INSTALLATION

GUIDE

HPAK SYSTEMS

v2.1.1

EXCELLENCE

BY DESIGN

TABLE OF CONTENTS

1. PREPARATIONS 3-10

2. HPAK INSTALLATION 11-14

3. PIPING 15-17

4. COMMISSIONING

18-22

5. O & M

22

6. NOTES 23-24

7. WARRANTY 25

1. PREPARATIONS

1.0. General Notes

1.0.0. Safety Guidelines

Carefully review all instructions in this manual for installation and use. Do not modify Gobi Collectors or Helio-Pak under any circumstances; use only as designed. This manual and its content are integral parts of both the Helio-Pak and Gobi Solar Collector warranties. Noncompliance with these guidelines will void all warranties.

Follow all local building codes and regulations, as well as these industry accepted guidelines and standards:

1.0.2. Collector Installation

Make a site visit prior to installation to verify adequate installation conditions:

• Collector sun exposure, especially during crucial solar hours of

10AM – 3PM. Take into consideration deciduous tree shading, structures, chimneys, etc.

• Use a minimum tilt of 10° in mild areas and 30° in areas with snow.

• Orient collectors within 20° of true South (in North latitudes); use internet maps rather than compass readings for verification.

• Ideal collector tilt for hot water production is equal to site latitude. For space heating combination systems, use tilt equal to latitude plus 15°. Heliodyne recommends a standard of 35° for hot water and 45° for space heating, regardless of location. Use racks only when necessary, as variation up to 15° can have only small effects on performance.

• Avoid banking of snow and ice below or on the collectors.

• Never mount Gobi collectors horizontally in a drainback system.

(HPAK is always used in a closed loop system.)

• Heliodyne recommends 6-12” of flex tubing before any rigid copper lines to allow for thermal expansion in the copper tubing.

1.0.3. Minimum Heat Storage

A minimum of 1.5 – 2.0 gallons of liquid heat storage per square foot of Gobi collector (e.g., 60 – 80 gallons per Gobi 410) is recommended.

Minimize stagnation (no load, no flow) conditions on peak output days by using appropriate system sizing and maximizing year round usage. For design assistance, contact Heliodyne.

Ensure the backup heating capacity is properly sized to produce hot water for installation site on days of little or no solar energy production. Use only ASHRAE 90.2 compliant storage tanks and heaters with R-16 or higher.

IAPMO

USEC, UBC, UPC

ASHRAE

Solar Energy Equipment

NFPA 70 National Electric Code

ASCE 7-05 Minimum Design Loads for Buildings and Other

Structures

Select an installation location that is easily accessible for maintenance and servicing

1.0.1. Collector Storage and Handling

Keep collectors covered when storing or filling.

Avoid lifting collectors by the headers. Take care not to scratch the tempered solar glass; follow the glass breakage guidelines at the end of this manual in case of breakage.

Gobi collectors nest and lock into each other for horizontal transportation. Do not transport Gobi upside down or standing on a side.

1.0.4. Equipment for Installation

For a complete and functional SHW system, ensure the following equipment is ready for installation at the job site:

• Gobi Solar Collectors

• Rack or Flush mount hardware kit

• Appropriate roof penetration hardware and sealant

• Copper tubing, type M or L for collector / heat transfer appliance connections, adapters, elbows and fittings.

• 96/4 Tin/Silver solder

• Use only rubber type insulation (Armaflex); 1/2” wall / R2.6l minimum

• UV resistant covering or coating for outdoor exposed insulation

• Helio-Pak heat transfer appliance (HPAK)

• Isolation valves, tempering valve, air vent

• Storage tank with adequate volume for collectors installed (1.5-

2gal/ft² collector area)

• Connections for storage tank (flexible or otherwise)

• Dyn-O-Flo HD high temperature propylene glycol or equal

(-50F to 325F° + 6% inhib)

• Pipe hangers or supports installed per code requirement installed without compromising any insulation.

• High temp. ball valve before air vent

WARNING! The approved HPAK solar loop heat transfer fluid is DYN-O-FLO

HD Propylene Glycol. The substitution of any other heat transfer fluid may cause irreparable damage and/or create a safety hazard.

1.0.5. Tools

Heliodyne collectors and heat transfer appliances do not require any special tools. Never use plumbing wrenches on hex connections.

Always tighten the bolts rather than the nuts. Aside from using the standard plumbing tools (torch, pipe cutter, etc.) the following tools and sizes are used in Heliodyne equipment:

• 9/16” wrench / socket for 3/8”- 16 bolts and nuts

• 3/4” wrench / socket for 1/2” - 13 hanger bolts and nuts

• Adjustable hex wrench for 1.25” thru 1.875” hex sizes

• Phillips screw driver (for tank sensor installation)

• 1/4” drill bit for 3/8” lag screws

• 3/8” drill bit for 1/2” lag screws

3

S O L A R H O T W A T E R

GENERAL NOTES

1. PREPARATIONS

1.0. General Notes (continued)

ABSORBER

TYPE

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Black paint

Black paint

Black paint

Black paint

Black paint

1.0.6. Safety Equipment

Working on roof tops and other elevated collector installation sites as well as using flames can be dangerous; use extreme caution and follow all local codes and good safety practices when installing.

Protection against auto-ignition of combustibles - Combustible materials used in solar equipment an adjacent structures shall not be exposed to an elevated temperature that could cause ignition.

Heliodyne is not responsible for job safety nor any accidents that may occur, and always recommends:

• Safety glasses

• Roof harness

• Scaffolding rather than ladders

• Solder in well ventilated areas

1.0.7. Heliodyne OG-300 Certified Systems and SRCC Numbers

Installers: circle OG-300 system installed (if applicable). NOTE: visit www.solar-rating.org for full certification specifications and diagrams.

HPAK, DUAL TANK SYSTEMS WITH ELECTRIC BACKUP

SRCC NUMBER SEF GOBI

SIZE

4X6

4X8

4X8

4X10

4X10

4X6

4X8

4X8

4X10

4X6

4X8

4X10

4X6

4X8

2

2

2

2

1

1

1

1

2

2

1

1

GOBI

QTY

1

1

SOLAR

TANK (GAL)

80

65

80

65

80

80

80

120

120

80

80

80

80

120

AUX TANK

(GAL)

50

50

50

50

50

50

50

50

50

50

50

50

50

50

2009035G

2009035F

2009035I

2009035A

2009035J

2009035H

2009035B

2009035C

2009035D

2009035K

2009035M

2009035O

2009035L

2009035N

2.6

3.9

1.3

1.4

1.6

1.9

2.1

1.4

1.5

1.5

1.8

1.8

2.2

2.8

HPAK, SINGLE TANK SYSTEMS WITH ELECTRIC BACKUP

ABSORBER

TYPE

GOBI

SIZE

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 10’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 10’

Black paint

Black paint

Black paint

Black paint

Black paint

Black paint

4’ X 6’

4’ X 8’

4’ X 10’

4’ X 6’

4’ X 8’

4’ X 10’

GOBI

QTY

1

2

1

1

2

2

2

2

2

2

1

1

1

1

1

SOLAR

TANK (GAL)

AUX TANK

(GAL)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

80

80

80

80

120

120

80

120

120

120

50

80

65

80

80

SRCC NUMBER SEF

2009034J

2009034K

2009034A

2009034N

2009034B

2009034L

2009034M

2009034C

2009034O

2009034P

2009034R

2009034T

2009034Q

2009034S

2009034U

1.5

1.7

1.9

2.3

2.7

3.3

3.1

2.8

4

8.6

1.6

1.6

1.8

1.8

2.2

HPAK, SINGLE TANK SYSTEMS WITH GAS TANKLESS (ON DEMAND) BACKUP

ABSORBER TYPE GOBI

SIZE

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 10’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 10’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 10’

GOBI

QTY

1

1

1

2

1

2

1

1

3

2

2

SOLAR

TANK (GAL)

50

80

50

50

80

80

80

120

120

120

120

AUX TANK

(GAL)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

SRCC NUMBER SEF

2010136A

2010136D

2010136B

2010136C

2010136E

2010136F

2010136G

2010136H

2010136I

2010136J

2010136K

1.3

1.5

1.5

1.8

2.6

1.5

1.8

2.4

6.8

3.4

7

HPAK, SINGLE TANK SYSTEMS WITH GAS BACKUP (ELECTRIC IGNITION)

HPAK, DUAL TANK SYSTEMS WITH GAS BACKUP

ABSORBER

TYPE

GOBI

SIZE

GOBI

QTY

SOLAR

TANK (GAL)

AUX TANK

(GAL)

SRCC NUMBER SEF

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Blue sputter

Black paint

Black paint

Black paint

4X10

4X6

4X10

4X6

4X8

4X6

4X6

4X8

4X8

4X10

4X6

4X8

4X8

1

1

2

3

1

2

2

2

2

1

1

1

1

120

120

8

80

80

80

80

65

80

65

80

80

120

50

50

50

50

50

50

50

50

50

50

50

50

50

2009036G

2009036F

2009036I

2009036A

2009036H

2009036B

2009036C

2009036D tbd tbd

2009036J

2009036L

2009036K

1.3

1.5

1.5

1.9

0.9

1

0.9

1.1

.9

.9

1.1

ABSORBER TYPE GOBI

SIZE

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 6’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 8’

Blue sputtered 4’ X 10’

Blue sputtered 4’ X 10’

Blue sputtered 4’ X 10’

GOBI

QTY

1

1

1

2

1

1

1

1

2

SOLAR TANK

(GAL)

50

75

50

65

75

65

75

50

65

AUX TANK

(GAL)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

SRCC NUMBER SEF

2010135A

2010135B

2010135H

2010135C

2010135D

2010135I

2010135E

2010135F

2010135G

0.9

0.9

1.3

1.0

1.0

1.7

1.1

1.1

1.1

The solar energy system described in this Manual, when properly installed and maintained, meets or exceeds the minimum standards established by the SRCC. This certification does not imply endorsement or warranty of this product by SRCC.

Contact Heliodyne for service in your area: 1.888.878.8750

4

HPAK, SINGLE TANK SYSTEMS WITH ELECTRIC BACKUP

COLLECTOR SPECIFICATIONS

1.1. Technical Specifications for Gobi

T

H

M

DIM

L

W

DESCRIPTION

Length

Width

Thickness

Header Length

Header Width

A

P

Aperture Length

Aperture Width

Plate Length

Plate Width

D

F

Flashing Base

Flashing Header

A

L x W Gross Area

L

x A g

W

Net Area

Dry Weight

G

V

Full Weight

Volume

-

-

-

Max Pressure

Test Pressure

Stag. Temp.

UNITS

inch ft

2 ft

2 lb.

lb.

Gal.

PSI

PSI

°F

GOBI 406

81.56

76.88

79.25

78.0

26.94

24.90

74

80

0.6

GOBI 408

97.56

47.56

2.75

92.88

50.25

95.25

45.25

94.0

46.25

0.61

1.93

32.22

29.93

102

108

0.7

150 (10 Bar)

300 (20 Bar)

397.6 (203 °C)

GOBI 410

121.56

116.88

119.25

118.0

40.15

37.47

127

135

0.8

1.2. Flow and Pressure Loss

1

F

D

RECOMMENDED DESIGN FLOW RATES WITH GLYCOL

2

GOBI 406

0.85 Gal / min

GOBI 408

1.0 Gal / min

GOBI 410

1.25 Gal / min

PRESSURE DROP PLOT

T

A

P

W

M

H

L

10

Number of Gobi in Array (8 Max)

1.

Losses calculated at recommended Gobi design flow rates for 50/50 propylene glycol / water solution.

2.

Minimum flow rates shown. Do not exceed recommended flow rates by more than (3) times.

S O L A R H O T W A T E R

Gobi 410

Gobi 408

Gobi 406

5

6

COLLECTOR ORIENTATION AND PLUMBING

1.3. Gobi Orientation and Plumbing

S

15°

15°

Combi DHW:

DHW / Pool:

45°

35°

+ / - 15°

Helio-Pak

Helio-Flo

Drain Back

Helio-Pak

Helio-Flo

Drain Back

Figure 1.3.-1 DOS-Disc Assembly (p/n: 50013)

2x

Figure 1.3.-2 Two DOS-Discs Per Vertical Array

OR

Figure 1.3.-3 Two DOS-Discs Per Horizontal Collector

OR

HPAK SPECIFICATIONS

7

1.4. Helio-Pak Heat Transfer Appliance HPAK

Insulated solar hot water system, closed loop glycol / water, double wall heat exchanger with visual leak detection, control and sensors, filling valve and hot / cold temperature and pressure indication.

Item

Numbers

Heat Exch.

HPAK 0XX 00X

016 ,000

Btu/hr

024 ,000

Btu/hr

032 ,000

Btu/hr

048 ,000

Btu/hr

45

17

Control

000 Std

001 Pro

002 Pro-LITE

11 12

3

20 21

8

7

14 13

15 13

9.7”

18.9”

25.0”*

Figure 1B-1: HPAK Dimensions

22.5”

*HPAK 032 shown.

024 & 048 HX’s measure 43”

1.5. Technical Specifications

Maximum Operating Conditions 150 psig / 275 °F

Heat Transfer Fluid

Solar Loop Connections

40-50% Dyn-O-Flo HD and Water

Sweat fittings for 3/4” Type M or L Copper,

Domestic Water Connections

Pressure Relief

3/4” Male NPT Fittings

Barbed Hose Connection (For 1/4” ID Hose)

Gaskets EPDM

Domestic Water Contact Material Type M or L Copper & Bronze (Pump)

Insulation

Thermal Conductivity

EPP Foam (Casing), Armaflex (HX)

0.25 Btu·in / hr·ft

2

·°F (0.036 W/m·K)

24 25 26

16 13

47

*001 and 002

Models Only

9

5

5

2

4

1

*032 Shown

61

*Optional

62

63

64

65

66

67

S O L A R H O T W A T E R

HPAK SPARE PARTS LIST

9

11

12

13

14

15

16

17

2

3

4

5a

5b

7

8

20

22

24

25

26

29

45

47

1.6. HPAK Replacement Parts

1.6.0. HPAK Spare Parts Table

ITEM

1

61

62

63

64

65

66

67

CODE

HPAK 16 DW

HPAK 24 DW

HPAK 32 DW

HPAK 48 DW

EPP Foam Front

EPP Foam Back

Acrylic Cover

UPS 15-58 Cil2

UPS 15-78 Cil2

PRV

PGauge

2-40FloCast

Combo DOS Nut

Combo DOS Flange

Combo Gasket

Combo Valve: Hot

Combo Valve: Cold

Combo Valve: Fill

EX-2

EX-5

Tank Bracket

Mtg Screws

HP Elec. Box - bot

HP Elec. Box - top

Delta- T

SENS 000 001

HPAK - DHW Tube

Grundfos VFS 2-40

ZZZZ 000 003

ZZZZ 000 009

SENS 000 002

DFLO 001 000

ZZZZ 000 005

ITLS 000 002

ITLS 000 001

21204

21194

21198

21197

21153

21270

23029

23031

21186

23090

23091

23092

23030

23031

PART NUMBER

40020

40095

40096

40097

21250

21251

21254

23098

23299

23001

21214

21199

21202

23030

Pre insulated double wall HPAK U Tube

Heat Exchanger with visual leak detection (IAPMO Listed)

Front insulation casing

Back insulation casing

DESCRIPTION

Front white acrylic cover with logo

PPG Volute 3-Speed circulation pump (HPAK 016 Models)

PPG Volute 3-Speed circulation pump (HPAK 024-048 Models)

150 psig, 1/4” NPT pressure only relief valve

Back entry pressure gauge, 0–160 psi

Bronze flow casting, with flow meter input, Pro models only

Bronze flow casting, without flow meter input

DOS nut combo valve fitting

DOS flange combo valve fitting

EPDM gasket for combo valves

Hot combination valve: ball valve, temperature gauge

Cold combination valve: check & ball valves, temperature gauge

Filling combination valve

2-gallon bladder type expansion tank

5-gallon bladder type expansion tank

Tank mounting bracket

1/4 - 20 x 1” Self-tapping screws for tank mount

HPAK electrical box - bottom

HPAK electrical box - top

Delta - T Control Board

Delta - T Pro Control Board, Pro models only

10,000 Ohm Thermistor Sensors

40029

23086

DHW pump inlet tube, flanged, 3/4” Type M

Grundfos vortex flow and temperature sensor, Pro models only

Optional Equipment (Not Included in HPAK Package)

23020

23021

Tempering valve, 3/4” sweat

Air vent for filling, 1/2” Male NPT

23025

23040

23023

50064

50078

Sensor wire

Dyn-O-Flo HD propylene glycol concentrate

Tank bypass valve

Collector loop filling station

Propylene glycol test kit

QUANTITY

1

-

-

1

-

-

1

1

1

2

2

3

1

1

1

1

2

1

1

2

1

1

1

1

1

1

8

1

2

1

1

8

HPAK SYSTEM COMPONENTS OVERVIEW

1.6.1. Tempering Valve

Install a tempering valve to prevent scalding; the solar storage may reach 180°F. Some areas may require a rated Anti-Scald valve.

Item

Numbers

61

For dual tank systems with a gas backup, install the tempering valve before the gas water heater and after installing the solar storage tank, to avoid a service call for high limit fuse replacement. For dual tank systems with an electric tank, the tempering valve may be installed before or after the tank. For instantaneous water heaters as backup, consult the manufacturer for the recommended method of tempering or bypass of solar heated water into the heater.

9

1.6.2. System Overheat Protection and Operation of Pressure Relief Valve and Expansion Tank

The HPAK comes with a pre-installed pressure relief valve, nonadjustable and pre-set at 150 psig. A 1/4“ barbed hose fitting is supplied for routing relief fluid to a drain or retaining vessel.

In addition, the system comes with a pre-sized bladder type expansion tank. The acceptance volume of the expansion tank should be large enough to store up to 17 – 20% of the total collector system fluid volume.

With these safety precautions, and high temperature Dyn-O-Flo HD propylene glycol, the system can stagnate for short periods.

If extended periods (2 weeks or more) are expected, install a Delta-T Pro with the proper vacation setting. Additionally, the system should never have less than 1.5 gallons of storage for each square foot of collector surface area.

7

17

1.6.3. Operation of Combo Valves

The combo valves are integrated ball valves with temperature gauges. The blue or ‘cold’ combo valve also has an integrated check valve to prevent system thermosyphoning. Cracking pressure (minimum fluid flow pressure) of the internal check valve is 0.30 psi.

The valves can be operated by turning the plastic handles clockwise, with note taken of the position of the slots on the handles, indicating valve position as pictured in figures 1.6.3.-1 – 3 below.

14

15

Figure 1.6.3.-1: Ball Valves Open

(Operation Position)

1.6.4. Operation of Filling Valve

The filling valve integrates three gate valves into one.

The green handles operate the inlet and outlet of the valve, while the drain fitting on the side enables either filling or system operation. Always fill the system in the direction of the flow path.

If not using a Heliodyne filling station, hose adapters are set into the HPAK foam to the right of the fill valve.

Figure 1.6.3.-2: Check Valves Open

(Fluid Servicing)

Figure 1.6.4.-1: Drain Fitting Open

(Operation Position)

Figure 1.6.3.-3: Ball Valves Closed

(HPAK Servicing)

Figure 1.6.4.-2: Drain Fitting Closed

(Fluid Servicing)

S O L A R H O T W A T E R

16

HPAK SYSTEM COMPONENTS OVERVIEW

10

1.6.5. Solar Control and HPAK electrical

THE ELECTRICAL INSTALLATION SHOULD BE PERFORMED BY AN AUTHORIZED PROFESSIONAL. FOLLOW ALL LOCAL REGULATIONS AND

CODES WHEN INSTALLING WIRE, FUSES, GROUNDING, ETC. PROTECT THE HPAK FROM OVERCURRENT. BEFORE ANY ELECTRICAL WORK

IS DONE, ENSURE THE HPAK LINE CORD IS DISCONNECTED FROM THE ELECTRICAL SOURCE.

Item

Numbers

24

All HPAK 000, 001 and 002 models come with the basic internal electrical wiring already completed. For simple DHW operation, the installer only needs to plug in the HPAK line cord into a nearby 120 VAC, 60 Hz grounded wall outlet and wire the storage and collector sensor appropriately. The control comes pre-wired with two sensor lines. Use 22 AWG or larger cable if the sensor lines need to be extended. Connect the sensors to wire using non-metal wirenuts, or other corrosion resistant connection method.

Ensure the control high limit is set at or below the tank manufacturer’s recommended limit.

If attaching additional sensors or wiring, such as for the Pro models, remove the top cover for the electrical box and make the appropriate connections. See the Delta-T or Delta-T Pro manual for controller installation.

25

26

The HPAK 016 Pro control version only comes as an Ethernet version and the Pro Lite HPAK 016 is WiFi. HPAK 24, 32, and 48

Pro models comes in either WiFi or Ethernet. The Pro Lite controller is not available in these larger models.

1.6.6. Flow Sensor: 001 and 002 Models

The HPAK Pro and Pro-LITE models come with a digital vortex flow and temperature sensor pre-installed and wired to the Delta-T

Pro or Pro-LITE controller. No adjustment is necessary. Please see the Delta-T Pro or Delta-T Pro-LITE Manual for information on digital sensor operation.

47

1.6.7. 3-Speed Pump Operation

The DHW and collector circulation pumps are identical bronze volute pumps; they come pre-wired, and pre-set at speed 2.

Depending on Gobi surface area installed, the speed may need to be adjusted by rotating variable speed dial to 1 (low),2 (med), or

3(high) located on the side of the pump. Use Table 1.6.7.-1 for pipe size, collector surface and speed reference. Table 1.6.7.-2 shows the pump performance.

UPS 15-58 Cil2 Power Ratings:

Speed 1: 55 Watts

Speed 2: 65 Watts

Speed 3: 75 Watts

5

5

SPEED

Figure 1.6.7.-1: Grundfos UPS 15-58 CiL2 Pump

HPAK HEAT EXCHANGER

Recommended Flow Rate (GPM)

Max Gobi Surface Area (Ft 2 )

Recommended Pump Speed

Max Piping Resistance (Ft H

2

0)

016

3

96

1

2

024

4

144

2

5

Table 1.6.7.-1: HPAK Piping Recommendations

032

6

048

9

192 288

2 3

6 7

4

4

2

2

8

8

6

6

0 0

0 0 2 2 4 4 6 6 8

Q [US GPM]

8 10 10 12 12 14 14

0

0

2

2

4

4

6

6

8

8

10

10

Table 1.6.7.-2: UPS 15-58 CiL2 Performance

12

12

14

14

HPAK INSTALLATION INSTRUCTIONS

2. HELIO-PAK INSTALLATION

2.0. Helio-Pak Connections and Hydraulic Schematic

Solar

Out

DHW in

DHW

Out

Solar

In

DHW Out (To Tank)

DHW In (From Tank)

Solar In (From Gobi)

PRV (Back Exit)

Solar Out (To Gobi)

Expansion Tank

M

T T

P

HPAK

Figure 2.0.-2: HPAK Hydraulic Figure 2.0.-1: HPAK Connections

11

2.1. Tank Orientation

If using a Helio-Tank for installation, orient the proper solar connections in line with the HPAK connections to eliminate piping. On all tanks: ensure proper dip tube length by inspection.

DRAIN

T&P

SHWM

Helio-Tank 119

LONG

DIPTUBE

SHORT

DIPTUBE

Figure 2.1.-1: HPAK and Helio-Tank 119 Connections

S O L A R H O T W A T E R

HPAK INSTALLATION INSTRUCTIONS

12

2.2. Plumbing Multiple Tanks

If using multiple tanks to achieve proper storage ratio, always use reverse return plumbing with the cold lines the longest, to ensure least heat loss, and that each tank gets the same amount of circulation. For Helio-Tanks, use the 119 and connect all 2” side ports for increased layering and higher performance.

Tank Interconnect

CTOR 000 000

Standard Solar 119

Helio-Tank 119 Helio-Tank 119

Figure 2.2.-1: HPAK with Multiple Helio-Tank 119

Figure 2.2.-2: HPAK with Multiple Standard Solar Tanks

2.3. Sensor Installation

HPAK’s come with the necessary sensors pre-wired into the control; for more information see the separate control manual. The controls require at least one tank sensor: on the bottom of the storage tank; the top tank sensor is optional. Most solar storage tanks have a stud near the bottom for placement; the Helio-Tanks have studs for both top and bottom. If a specific area is not available, attach to a metal drain, disconnected lower element, or use the cold in for lower tank sensor; use the hot out for a top tank sensor. The collector sensor must go on the outlet header of the array.

For Pro models: the energy production is default set to calculate via the collector outlet sensor and the pre-installed flow meter temperature and flow sensor. For greater accuracy, install an additional thermistor sensor just above the inlet to the heat exchanger and connect to T4 at the Delta-T Pro. See the hydraulic schematic on the opposite page for T4 position.

2.3.0. Storage Sensor Panel Removal and Installation 2.3.1. Collector

Sensor Installation

T

ank Sensor (T

2

)

Be sure to connect to bottom stud on tank

(Heliodyne brand solar storage tank pictured in the example)

Collector Sensor (T

1

)

Be sure to connect to outlet header of the last collector in the array. A DOS combo fitting with sensor well is recommended to ensure optimal sensor connection.

HPAK INSTALLATION INSTRUCTIONS

2.4. Helio-Pak Tank Mounting

Choose the mounting location for the HPAK. Using the X-Bracket supplied with the HPAK, measure and level a spot 6” down from the desired position of the top of the HPAK foam. With the 4 self - tapping screws provided with the HPAK; on a tank use the inner mounting holes on the curved part of the X, on a wall, use the outer mounting holes on the flattened part of the X. Align the top and bottom lugs on the X with the top and bottom mating holes on the HPAK pre-mounted bracket and hang. Pull the HPAK down to lock in the lugs with the

HPAK bracket holes.

NOTE: For single gas tank systems with side ports, mount the HPAK as per section 3.2.1

13

Tank Mount

6”

Figure 2.4.-1: HPAK Tank Mounting

Tank Mount

2.5. Expansion Tank Mounting

Helio-Paks come with a pre-sized expansion tank of bladder type pre-charged to 25 PSI. If the shipped expansion tank volume is less than

1/5 th of the total collector system fluid volume, contact Heliodyne to purchase the appropriate additional expansion.

Use flex hose provided to connect the expansion tank to the HPAK. Apply pipe tape the the threads of both connection to ensure a watertight seal. Secure the expansion tank to the storage tank or wall. The orientation of the bladder type tanks does not matter; any location is acceptable. A rigid mounting bracket is available through Heliodyne.

S O L A R H O T W A T E R

HPAK INSTALLATION INSTRUCTIONS

2.6. Connect the PRV to Hose for Drain

The PRV comes with a barbed hose fitting on the back of the HPAK, to attached a 1/4” ID hose for funneling glycol to a bucket or drain, in the rare even of release. Since this is not part of a pressurized system, there is no need to use expensive copper; PEX or other high temperature suitable plastics are okay here only. Check with local plumbing codes if copper is required.

In the even of a pressure release, contact Heliodyne to discuss expansion tank sizing.

2.7. Helio-Pak Water Loop Connections

The Helio-Pak water loop connections are NPSM fittings. Copper piping or corrugated stainless-steel flextube can be used to connect the Helio-pak water connections to the top of the solar storage tank. A 3/4” NPT adaptor

(part number 21422) is available for those that want to plumb to hard copper.

Be sure to connect the piping such that the HPAK takes suction from the cold, or long diptube, and returns water to the to the hot, or short diptube.

In other words, the HPAK should always pull cold water from the bottom of the tank and return the solar heated water to the top portion of the tank.

2.8. Helio-Pak Solar Loop Connections

The Helio-Pak solar loop connections will require 3/4” copper sweat fittings.

Copper piping or corrugated stainless-steel solar flextube can be used to connect the Helio-pak solar loop connections to the solar collectors on the roof. If using corrugated flextubing, refer to the Solar FlexTube Installation

Guidelines for further instructions and for information on any adaptor components required.

1/4” ID line to floor drain or catch tank.

14

PLUMBING THE HPAK

3. PIPING

3.0. Connect the HPAK to the Tank

Insulate all hot water piping, as well as the final five feet of cold water storage inlet piping to a minimum R2.6. To enable backup heat during solar system maintenance, isolation and shut off valves must be installed as recommended in installation schematics below.

Use dielectric unions when connecting piping to the storage tank nipples. When using the Helio-Tank, appropriately sized flex hoses can be purchased from Heliodyne to avoid rigid copper plumbing. In the case of standard storage tanks, Heliodyne Gas Tank, or multiple tanks, this is unavoidable.

In tanks that have only three connections on the top, it is possible to share the cold connection between the tank cold inlet, HPAK tank cold feed, and cold supply to a tempering valve. This requires that the HPAK cold suction is located next to the tank inlet and that a check valve is used to prevent back flow from the HPAK into the tempering valve cold water supply.

When using the Helio-Tank, the DHW Cold is shared with the HPAK Cold.

NEVER share the hot DHW and HPAK return line to prevent cold water entering the hot line.

Ensure that the HPAK return has a dip tube in the tank as shown

15

1

Tempering Valve

11

2

Expansion Tank

12

3

Combo Valve*: Cold 13

4

Flow & Temp Meter 14

5

Collector Pump

15

6

Storage Pump

16

7

Tank Sensor 17

8

Normally Open Valve 18

9

Normally Closed Valve

19

Bypass Valve

20

10

Air Vent/check valve

Collector Sensor

Gobi Collector

Filling Valve

Combo Valve*: Hot

150 psi PRV

Pressure Gauge

P & T Valve

HSTG Solar Storage

Optional Isolation Valve

*The ‘hot’ combo valve is an integrated temperature gauge and ball valve. The ‘blue’ combo valve is an integrated temperature gauge, ball and check valve.

The ball valves can be operated as described in the components section 1.6.3 above and is normally open.

12

13

15

16

14

4

5

M

T

S

T

P

1

3

2

11

10

6

7

9

8

18"

12"

11

WARNING: The solar storage

tank may reach 180°F

(82.2°C). Water temperatures over

125°F (51.6°C) can cause severe burns instantly, or death from scalds.

Install tempering valve and inspect tank to ensure the presence of a scald warning label on the storage tank.

17

18

S

Figure 3.0-1: Typical HPAK Installation Schematic

S O L A R H O T W A T E R

DATE

DOC NO.

06 / 18 / 08

000009

BY

M STARKEY

FLUID PLUMBING SCHEMATIC AND GUIDELINES

3.1 Different Tank Schematics

16

If your tank is not here, contact Heliodyne with questions. Refer to the valve descriptions on the previous page. In accordance with

SRCC standard OG-300, all piping and valves must be labeled. Attach the waterproofed labels provided with this manual to the appropriate components using zip-ties.

NOTE: For single tank electric systems: disconnect lower element for proper operation.

NOTE: For single tank gas systems: tanks with electric pilot and HP Pro ONLY

NOTE: In Canada, the tank must be CSA approved and all plumbing fittings must comply with CSA B.125. All CSA system tanks must have a Scald warning label.

HPAK

18

HPAK

18

19

20

HPAK

18 18

12"

19

20

12"

18"

12"

18"

S

T1

Figure 3.1-1: Single Standard Tank

S

TOP VIEW

Figure 3.1-2: Dual Tank: Electric Backup

3.1.0. Solar heating with Tankless Water Heaters

For systems with Tankless or On-Demand Water Heaters, solar pre-heated water can potentially overheat the internal gas water heater components. For this reason Heliodyne recommends using a Mixing Valve prior to entry into the On-Demand Unit, to mix down the solar heated water to the maximum temperature limit of the gas heater.

T & P

DRAIN

Connect the solar storage tank top ports as per tank manual for normal DHW applications

FRONT VIEW

T3

18"

T

T4

T

P

From

Solar

Storage

To

Solar

Storage

12"

S

Figure 3.1-3: Dual Tank: Gas Backup

From

Mains

Figure 3.1.-4: Flow Thru Connection

M

T5

HPAK

T2

Solar Water Heating with Instantaneous Heater

HPAK, Helio-Tank 80, Instantaneous Backup

FLUID PLUMBING SCHEMATIC AND GUIDELINES

T1

3.2 Single Gas Tank Systems with Electric Ignition Pilot Light.

17

Heliodyne Delta-T Pro and Pro-LITE controllers have built in logic to control an electric-ignition pilot light for single gas tank systems, allowing their use for the first time with solar thermal collectors. The solar thermal controller will override the gas tank ignition if there is abundant solar energy. For more information on the controller logic, refer to Delta-T Pro and/or Pro-LITE manuals.

The following are requirements for single gas tank usage:

1. Storage tank must have an Electric Ignition Pilot Light

2. Solar Thermal Controller must be either a HPAK Pro or Pro-LITE Model.

3. An additional temperature sensor is required at the top of the storage tank.

For HPAK Pro systems, this extra sensor can be a RTD Thermistor sensor (T3).

For HPAK Pro-LITE systems, this MUST be a digital Grundfos RPS sensor. Please contact local Heliodyne dealer for more information.

T5

Hot Water Out

3.2.1. Gas-Fired Tank with Side Ports:

The preferred method of plumbing will use tank side ports. Plumb the HPAK cold suction line into cold inlet, the HPAK hot return to the top side port. Install a check valve on the cold inlet prior to the HPAK suction line, which will ensure

T P

To HPAK

WARNING: No check valve on the cold groundwater line prior to the HPAK cold suction connection may cause severe burns at hot water fixtures.

T4

T3 or

P top of tank

11

Delta-T Pro-LITE: RPS sensor or Delta-T Pro: T3 Thermistor sensor

HPAK

Tank 115 VAC cord plugged to

Delta-T controller

Pro LITE: @ Relay 2

Pro: @ Relay 3

DATE

06 / 18 / 08

DOC NO.

000008

BY

M STARKEY

3.2.2. Valve Block Kit Installation

Though not required when installing an HPAK, Heliodyne offers a SRCC compliant valve block kit for use with single tank systems. Refer to the Valve Block Kit manual for more information on its function.

NOTE: If installing a valve block kit, be sure to follow its HPAK mounting instructions as they differ from this manual’s HPAK mounting instructions.

18

T2

Figure 3.2-1: HPAK PRO or PRO LITE with side-port

Cold Ground Water In

Electric-Ignition Gas Tank

HPAK, Bock Electric Ignition Gas Tank

Solar Water Heating with Single Tank Gas

SYMBOL

P

P

T

M

M

DESCRIPTION

AIR VENT

DRAIN VALVE

VALVE

EXPANSION TANK

HELIO-PAK SERIES PUMP

RTD TEMPERATURE SENSOR

PRESSURE RELIEF VALVE

P & T RELIEF VALVE

PRESSURE GAUGE

TEMPERATURE GAUGE

TEMPERING VALVE

GRUNDFOS DIGITAL RELATIVE

PRESSURE SENSOR (RPS)

GRUNDFOS DIGITAL VORTEX

FLOW SENSOR (VFS)

S O L A R H O T W A T E R

SYSTEM FILL AND STARTUP

4. COMMISSIONING

4.0. Pressure Test and Clean Collector Loop

Before filling the collector loop with Dyn-O-Flo HD glycol solution, flush and pressure test the collector loop with water to check for soldering leaks. Rinse system with 1-2% TSP solution:

18

WARNING: Collectors must be cool or covered to prevent damage during charging

1. Cover the collectors to prevent heating, or commence the fill at night when collectors are cool.

2. Remove the expansion tank and cap off the exposed HPAK expansion tank port.

3. Open all Air Vents.

4. Connect the HPAK fill valve position #3 (see figure 4.0-1) to a site mains supply hose or filling station supply hose.

5. Connect the HPAK fill valve position #2 to a return hose which can drain into a bucket or floor drain.

6. Turn fill valve #1 so the slot is horizontal.

7. Flush then fill the collector loop with water forcing fluid in through fill port #3 and returning from fill port #2.

8. Close fill ports #2 and #3 to pressurize loop up to mains pressure (60 – 80 psig.) and check for leaks.

9. Purge air out of the HPAK pumps windings as per section 4.2. After a minute of purging, re-install pump screwcap until snug.

WARNING! DO NOT OVERTIGHTEN

10. Drain system to a bucket or drain until the water comes out clean.

11. Reinstall expansion tank to the HPAK connection port.

12. For the final fill of the system, monitor the pressure gauge for drops in pressure, inspect all joints. Turn the collector loop pump on

ONLY after pumps have been purged as in section 4.2. If the loop is drained, proceed to section 4.3 once the system is ready for final filling.

4.1. Calculate System Fluid Volume and Necessary Glycol Concentration

Find the total fluid capacity by adding in the volume of the collectors, HPAK and supply and return lines. With the total volume, use the equation below to find out necessary gallons of glycol. Glycol concentration should be 40 – 60% for proper inhibitor concentration, regardless of required freeze protection. A higher concentration than is required for freeze protection is recommended in case of errors in fluid calculation. Dyn-O-Flo HD propylene glycol is the recommended heat transfer liquid; the substitution of any other heat-transfer fluid can cause irreparable damage and/or create health and safety hazards. Use mineral spring water or good quality tap water and only fill system when collectors are cold.

Gallons of Dyn-O-Flo HD = Desired Concentration (%) * Total System Fluid (gal.) / 100

SYSTEM COMPONENT

GOBI 406 001 & 002

GOBI 408 001 & 002

GOBI 410 001 & 002

HPAK 016 000 & 001

HPAK 024 000 & 001

HPAK 032 000 & 001

HPAK 048 000 & 001

FLUID CAPACITY (GAL.)

0.60

0.70

0.80

0.80

0.95

1.00

1.25

ASTM B88 COPPER TUBING

Type M 1/2” (5/8” OD)

Type M 3/4” (7/8” OD)

Type M 1” (1-1/8” OD)

Type M 1-1/4” (1-3/8” OD)

Type M 1-1/2” (1-5/8” OD)

Type M 2” (2-1/8” OD)

GALLONS / 100’

1.32

2.68

4.54

6.80

9.51

16.5

2

1

3

Figure 4.0-1: Drain Fitting Open

(Operation Position)

Figure 4.0-2: Drain Fitting Closed

(Fluid Servicing)

COLLECTOR FLUID PIPING

19

4.2. Gobi Collector Plumbing

Use only copper piping on the collector loop, solder to appropriate conditions in technical specifications. Always plumb in reverse return with the longest line the cold, or use automatic balancing valves. Insulate piping for least losses; use rubber based insulation with environment protection or Solar Flex Tube from Heliodyne. Gobi collectors can be put in portrait arrays of up to eight. Install bleed vents for filling at local high points.

4.2.0. Portrait Single Collector or Array 4.2.1. Single Horizontal Collector

4.2.2. Multiple Horizontal Collectors

4.2.3. Multiple Horizontally Aligned Portrait Arrays

4.2.4. Multiple Vertically Aligned Portrait Arrays

Min. Distance = Gobi Length * Sin (Tilt from Horiz.)

0.577

S O L A R H O T W A T E R

SYSTEM FILL AND STARTUP

4.3. Pump Venting

After the clean water flushing procedure, during the pressure test and before charging the solar collector loop with glycol, remove the center screw/air vent in the pump faceplate on both pumps on the HPAKs to purge out trapped air (see image to the right). If this is not done before glycol charging, then make sure to do this after the systems are charged with glycol, prior to starting the glycol and potable water pumps.

The operating fluid lubricates the interior of the HPAK pumps. It is extremely important to vent the pumps prior to energizing, to lubricate the pumps bushings.

Failure to vent air from the pump housing will cause pump damage and failure.

20

4.4. Fill System

WARNING: Ensure that there is enough excess glycol/water mixture in the filling station container at all times to prevent the fill pump from sucking air into the collector loop. This normally requires at least two gallons of glycol/water mixture in addition to the quantity required to fill the solar system.

Flow Direction

Heliodyne strongly recommends use of a fill pump station. At a minimum, you should use a 1/2 hp pump capable of developing at least 85 psi shutoff head.

The system can be filled easily with a filling pump from Heliodyne or manually.

If using a Fill Station, consult the Filling Station manual for proper operation.

Take care to use mineral spring water or good quality water and only fill the system when the collectors are cold. It is important to charge the collectors only when they are cold. If you cannot charge early in the morning, before the sun has started heating the collectors, collectors must be covered to prevent heating during charging See installation notes at the end of this manual for water requirements. Install air vents or bleed vents at the high points in the system to help rid the system of air during filling only. If using any type of automatic air vent, close vent after filling is complete as vents are not suitable for glycol systems, or systems without continuously replaced fluids.

Use a high-temperature ball valve between the collector outlet and air vent, to allow for removal of the air vent after purging of all air is complete. The hightemperature ball valve will also help protect the air vent from high temperatures associated with stagnation if the air vent is not removed post commissioning.

1. Open all air vents at the collector array outlets.

2. If using multiple arrays, close all array inlet and outlet isolations except for the array furthest from the HPAK(s)

3. For a system with multiple HPAKs, close all HPAK ball valves except for the HPAK you are connecting the fill pump to.

4. Connect fill pump supply hose to fill port # 3 at right, and return hose to fill port # 2. Turn valve #1 so slot is horizontal, forcing return fluid out of 2. Turn on pump to begin filling.

5. After fluid begins to return back into tank from 2, open next set of array inlet and outlet valves to fill the array.

6. Continue to open all array inlets and outlets until all arrays are full.

7. After fluid begins to come back out of return hose from port #2 without any air bubbles, pressurize the system to 40-60 PSI and then close fill port #3.

8. Return fill valve #1 to vertical.

9. Turn off pump.

10. If using multiple HPAKs , move fill pump and hoses to the next HPAK. Connect fill supply hose to port #3 and return hose to #2. Open fill vales #3 and #2, turn valve #1 to horizontal position.

2

1

3

Figure 4.4-1: Fill port flow connections

SYSTEM FILL AND STARTUP

21

4.4. Fill System (continued)

11. Turn on fill pump and open up the HPAK combination valves to fill the HPAK internals.

12. Once steady stream comes back from fill return line, close off fill valves #2 and #3, return valve #1 to vertical position and turn off pump.

13. At the last HPAK station: once fluid begins to come back out of return hose, close off valve at fill port # 2 and open fill port #1,

KEEPING VALVE #3 OPEN. System will pressurize rapidly; monitor gauge and close off valve at fill port # 3 once system pressure reaches 40 – 60 psi.

14. Turn off fill pump.

15. If using multiple HPAKs, check to make sure all HPAK pressure gauges are recording the same pressure

16. Close off any bleed or air vents and run system throughout the day. Verify HPAK pumps are vented as per section 4.2 prior to plugging in the HPAK. Check after a day cycle to ensure the cold pressure of the system is above 30 psig when cold. If further pressurization is necessary, hook up pump supply to 3, turn pump on, open valve and pressurize back up.

For manual fill, pour in proper glycol and water mixture with a funnel into the top unused header connection of Gobi. Pressurize with house water using the valve at position 3; follow pressure guidelines as above. Hose nipples are provided, pre-set into the foam next to the fill valve. Heliodyne highly recommends only filling with a pump station.

4.5. Fill System: Potable Water Side

Connect the HPAK potable supply and return connections to the storage tank. Next, connect a potable water supply hose, or open the cold groundwater main supply valve to begin to fill the tank with water. Provide a way for air to escape from the solar tank, such as through a tank air vent.

Best Practice: Filling the solar tank with potable water may take as much as ½ hour. While the solar tank is filling flush, pressure test and charge the collector loop.

After the solar storage tank is full, close the tank’s air vent. If possible vent air from any high points in the potable supply piping. On the HPAK lower pump, unscrew the center screw/air vent in the pump faceplate to purge the pump as described in section 4.2. Replace the center screw in the pump being careful not to damage the O-ring from over tightening.

After the potable piping system is pressurized inspect the piping system carefully for leaks.

4.6. System Startup and Testing:

Plug in the HPAK device and switch the Controller to AUTO operation to startup the solar system. To ensure proper operation of the

Solar Thermal System, perform the following checks during the first days of operation when both the glycol loop and water loop are filled:

Check System Pressure

• After the system is filled, it is normal for the initial pressure to drop slightly as air comes out of solution. Check pressure gauge on side of

HPAK reads greater than 30 psig when cold. If further pressurization is necessary, hook up a pump supply to fill port #3, turn pump on, open valve #3 and pressurize system to above 30 psig.

Check Collector and Water pumps for proper operation.

• With proper operation, the hot or red gauge should read 10-20°F hotter than the blue gauge.

• With a temperature difference greater than 20°F, set the pump speeds to a higher level. For a difference less than 10°F, set the pump speeds to a lower level.

• Flow sounds, loud operation or squealing means air in the system. Purge air through air vents and through HPAK pump front ports if necessary. Unplug HPAK from wall prior to purging air from pumps. Follow filling guidelines for re-pressurization if needed.

• No temperature difference could mean a flow failure. Ensure all valves aligned correctly and check for pump operation. Consult section 6.0 of the HPAK Manual for more troubleshooting steps.

Check the control and sensors

• Ensure the sensors are giving proper readings by either viewing the computer software for the Delta-T Pro or Pro-Lite , or using a multi meter to measure thermistor resistance. See the control manual for further details.

• Check wiring to ensure it is undamaged and continuous.

System Shutdown.

• If the operation checks cannot be met, or a problem is discovered in the solar system, shut down the HPAK by unplugging it from the wall. Cover the collectors if they are to remain full to protect against stagnation conditions. Avoid any prolonged length of time that the heat-transfer fluid can remain in the system without any attention and the collectors uncovered.

S O L A R H O T W A T E R

MAINTENANCE

5. O&M

5.0. Annual Operational Checks and Troubleshooting

Every year the solar system should be checked to ensure optimal performance; these annual checks performed by a qualified professional should not take the place of good operation overview by the systems owner.

22

Annually or more often, the following should be verified:

5.0.0. Check collector and water side pumps for operation

• With proper operation, the hot or red gauge should read 10-20°F hotter than the blue gauge.

• If the blue gauge is higher than the red gauge, the system is indicating that there is no flow. If this is the case, then there may be air locks in either or both the glycol loop and potable water lines. To remedy this, open the air vent/center screws on both pumps by turning 1.5 turns, leaving them to vent for up to a minute, to remove additional air, and then carefully tighten them down, taking care not to overtighten which could damage the gaskets on the pumps

• With a temperature difference greater than 20°F, set the pump speeds to a higher level. For a difference less than 10°F, set the pump speeds to a lower level.

• Loud operation or squealing means air in the system, follow filling guidelines for re-pressurization.

• No temperature difference could mean a pump failure, test pump supply voltage at pump electrical box, listen and feel for OP.

• No temperature difference could also mean a diptube wasn’t installed correctly, or at the right length. Review tank schematics in this manual for proper length.

• The hot and cold ball valves could be turned incorrectly; ensure the slots on the top and bottom of the plastic red or blue colored handle are aligned vertically.

• The filling valve bypass could be turned incorrectly; ensure the slot aligns vertically.

5.0.1. Check pressure gauge

• Pressure gauge on HPAK should be no less than 30 psig when system is cold. Follow filling guidelines for re-pressurization.

• Inspect system for leaks.

5.0.2. Check expansion tank pressure

• The expansion tanks have a shraeder valve (like a bicycle tube valve) for pressurization; it should be charged with approximately 25 psig.

5.0.3. Check the glycol color, concentration and pH.

• Heliodyne has glycol testing kits that perform the required analysis. Review the data sheet for Dyn-O-Flo HD in this manual for proper levels.

• Glycol should be a bright green color; anything else needs to be replaced. Use only Dyn-O-Flo HD or equivalent.

5.0.4. Check the control and sensors

• Ensure the sensors are giving proper readings by either viewing the software in the Delta-T Pro, or using a multimeter to measure resistance. See the control manual for further details.

• Check wiring to ensure it is undamaged and continuous.

6.1. Maintenance

To replace parts on the HPAK, close the hot and cold ball valves for servicing equipment underneath them such as pump, heat exchanger, flow sensor, etc.

For servicing PRV, pressure gauge, expansion tank or collectors and piping, the system should be drained in the direction of flow via the fill valve. If the fluid is good, drain it to a bucket for reuse. Estimated time per component: 1-2 hours.

Motor

Bolts

Close Ball Valves:

Rotate 90° CW

To replace any of the combo valves, unscrew appropriate valve, and replace gasket with valve; torque connections to 30 lb-ft. Estimated time per component:

2 hours.

To service a pump, the motor housing only needs replacing, as volutes have no moving parts. Disconnect electricity from HPAK, then disconnect the pump wiring with the spring clamps. Unscrew the two allen-keyed bolts and replace motor and electrical connections. Torque bolts to 80 lb-in. Estimated time per component:

2 hours.

To service the controller, disconnect the electricity from the unit and remove the box housing, unplug all connections and power wiring, and replace the board. After reinstalling a new controller, test operation by turning the control on manually. Estimated time per component: 1 hour.

HEAT TRANSFER FLUID SPECIFICATION AND SYSTEM NOTES

6. NOTES

6.0. General Dyn-O-Flo HD Notes

D yn-O-Flo HD is a 100% concentrate inhibited propylene glycol and is recommended for use in applications where low acute oral toxicity is important or where incidental contact with drinking water is possible.

Extra strength corrosion inhibitors in the HD fluid are formulated for high temperature use, resulting in reduced maintenance and longer inhibitor life in most applications. Freeze tolerances are based on a set of acceptable limits.

•

Spills: Cover with absorbent material, soak up and seep into bag.

•

Disposal: Discharge into sanitary sewers only with the explicit preapproval of the local waste water facility. Any disposal practice must be in compliance with federal, state, provincial and local laws and regulations. Check with the appropriate agencies.

6.0.5. Maintenance

The glycol / water mix should be tested periodically for freeze protection and pH. Empty the system and flush thoroughly before replacing with a fresh mix when the pH drops below 8, or reserve alkalinity approaches zero.

6.0.0. Use Directions

• Do not use full strength.

• Recommended concentration is 40 – 60%.

• Dilute with good quality soft water. If the tap water has more than 25 ppm of chloride or sulfate ions, or more than 50 ppm of calcium or magnesium, use mountain spring water.

• Do not use zinc or galvanized components in contact with the fluid.

• System preparation: Flush thoroughly with water (use 1 – 2% TSP) and circulate without adding heat, before introducing the operating fluid.

• Fluid Introduction: Please see the Helio-Pak systems Manuals for filling, venting and priming.

• Maintenance: The fluid should be checked periodically for pH, which should not drop below 8, and reserve alkalinity, which should stay greater than zero at all times.

• Flush thoroughly before replacing with new mix.

• The Dyn-O-Flo HD has an operating temperature range of -50 – 325 ˚F.

6.0.1. Specifications

• Specific Gravity: 1.053 – 1.063

• Propylene Glycol: 94%

• Inhibitor Concentration by Weight: 6%, inhibitors and water

• Dye: Bright yellow

• Suspended Solids: substantially free

• Reserve Alkalinity: 15 mL

6.0.2. Values at 50% Concentration

The listed values are typical of a 50% by volume aqueous solution at 120˚

F and should not be regarded as specifications.

•

pH: 9.5 – 10.5

•

Specific Heat: 0.842 BTU / lb ˚F

•

Freezing Point: -30 ˚F

•

Burst Protection: < -60 ˚F

•

Viscosity: 2.36 Cps

6.0.3. First Aid

While essentially non-irritating, absorbing or toxic, Dyn-O-Flo HD heat transfer fluid should be kept away from children and be treated with care.

In case of physical contact, follow these directions:

6.0.6. System Fluid Information

Always use copper tubing for collector supply and return connections. Black iron pipe can also be used, with proper dielectrics. Never use galvanized pipe or plastic based products, such as PEX.

Use only Dyn-O-Flo HD or similar heat transfer fluid with good quality water mixture: min 40% HD mixture, max 60% HD mixture. Substitution of any other heat-transfer fluid may cause irreparable damage and create a health and safety hazard. Do not use distilled water. Good quality water: chlorides and sulfates must be less than 25 ppm; calcium and magnesium must be less than 50 ppm (as calcium carbonate, with hardness less than 100 ppm).

If unsure, use bottled mountain spring water.

Rinse system with 1 – 2% mixture of trisodium phosphate and water.

Remove the expansion tank for testing only, and pressure test system with water before filling.

Maintain minimum operating pressure of 30 psig when system is cold to avoid pump cavitation. If using an air vent during filling, ensure it is closed during system operation.

6.0.7. Safety Precautions

Follow all local codes and regulations. Work should only be performed on the

HPAK and system when it is disconnected from the power supply.

When creating and repairing roof penetrations, ensure final seal disallows any unwanted animal or creature intrusion, and the integrity of the structure is not compromised. Penetrations through fire-rated assemblies must not reduce fire resistance capacity below code. Ensure building materials adjacent to solar components are not exposed to elevated temperatures.

6.0.8. Components

Always install a tempering valve, or rated anti-scald valve, after the solar storage tank. Route the pressure relief port on the HPAK to avoid accidental scalding in case of release.

Place the HPAK and tank in a non-freezing environment.

•

Eyes: Flush with plenty of water

•

Skin: Wash off with flowing water

•

Ingestion: Induce vomiting and consult a physician

•

Inhalation: Remove to fresh air, consult physician.

Notice to Physician: No specific antidote. Supportive care based on judgment of physician.

6.0.4. Handling

•

Exposure Guidelines: Propylene glycol: AIHA WEEL is 50 ppm total,

10 mg / m

3

aerosol only.

•

Ventilation: Good general ventilation should be sufficient for most conditions.

•

Respiratory Protection: No respiratory protection should be needed.

•

Skin Protection: For brief contact, no precautions other than cleaning of body and covering. Use impervious gloves when prolonged or frequently repeated contact occurs.

•

Eye Protection: Use safety glasses.

Solder suitable for 400°F and 150 psig must be used: 96/4 Tin / Silver is recommended.

6.0.9. Description Of Product and Operation

The HPAK is a fully automatic solar energy heat transfer appliance. The controller senses the collector and storage temperatures and powers both circulation pumps when the collector has achieved enough temperature over the solar storage tank. See the Delta-T and Delta-T Pro manuals for full descriptions of operation and functions.

6.0.10. Commissioning

After the system is filled, it is normal for the initial pressure to drop as air comes out of solution. Repressurize the system to ensure at least 30 psig when cold.

23

S O L A R H O T W A T E R

HEAT TRANSFER FLUID SPECIFICATION AND SYSTEM NOTES

6.1 Installer Notes

This page is set aside for Installer Notes on the System:

INSTALLER NAME/COMPANY:

ADDRESS:

INSTALLATION DATE:

COMMISSIONING DATE:

HEAT TRANSFER FLUID TYPE AND

CONCENTRATION:

OTHER:

24

WARRANTY

7. WARRANTY

7.0. Warranty

HELIODYNE, shall provide a warranty for defects in compliance with the purchased goods delivered after 3/1/2009 as follows:

HPAKS have a Five (5) year limited warranty (parts only, no labor, no shipping) from date of installation when installed with HELIODYNE

Collectors.

• Three (3) year limited warranty (parts only, no labor, no shipping) on Integrated Electronics (such as controller, pumps, sensors, etc.)

• In the event that the Product is installed with another brand of collector, or any equipment other than HELIODYNE collectors, then the period of time shall be one (1) year from date of installation for Product and Electronics.

The GOBI Collectors and their variants.

• Ten (10) year limited warranty (parts only, no labor, no shipping) from date of installation.

Oral communication or communication by telephone is not sufficient.

To obtain service on the Product, notify Heliodyne Customer Service by email at

[email protected], by letter to 4910 Seaport Ave.,

Richmond, CA, 94804. Provide proof of purchase and date.

Should service be requested and no defect found in the

Product, then a reasonable charge will be made for the service.

In no event shall HELIODYNE be liable for the following:

• Conditions resulting from a defect in a component or part that does not make up the HELIODYNE Product.

• Conditions resulting from a significant departure from Heliodyne’s

Installation Instructions.

• Conditions resulting from any misuse, abuse, negligence, weather damage, accident or alteration.

• Consequential damages such as: damage to your property, loss of time, inconvenience or loss of use of the Product or any incidental expenses resulting from any breach of the express warranty.

Conditions that may occur in the normal operation of the Product shall not be invoked by HELIODYNE to reduce or defeat the coverage of this warranty.

The DELTA-T Products and their variants.

• Three (3) year limited warranty (parts only, no labor, no shipping) from the date of installation”

In the event that evidence cannot be provided to indicate the date of installation, then the period of time shall be thirty six (36) months from the date of manufacture.

Objects are warranted at HELIODYNE’s discretion by repair of the object of purchase or replacement of defective parts, exchange or reduction of price. The right of the contractor to convert objects is ceded by common consent. Replaced parts become the property of

HELIODYNE. Wages and costs spent on installation and disassembly must be covered by the client. This provision similarly applies to all warranty agreements. It is at HELIODYNE’s discretion to replace defective goods with similar, faultless goods. In this case, any rights to cancel the agreement cease. The client expressly waives the right for it and its legal successors to assert claims for damages or loss of profit

(including without limitation special, indirect, loss of use, contingent, or consequential damages) due to defects or nonconformity in the purchased good. The warranty set forth above constitutes the sole and exclusive remedy against HELIODYNE for the furnishing of any nonconforming or defective goods. THE ABOVE WARRANTY IS

EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY AS

TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR

PURPOSE.

HELIODYNE’s liability under this warranty shall be in lieu of all warranties of fitness and in lieu of all warranties of merchantability.

Heliodyne shall not be liable for any incidental or consequential damages covered by a defective product. The maximum liability under this warranty shall not exceed the contract price of the Product.

Some states do not allow the exclusion or limitations of incidental or consequential damages, and some states do not allow limitations on implied warranties, such as that of fitness and of merchantability.

Therefore the above exclusions and limitations do not apply to you.

The warranty excludes damage caused by force majeure and malfunction that are due to improper assembly, and/or product installation. HELIODYNE is not liable for possible costs resulting from defects. In order for HELIODYNE to accept liability:

• Installation must have been carried out by a licensed specialized company (heating contractor or plumber) following the version of installation instructions in force;

• HELIODYNE or its representative was given the opportunity to check complaints on site immediately after any defect occurred;

• Confirmation exists that the system was commissioned properly and that the system was checked and maintenance was performed annually by a specialized company licensed for this purpose. The warranty agreed by HELIODYNE is only valid for their clients.

If the Product contains a defect that cannot be repaired after a reasonable number of attempts to do so, you, the buyer, may elect either a refund of its purchase price, or a replacement without charge.

A replacement may consist of a new or factory rebuilt product of at least the same quality. A new warranty shall apply to any replacement.

Claims on warranty will only be admitted and considered if they are announced in writing immediately after the defect was first noticed.

This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. Unless otherwise explicitly agreed in writing, it is understood that these are the only written warranties given by HELIODYNE, and HELIODYNE neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with the Product.

25

S O L A R H O T W A T E R

Heliodyne, Inc. • 4910 Seaport Avenue • Richmond, CA 94804

T: 510.237.9614 • F: 510.237.7018

www.heliodyne.com

Sales Inquiries: [email protected]

Information and Support: [email protected]