set Point is adjustable from 90°F (42°C) to
140°F (60°C). The factory setting is 120°F (49°F). See the
“Operating Set Point and Differential Adjustment” section in
the solar water heater installation manual on how to adjust
the Operating Set Point and other user settings.
Set the Operating Set Point at the lowest setting which
produces an acceptable hot water supply. This will always
provide the most energy efficient operation.
MANUFACTURER / MODEL INFORMATION
Tank Temperature
Operating Set Point
103°F
120°F
Status: Heating
OFF
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.
DN
GAS O
N
MENU
HELP
Figure 5.
11
UP
High Temperature Limit Control (ECO)
This solar water heater is equipped with an ECO (energy
cut out) non adjustable high temperature limit switch. The
ECO switch contacts will open when the water temperature
reaches approximately 202°F (94°C) and close at
approximately 140°F (49°C).
If the ECO activates (contacts open) due to abnormally high
water temperatures in the solar storage tank the control
system will “lock-out” and will display the “Energy Cut Out”
(ECO) fault message on the LCD screen. It is important that
a Qualified Service Agent be contacted to determine the
reason for the ECO activation before resetting the ECO.
Once the reason has been determined and corrected the
ECO can be reset per the “High Temperature Limit Control
(ECO)” section of the solar water heater installation manual.
3. Ensure the cold water inlet valve is open.
Tank Sensor
10.If the solar water heater is going to be shut down for an
extended period, the drain valve should be left open.
4. Open a nearby hot water faucet and let the water run
until the water is no longer hot.
5. Connect a hose to the solar water heater drain valve
and terminate it to an adequate drain.
6. Close the cold water inlet valve.
7. Open the water heater drain valve and allow all the
water to drain from the storage tank.
8. Close the water heater drain valve when all water in
the storage tank has drained.
9. Close the hot water faucet opened in Step 4.
The solar surface mount tank temperature sensor (installed)
is located on the lower front of the solar water heater. The
connection leads of the sensor extend out from the top cover
and shall be connected to the controller in the tank sensor
position by means of the use of sensor extension wires.
To Flush the tank perform the following steps:
1. Turn off the electrical supply to the solar water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run
until the water is no longer hot. Then close the hot
water faucet.
Draining and Flushing
It is recommended that the solar water heater storage tank
be drained and flushed every 6 months to reduce sediment
buildup. The solar water heater should be drained if being
shut down during freezing temperatures. See the Features
and Components section for the location of the solar water
heater components described below.
4. Connect a hose to the drain valve and terminate it to
an adequate drain.
5. Ensure the drain hose is secured before and during
the entire flushing procedure. Flushing is performed
with system water pressure applied to the solar water
heater.
Burn harzard.
6. Open the solar water heater drain valve to flush the
storage tank.
Hot water discharge.
7. Flush the solar water heater storage tank to remove
sediment and allow the water to flow until it runs clean.
Keep hands clear of drain
valve discharge.
8. Close the solar water heater drain valve when flushing
is completed.
9. Remove the drain hose.
10.Fill the solar water heater - see Filling the Solar Water
Heater section.
To drain the solar water heater storage tank:
1. Turn off the electrical supply to the solar water heater.
11.Turn on the electrical supply to place the solar water
heater back in operation.
2. Turn off the gas supply at the Main Gas Shutoff Valve
if the solar water heater is going to be shut down for an
extended period.
12.Allow the solar water heater to complete several
heating cycles to ensure it is operating properly.
12
Powered Anode Rods
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.
To insure a long, trouble-free operating life, the solar
water heaters covered in this manual are factory equipped
with a powered anode system. The anode rods (2) are
of a permanent design and do not need replacing unless
damaged. Inspection and cleaning should be performed
once a year.
Note: Follow the instructions to drain the solar water heater
storage tank first. Remove the powered anodes from the
solar water heater by loosening the 3/4” NPT bushing
that forms the top of the anodes. Do not disassemble the
retaining nut and wire terminal from the top while installed
in the solar water heater, the anode’s electrode may fall
inside the tank. Remove the entire anode rod from the
water heater prior to inspection. Clean the anode rods with
a soft cloth and reinstall.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
13
SOLAR COLLECTOR INSTALLATION
Collector Location
location plus 10°. 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 6 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.
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
Figure 6.
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 10°.
This 10° 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 7 and Table 3.
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.
If a collector must be installed horizontally, replace the
upper vent with a rubber plug in order to prevent rain
penetration. See Figure 8 & Figure 9.
14
COLLECTOR TILT
48”
A”
Figure 7.
LATITUDE
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°
COLLECTOR TILT
ROOF
ANGLE
&
PITCH
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)
UNPLUGGED VENT HOLE
PLUGGED VENT HOLE
Figure 8.
Figure 9.
15
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 14.
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.
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
13.
1. After locating the mounting points from Figure 10 for
vertical collector mounting, Figure 11 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 13.
2. Insert the flashing (not included with Standard Systems)
so the top part is under the next row of shingles and the
flashing hole/grommet aligns with the mounting hole.
See Figure 12.
3. The compression bracket washer (not included with
Standard Systems) is positioned over the flashing seal
with the concave side towards the seal. See Figure 13.
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 (approximately. 97 inch pounds). Be careful not to
overtighten and dish out the roof tiles underneath the
mounting bracket.
Repeat steps 2 - 8 for the remainder of the mounting
bracket locations.
4. The mounting bracket is then placed on the compression
bracket washer (not included with Standard Systems).
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 flat washer or EPDM bonded washer
(not included with Standard Systems) secures the allthread to the mounting bracket. The all-thread should
extend about 4” below the roof rafters.
16
DRILL POINTS
(CLEARANCE HOLE
for 5/16” BOLT)
B”
C”
B”
MOUNTING
BRACKETS
C”
A”
RAFTER
RAFTER
D” BASED ON 16” (40.64 cm) CENTER RAFTERS
VERTICAL MOUNTING
Figure 10.
DRILL POINTS
(CLEARANCE HOLE
for 5/16” BOLT)
B”
C”
B”
A”
C”
RAFTER
D”
BASED ON 16” (40.64 cm) CENTER RAFTERS
MOUNTING
BRACKET
RAFTER
RAFTER
HORIZONTAL MOUNTING
Figure 11.
17
Flashing
Bushing
NOTICE
* 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 12.
(Not Included with Standard Systems)
Table 4.
STAINLESS STEEL NUT, ALL THREAD ROD,
LOCK WASHER, & FLAT WASHER OR
*EPDM BONDED WASHER
*CP COMPRESSION
BRACKET WASHER
SHINGLES
4” MOUNTING BRACKET
*FLASHING
PLYWOOD
SHEETING
ROOF
RAFTER
DECKING/WOOD
SCREWS
Flashing
ROOF
RAFTER
SPACER
BLOCK
FENDER WASHER
LOCK WASHER
NUT
* NOT INCUDED WITH STANDARD SYSTEMS
WOOD SPANNER
(2” x 4” or 2” x 6” LUMBER)
Figure 13.
18
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 14 for these instructions.
The 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.
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 14.
* Not included with Standard Systems.
19
Collector Piping
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.
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 1” copper caps while on the ground. Refer to
Figure 15 and Figure 16 for typical horizontal and vertical
collector piping layouts. These typical piping layouts are
designed to maintain the proper fluid flow rate through
each collector.
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.
2
1
COLLECTOR HORIZONTAL CONFIGURATION REVERSE RETURN PIPING
PIPE CAPS
TO PUMP
STATION
FROM PUMP
STATION
1
INSTALL TEMPERATURE SENSOR AT OUTLET FROM
LAST COLLECTOR IN THE ARRAY
2
INSTALL AIR VENT OUTLET FROM COLLECTOR ARRAY
AT HIGHEST POINT IN THE SOLAR LOOP PIPING
Internal piping detail of solar collectors. Parallel tube (harp)
internal piping with one inch manifolds at each end.
Figure 15.
2
1
TO PUMP
STATION
COLLECTOR VERTICAL CONFIGURATION PIPING
PIPE CAPS
FROM PUMP
STATION
1
INSTALL TEMPERATURE SENSOR AT OUTLET FROM
LAST COLLECTOR IN THE ARRAY
2
INSTALL AIR VENT OUTLET FROM COLLECTOR ARRAY
AT HIGHEST POINT IN THE SOLAR LOOP PIPING
Figure 16.
20
Collector Piping Detail
The outlets of the collector are 1” copper pipe nipples. See
Figure 17. They should be piped as shown with provisions
for an air vent and air vent isolation valve. 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.
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
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 17. 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.
AIR VENT
TEMPERATURE
SENSOR
SENSOR WIRE
(to COLLECTOR)
1” COPPER
SOLAR
PIPE
COLLECTOR
HEADER
ISOLATION
VALVE
Figure 18.
PIPE
ADAPTER
Pipe Insulation
The collector loop piping (exterior and interior) must be well
insulated with high temperature resistant (300°F/149°C)
good quality flexible EPDM closed cell insulation to
minimize heat loss. The recommended insulation is
Armacell UT Solaflex or equivalent. 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. As part of the insulation
requirements the final 5 ft (1.52 m) of the cold water inlet
to the storage tank must be insulated.
Figure 17.
Piping through the Roof
Note: Solar piping flashing not included with Standard
Systems
Penetration of the building through which piping or
wiring is passed shall not reduce or impair the function
of the enclosure. Penetrations through the wall or other
surfaces shall not allow intrusion by insects and/or vermin.
Required roof penetrations shall be made in accordance
with applicable codes and also practices recommended by
the National Roofing Contractors Association.
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 protective oversleeving. Insulation to complete the outdoor portion of the
installation has been provided.
Piping through the roof should be weatherproofed as
shown in Figure 18. 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
21
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 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:
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.
• Relevant local and national codes
• Accident prevention regulations of the professional
association
• Instructions and safety instructions mentioned in this
manual
The solar station is a premounted valves and fittings group
checked for leakage used to circulate the solar fluid in the
solar circuit.
B
A
K
L
M E
O
C
J
N
Q
R
I
F
P
D
T
S
w
U
H
G
V
COMPONENTS
COMPONENTS
A
Premounted Solar Controller
L
Supply (collector loop)
B
Differential temperature controller
M
Pressure relief valve
C
Temperature gauge (red) with immersion sleeve for insertion
into the return ball valve
N
Connection for expansion tank
D
Front cover
O
Pressure gauge
Fill valve
E
Temperature gauge (blue) with immersion sleeve for insertion
into the supply ball valve
P
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)
W
Power Cord
Return (collector loop)
Figure 19.
22
Safety Equipment
5. After the mounting plate is secured to the wall replace
the solar pump station back cover, insert the retaining
clips half way onto the mounting retaining stud (see
Figure 21) 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 21.
Wall Mounting the Solar Pump Station
6. 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.
CONNECTION FOR
DISCHARGE LINE
1. Choose the position to install the solar pump station
next to the storage tank (noting that the tank solar
loop inlet (from collector), outlet to pump (on the right
side of the tank), and the additional height of the solar
controller section of the pump station.
FILL
PORT
2. Remove the front cover (D) of the solar station and
slide off the premounted solar controller (A).
CONNECTION FOR
EXPANSION TANK
3. 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).
Figure 22.
CONNECTION SET
WITH EXPANSION TANK
7. 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).
8. Unscrew the tank connector (Figure 23) 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.
9. 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.
Figure 20.
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.
Note: The tank connector allows you to isolate the
expansion tank from the solar circuit (Figure 22). 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.
4. Line the mounting plate up level on the wall and mark
the drill holes. (Holes will be 5-7/8” (149 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.
The expansion tank should not be connected to the system
until it has been flushed and charged.
23
Plumbing Configuration
K
1
2
1. ½” copper tube - from
the collector outlet
(top) to the collector
return compression
fitting (K)
L
2. ½” copper tube –
from the collector
inlet
(bottom)
to
the collector supply
compression fitting (L)
FLOW
CLOSED
Figure 23.
10.Check and set the pressure of the air bladder in the
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.
3
Function
Check Valves
Refer to Figure 16 and Figure 26.
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 remove the top cover
(D) take off the temperature gauges (C, E), and turn the
ball valves into the proper position using a wrench. See
Figure 26. In the 45° position the balls in the ball valves
push the check valves open.
13.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.
During operation the ball valves must be in 0° position.
 and the cutting
0°
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
copper pipe.

4. ¾” copper tube –
from the lower tank
coil outlet marked
“to pump” to the tank
return threaded fitting
(V)
4
Figure 25.
12.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)
1. Push the union nut
V
H
11.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.
3. ¾” copper tube – from
the upper tank coil
inlet marked “from
collector” to the tank
supply threaded fitting
(H)
45°
90°
into the
3. Insert the copper pipe with the pluggedon 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
Check valve is
operating, flow
only in flow
direction
compression fitting  to avoid rotation
in order to avoid damaging the sealing
ring.
Figure 24.
Check valve is not
operating, flow in
both directions.
Figure 26.
24
Ball valve
closed,
no flow.
Flowmeter
3. Turn the two isolation ball valves (J, Q) to 45° using
an appropriate wrench to allow flow in both directions.
Refer to Figure 16, Figure 20 - Figure 29.
4. Close the drain valve (T).
The flowmeter (U) serves to measure and display flow
volume of the system in a range of 0.8 - 6.0 US gpm.
5. Be sure the air vent at the collector array is closed.
6. Connect an air pressure hose to the fill valve (P) below
the pressure gauge (O) and open this valve.
It has an integrated restrictor (S) with adjustment valve
which allows fine adjustment of the flow volume of the
solar installation.
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).
In order to guarantee the flawless function of the measuring
device the installation must be flushed and free from
foreign substances.
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.
The flowmeter MUST be mounted vertically.
FLOW RESTRICTOR
Flushing
DRAIN VALVE (OPEN)
Refer to Figure 16 and Figure 26.
SCALE
OPEN CLOSED
CAUTION
Figure 27.
Figure 28.
Use a flat head screwdriver to adjust the flowmeter. Read
the flow rate from the upper edge of the floating body.
SOLAR THERMAL INSTALLATIONS CANNOT BE COMPLETELY EMPTIED
AFTER FLUSHING. THERE IS A DANGER OF FROST DAMAGE IF WATER IS
USED FOR FLUSHING. ONLY USE WATER TO FLUSH 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).
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.
Figure 29.
Start-up & Operation - Solar Pump Station
12.Turn the supply ball valve (Q) to 90° (horizontal) so that
the valve is closed.
Slide on the premounted solar controller section (if it is
not already installed on top of the pump station). Observe
the following safety instructions when starting up the solar
thermal installation:
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.
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
To prevent the solar fluid from
boiling in the collectors, the
installation should not be
flushed or filled during periods
of strong sunshine or the panels
should be covered with a
blanket to keep collectors cool.
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)
Leak Detection
Refer to Figure 16 and Figure 26.
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.
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.
2. Remove the front cover (D) of the solar pump station.
25
Preparation of the Heat Transfer Fluid
turn on the transfer pump. Repeat system pressure
setting in step 26.
Pour 100% Propylene Glycol (such as Dowfrost™) into a
large clean bucket. Add an equivalent amount of distilled
or de-mineralized water for a 50/50 solution by volume.
10.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.
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 solution provides
freeze protection down to -30° F and burst protection
down to -60° F.
Use of heat-transfer fluid other than a maximum 50/50 mix
by volume of Propylene Glycol and distilled or de-mineralized
water is not permitted. Use of any heat-transfer 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.
Figure 30.
11.Plug in the solar pump station to a 115V outlet and turn
the pump on using the MAN mode (see Pump Station
Control Instruction section). MAN setting should be set
to “ON”.
No other fluids shall be used that would change the original
classification of this system. Unauthorized alterations to this
system could result in a hazardous health condition.
12.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
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.
Filling the Solar Loop
Refer to Figure 16 and Figure 26.
1. 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.
NUMBER OF COLLECTORS
COLLECTOR
SIZE
2. Turn the return ball valve (J) to 0° (vertical) so that flow
is only allowed in the proper direction.
3. 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.
4. 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.
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.
13.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.
5. Open the air vent isolation valve and the automatic air
vent at the top of the collector array 1 - 3 turns.
6. Remove the cap from the front of the Air Scoop (I) and
open the vent with a flat head screwdriver. This will
release air 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).
14.Replace the temperature gauges (C) & (E), and the
front cover (D).
15.Set the controller to operate in automatic mode (see
Pump Station Control Instruction section).
7. 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).
16.After the system has been running for several days
close the automatic air vent and the air vent isolation
valve located at the top of the collector array.
8. 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.
9. Connect the expansion tank and verify the system
pressure. If it has dropped, open the fill valve (P) and
26
Draining the Solar Loop
Refer to Figure 16 and Figure 26.
The discharged fluid can
have very high temperatures.
Place the collecting container
so that people standing
nearby are not endangered
when the solar thermal
system is being emptied.
1. Switch off the controller by unplugging the power
supply from the outlet.
2. 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
3. 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).
5. Open the drain valve at the lowest point of the solar
thermal installation.
6. Open the air vent and air vent isolation valve at the top
of the collector array. This will serve as a vacuum break
to aid in draining.
7. Dispose of the solar fluid observing any local codes.
4. Connect a temperature resistant hose to the drain
valve with the discharge end placed in the collection
container.
ATTENTION: Upon completion of the pump station
installation and prior to 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.
27
PUMP STATION CONTROL INSTRUCTIONS
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)
Control Instructions
WARNING
Electrical Shock Hazard
• Before removing any access panels or
servicing the pump station, make sure
the electrical supply to the pump
station is turned off.
9/10 = VBus (See VBus note)
The power supply is connected to the following terminals:
• Failure to do this could result in death,
serious bodily injury, or property
damage.
19 = Neutral - N
20 = Line power - L
12 = Ground
WARNING
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:
ESD SENSITIVE
• Relay 1 (primary pump)
18 = Line power - R1
Electrostatic discharge can
lead to damage of electronic
components.
17 = Neutral - N
13 = 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.
• Relay 2 (secondary pump – optional, not included)
16 = Line power - R2
15 = Neutral - N
14 = Ground
DISPLAY
The controller is equipped with a VBus® for data transfer
with an energy supply to external modules (not included).
The connection is carried out at the terminals marked
“VBus” and is not polarity dependent.
COVER
System Description
The DeltaSol BS/4 controller is used with this solar
thermal system. The controller calculates the temperature
difference between the collector sensor S1 and the tank
temperature sensor S2. If this temperature difference
reaches the switch-on temperature difference, the solar
pump is switched on. If the temperature difference falls
below the switch-off difference the pump is switched
off. Sensors S3 and S4 can optionally be connected for
measurement purposes.
PUSHBUTTONS
CABLE CONDUITS
WITH STRAIN RELIEF
CAN FUSE 4A
Figure 31.
fuse
VBus
9 10
T4A
100 ... 240 V~
50-60 Hz
D-31789 Hameln
DeltaSol BS/4V2
S1
CU 72091163 01
S1
1
Temp . Sensor Pt1000
2
3
S2
4
S3
5
6
R1 1 (1) A 100 ... 240 V~
R2 1 (1) A 100 ... 240 V~
IP 20
S4
7
8
VBus
9 10
12 13 14
N R2 N R1 N L
15 16 17 18 19 20
R1
sensor terminal
VBus
®
ground
terminal
S3
load power supply
terminals terminals
S4 / TR
Figure 32.
S2
Figure 33.
28
Operation and Function
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 SET is indicated. To change the set value press the
Set button (3) so that SET flashes. Adjust the value using
button 1 or 2 until the desired value is shown then press
button 3 so that SET permanently appears. The adjusted
value is now saved.
OPERATION
CONTROL LAMP
BACKWARDS
FORWARDS
2
1
3
SET
(SELECTION / ADJUSTMENT MODE)
Figure 34.
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
STANDARD
FLASHING
STATUS
Relay 1 active
Relay 2 active
!
+
!
+
Maximum tank limit reached / maximum tank temperature exceeded.
Tank emergency shutdown active
Collector emergency shutdown active
Collector cooling active / System cooling active
Tank cooling active
!
Holiday cooling function active
Collector minimum limitation active
Antifreeze function activated
+
+
Antifreeze function active
!
Manual operation relay 1 ON
!
Manual operation relay 2 ON
!
Manual operation relay 1 / 2 OFF
!
Sensor defective
29
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.
TANK TOP SENSOR (OPTIONAL)
COLLECTOR SENSOR
COLLECTOR
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:
PUMP
System operation normal
Red/green blinking: Initialization phase, manual
operation
Red blinking:
TANK HEAT EXCHANGER
TANK
Sensor error
TANK BOTTOM SENSOR
Start-UP / 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. Refer to the solar controller manual supplied with the pump station for additional
system settings.
If the system layout selection is changed later on, any previous adjustments which have been made in the other
channels will be lost. Therefore, changing the system layout is always followed by a security enquiry. Only confirm the
security enquiry if you are sure you wish to change the system layout selection!
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.
COMMISSIONING MENU
LANG:
Language Selection
Selection: dE, En
Selects the units language
UNIT:
Temperature Unit Selection
Selection: °F, °C
Recommended Setting °F
Adjusts the units in which temperatures and temperature differences
are displayed
TIME:
Current Time Adjustment
Sets the current local time.
dE German
En: English
Display Channels
COL:
Collector Temperature
Display range: -40 to +500 °F
Shows the current collector temperature.
TST:
Tank temperature
Display range: -40 to +500 °F
Shows the current tank temperature (from tank bottom sensor).
30
S3, S4:
Additional sensor temperature
Display range -40 to +500 °F
Shows the current temperature of the corresponding optional sensor
(without control function).
TR:
Temperature return flow
Display range -40 to +500 °F
Shows the current temperature of the optional temperature return flow
sensor (S4) when the heat quantity measurement option is activated.
n%:
Current pump speed
Display range 30 - 100%
Indicates the current solar pump speed.
kWh/MWh:
Heat Quantity in kWh/MWh
Display channel
Indicates the energy gained in heat quantity – only available if energy
metering (OHQM) is activated.
S3 and S4 are only indicated if extra temperature sensors (not
included) are connected.
The flow rate as well as the reference sensors S1 (flow) and S4
(return) are used for calculating the heat quantity supplied. It is
shown in kWh in the channel kWh and in MWh in the channel MWh.
The overall heat quantity results from the sum of both values.
The accumulated heat quantity can be set back to 0. As soon as
one of the display channels of the heat quantity is selected, the SET
symbol is permanently shown on the display.
Press button 3 for about 2 seconds in order to access the RESET
mode of the counter.
The display symbol
set to 0.
SET
will flash and the heat quantity value will be
In order to finish this process, press button 3 to confirm. In order to
interrupt the RESET-process, do not press a button for about five
seconds. The display returns to the display mode..
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.
The total operating hours can be reset. When the operating hours
channel is selected the symbol SET 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 SET 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.
ADJUSTMENT CHANNELS
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.
31
DTF:
Switch-off temperature diff.
Adjustment range
1.0 - 39.0 °F
Recommended setting: 4.0
If the switch-off temperature, DT F, is reached the pump is deactivated.
DT S:
Nominal Temperature Diff.
Adjustment Range:
3.0 - 60°F
Recommended setting:
14.0°F
For pump speed control, the operation mode of relay 1 must be set
to Auto.
RIS:
Switch-on temperature diff.
Adjustment range
2.0 - 40.0°F
Recommended setting: 4°F
If the temperature difference reaches the adjusted nominal
temperature difference, the pump speed increases by one step (10
%). If the difference increases by the adjustable rise value, the pump
speed increases by 10 % respectively until the maximum pump
speed of 100 % is reached.
nMN:
Pump Speed Control
Adjustment Range:
30 - 100% In steps of 5%
Recommended Setting: 40%
A relative minimum pump speed can be allocated to the output R1 via
the adjustment channel nMN.
SMX:
Maximum tank temperature
Adjustment range:
40 - 200°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 switch-off temperature must be at least 2 degrees lower
than the switch-on temperature.
When the switch-on temperature difference is reached, the pump is
activated at full speed for 10 seconds. Then, the speed is reduced to
the minimum pump speed value.
Note: The controller will only allow the tank temperature to exceed
the maximum tank temperature setting when the optional system
cooling function (OCC) is active and the maximum collector temp
(OCC) 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 200°F and no further heating will be
done.
If the maximum tank temperature setting is exceeded the
will be shown on the display.
EM:
Collector temperature limit
Adjustment range:
170 - 390°F
symbol
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).
If the collector temperature limit setting is exceeded the
! symbol will be shown flashing on the display.
Recommended setting: 260 °F
OCC:
Collector cooling
Adjustment: OFF / ON
Recommended setting: ON
CMX:
Maximum collector temp.
Adjustment range:
150 - 320°F
Recommended setting: 220°F
Channel only available when
OCC is active
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 200°F.
When the system is actively cooling the collectors (CMX exceeded)
the symbol will be shown flashing on the display.
32
OSTC:
Tank cooling option
Adjustment Range: OFF/ON
Recommended Setting: ON
OHOL:
Holiday cooling option
Adjustment Range: OFF/ON
Recommended Setting: OFF
THOL:
Holiday cooling temperature
Adjustment Range: 70 - 175°F
in steps of 1°F
Recommended Setting: 120°F
OCN:
Minimum collector limit
Adjustment: OFF / ON
Recommended setting: OFF
CMN:
Minimum collector temp.
Adjustment range:
50 - 190°F
Recommended setting: 50 °F
Channel only available when
OCN is active
OCF:
Antifreeze function
Adjustment: OFF / ON
Recommended setting: OFF
CFR:
Antifreeze temperature
Adjustment range:
-40 to 50°F
Recommended setting: 40 °F
Channel only available when
OCF is active
When the tank cooling function is activated, the controller aims to
cool down the tank during the night in order to prepare it for solar
loading on the following day.
If the adjusted maximum tank temperature S MX is exceeded and the
collector temperature falls below the tank temperature, the system
will be reactivated in order to cool down the tank. Cooling will continue
until the tank temperature has fallen below the adjusted maximum
tank temperature S MX again. A fixed hysteresis of 4 °Ra [2 K] is set
for this function. Reference threshold temperature differences for the
tank cooling function are DT O and DT F.
If no DHW consumption is expected for a longer period of time, the
additional holiday cooling option OHOL can be activated in order to
extend the tank cooling function. The adjustable temperature THOL
then replaces the maximum tank temperature S MX as a switch-off
temperature for the tank cooling function.
When the holiday cooling function is activated, and ! (flashing) are
shown on the display.
While the holiday cooling function is active, , , and ! (flashing) are
shown on the display.
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.
This function is unnecessary if the system backup heating element
has a set point maintained at 120 °F.
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.
OTC:
Tube collector function
Adjustment: OFF / ON
Recommended setting: OFF
The tube collector function is only needed for systems that use
vacuum tube solar collectors.
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 to 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:
0.5 - 100.0 in steps of 0.5
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.
This function is not necessary for this system.
Channel only available when OHQM is active
33
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 - 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.
ODB:
Drainback Option
Adjustment range:
OFF / ON
Recommended setting: OFF
This function is not necessary for this system.
MAN 1, MAN 2:
Pump operating mode
Adjustment range:
OFF / AUTO / ON
Recommended setting:
AUTO
Both channels must be set to auto for proper operate For system
setup and service work the operating mode of the pump can be
manually adjusted by selecting the adjustment value for MAN 1
(primary pump) or MAN 2 (optional secondary pump, not included).
Operating mode:
OFF: relay off ! (flashing) +
AUTO: relay in automatic operation
ON:
relay on ! (flashing) +
LANG:
Controller language
Adjustment range:
De, En
Recommended setting: En
The menu language can be adjusted in this channel:
RESE:
Reset Function
By using the reset function all adjustments are set back to the factory
settings.
dE: German
En: English
To initiate a reset press button 3. Any previous adjustments will be
lost. Therefore, initiating the reset function is always followed by a
security inquiry. Only confirm the security inquiry if you wish to
reset all adjustments to the factory settings!
Security Inquiry:
To confirm the security enquiry press button 3.
Whenever a reset has been completed, the controller runs the
commissioning menu again.
The final channel indicates the 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).
34
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
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
Storage water heater
Differential Controller
is shown and control
reads 888.8 instead of
temperature
Faulty sensor
is shown and control
reads -88.8 instead of
temperature
35
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
36
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
37
SYSTEM MAINTENANCE
System Checkpoint
Expansion Tank
To check system: temperature, pressure and flow
conditions,reference Figure 19 on page 22.
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.
• Components C & E: Provide system temperature.
• Component O: Provides system pressure.
• Component U: Provides flow information.
• Component B: Provides an overall digital read-out of the
system. Reference Pump Station Control Instructions
for detailed information on the Operation and Function
of the Pump Station Control.
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.
Heat Transfer Fluid (HTF) Quality
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.
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 35. The inlet water shut-off
to the unit itself shall also be closed. This will isolate any
electricity or fluids from entering the unit.
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.
Piping and External Insulation
Annually all piping should be checked for leakage at joints,
and unions. Any damaged external insulation should be
repaired or replaced.
Wiring and Connections
Annually 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.
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.
Solar Panel Clarity
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.
Figure 35.
38
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.
7
4
3
6
1
5
Refer to the manual and parts list provided with the solar
storage tank for its serviceable parts.
SERVICE
ITEM
PART DESCRIPTION
PART #
SENCON SWHX PUMP STATION SERVICE PARTS
1
2
3
4
5
6
7
8
Temperature Gauge-Supply (Red)
Temperature Gauge-Return (Blue)
Pressure Gauge
Resol BS/4 Controller
Flowmeter 0.8 - 6.0 US gpm
Wilo Star S 21U - 15 Primary Pump
Pressure Relief Valve
Sealing Cap
ITEM
14
15
9008354005
9008353005
9007454005
9008352005
9008113005
9007783005
9007460005
9007792015
16
17
18
19
MISCELLANEOUS SYSTEM SERVICE PARTS
9
10
11
12
13
Collector Temperature Sensor (Not
Pictured)
Tank Temperature Sensor (Not Pictured)
Armacell UT/SolaFlex Pipe Insulation
1/2” X 6” (Not Pictured)
Armacell UT/SolaFlex Pipe Insulation 1”
x 6’ (Not Pictured)
Temperature Sensor Wire Assy (Not
Pictured)
20
9007461015
21
9007462015
22
318002-000
23
318002-002
2
8
PART DESCRIPTION
Chromagen CR110 AP Solar Collector
(Not Pictured)
Chromagen CR130 AP Solar Collector
(Not Pictured)
Chromagen CR140 AP Solar Collector
(Not Pictured)
Water Tempering (Mixing) Valve 1”
Sweat Connections (Not Pictured)
Propylene Glycol Heat Transfer Fluid
(DOWFROST) 5 Gallon (Not Pictured)
Air Vent (Not Pictured)
Solar Loop Expansion Tank 2 Gallon
(Not Pictured)
Solar Loop Expansion Tank 4.5 Gallon
(Not Pictured)
Roof Flashing w/Cap (Not Pictured)
Roof Flashing w/Cap and Gooseneck
(Not Pictured)
SERVICE
PART #
9910010000
9910012000
9910014000
9008355005
9910055000
9007451005
9910054000
9910104000
9910049000
9910050000
9910051000
Fill in the following for your own reference. The model and serial number are found on the solar system’s rating plate located on the
pump station.
Date Installed___________ Model No.______________________ Serial No.______________________ Installers Name_____________________
Phone No.______________ Installers Address:_____________________________ City and State_______________________ Zip Code________
39
Dowfrost Heat Transfer Fluid Properties
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.
ComponentCAS # Amount
Propylene glycol 57-55-6 > 95.0 %
Dipotassium hydrogen phosphate 7758-11-4 < 3.0 %
Deionized water 7732-18-5 < 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
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