320009

User Manual: 320009

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KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

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.

Instruction Manual

RESIDENTIAL SOLAR WATER HEATING SYSTEMS

STANDARD SYSTEMS

WITH DOUBLE WALL HEAT EXCHANGER

FOR POTABLE WATER HEATING ONLY

Solar Water Heater

C US

LISTED

Solar Collector

SRCC OG-100

™

Solar Water Heating System

SRCC OG-300

™

http://waterheatertimer.org/Should-you-buy-solar-water-heater.html

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 pres-

ent, 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.

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

WARNING

CAUTION

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death

or injury.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or injury.

CAUTION indicates a potentially hazardous

situation which, if not avoided, could result in

minor or moderate injury.

CAUTION used without the safety alert symbol

indicates a potentially hazardous situation

which, if not avoided, could result in property

damage.

CAUTION

GENERAL SAFETY

Thank You for purchasing this water heating system.

Properly installed and maintained, it should give you years

of trouble free service.

Abbreviations Found In This Instruction Manual:

• ANSI - American National Standards Institute

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturers Association

• NEC - National Electrical Code

• NFPA - National Fire Protection Association

• UL - Underwriters Laboratories Inc.

• SRCC - Solar Rating and Certification Corp.

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

uid.

The solar pump station uses a pump to circulate a heat-

transfer uid through the “collector loop”. This collector

loop includes the solar collectors, the uid lines or “line-

set” and a heat exchanger. The collector loop is a “closed

loop”, meaning there is no contact of the heat transfer uid

with your potable water or with the atmosphere. The collec-

tor loop contains only a small volume of heat-transfer uid

which is non-toxic and freeze-protected to -30°F (Freeze

tolerance limits are based upon an assumed set of environ-

mental conditions). Though freeze protection may not be

necessary in all areas, the heat-transfer uid 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 uid passes through the collectors,

it absorbs the heat and then travels down the line-set to

the tank. The hot uid 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 uid 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 electric-heating guarantees hot

water even under poor solar conditions (at night or when

very cloudy). The minimum acceptable temperature set-

point is specied 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 pos-

sible. 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.

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section of this manual first and

then the entire manual carefully. If you don’t follow the

safety rules, the water heater will not operate properly. It

could cause DEATH, SERIOUS BODILY INJURY, AND/

OR PROPERTY DAMAGE.

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.

2. The installation must conform with these instructions

and the local code authority having jurisdiction and the

requirements of the power company. In the absence of

local code requirements follow NFPA-70, the National

Electrical Code (current edition), which may be

ordered from: National Fire Protection Association, 1

Batterymarch Park, Quincy, MA 02169.

3. If after reading this manual you have any questions or

do not understand any portion of the instructions, call the

local utility or the manufacturer whose name appears on

the rating plate.

4. Carefully plan your intended placement of the water heater

and collectors. INSTALLATION OR SERVICE OF THIS

WATER HEATER REQUIRES ABILITY EQUIVALENT

TO THAT OF A LICENSED TRADESMAN IN THE FIELD

INVOLVED. PLUMBING AND ELECTRICAL WORK ARE

REQUIRED.

Examine the location to ensure the water heater complies

with the “Facts to Consider About the Location” section

in this manual.

5. For California installation this water heater must be

braced, anchored, or strapped to avoid falling or moving

during an earthquake. See instructions for correct

installation procedures. Instructions may be obtained

from California Office of the State Architect, 400 P Street,

Sacramento, CA 95814.

6. Massachusetts Code requires this water heater to be

installed in accordance with Massachusetts 248-CMR

2.00: State Plumbing Code and 248-CMR 5.00.

7. The solar energy system described by this manual, when

properly installed and maintained, meets the minimum

standards established by the SRCC. This certification

does not imply endorsement or warranty of this product

by SRCC.

INTRODUCTION

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE............................. 2

Important Denitions .................................................. 2

GENERAL SAFETY .................................................................. 3

INTRODUCTION ...................................................................... 4

System Description .................................................... 4

Preparing for Installation ............................................. 4

TABLE OF CONTENTS ............................................................ 5

SYSTEM DIAGRAM/TYPICAL INSTALLATION ....................... 6

SYSTEM COMPONENT PART ................................................ 7

STORAGE TANK INSTALLATION ............................................ 7

Local Codes ............................................................... 7

Temperature-Pressure Relief Valve ........................7-8

Closed System/Thermal Expansion ............................ 8

Locating the Solar Water Heater ................................ 8

Water Piping ............................................................8-9

Installation in Residential Garages.............................. 9

Filling the Solar Water Heater with Water ................... 9

Wiring of Element ..................................................... 10

Thermostat ............................................................... 10

Temperature Regulation ...................................... 10-11

Temperature Settings ............................................... 11

Temperature Adjustment .......................................... 11

Tank Sensor ............................................................. 11

Draining ............................................................... 11-12

Element .................................................................... 12

Element Replacement .............................................. 12

Anode ....................................................................... 12

Water Heater Sounds ............................................... 12

SOLAR COLLECTOR INSTALLATION .................................. 13

Collector Location .................................................... 13

General Considerations ........................................... 13

Collector Orientation ...........................................13-14

Spanner Mounting ...............................................15-17

Attaching Collector to Mounting Brackets ................ 18

Collector Piping ........................................................ 19

Collector Piping Detail .............................................. 20

Sensor Wiring at Collector ....................................... 20

Sensor Mounting at Collector ................................... 20

Piping Through the Roof .......................................... 20

Piping Insulation ....................................................... 20

PUMP STATION INSTALLATION ........................................... 21

Pump Station ............................................................ 21

Safety Instructions .................................................... 21

Safety Equipment ..................................................... 22

Wall Mounting the Solar Pump Station .................... 22

Plumbing Conguration ............................................ 23

Function ................................................................... 23

Flowmeter ................................................................ 23

Start-up and Operation of the Solar Pump Station ... 24

Leak Detection ......................................................... 24

Flushing .................................................................... 24

Filling ........................................................................ 24

Preparation of the Heat Transfer Fluid ..................... 24

Filling the Solar Loop ...........................................24-25

Draining ..................................................................... 25

PUMP STATION CONTROL INSTRUCTIONS ....................... 26

Control Instructions .................................................. 26

System Description .............................................26-33

TROUBLESHOOTING ......................................................34-36

SYSTEM MAINTENANCE ...................................................... 37

REPAIR PARTS ...................................................................... 38

HEAT TRANSFER FLUID PROPERTIES .............................. 39

SOLAR RATING / MODELS / WARRANTY.......INSERT SHEET

SYSTEM DIAGRAM/TYPICAL INSTALLATION

Figure 1.

INSTALL VACUUM

RELIEF IN COLD

WATER INLET LINE AS

REQUIRED BY LOCAL

CODES.

INSTALL SUITABLE METAL DRAIN

PANS UNDER HEATERS TO PREVENT

DAMAGE DUE TO LEAKAGE. REFER

TO WATER HEATER LOCATION, SEE

“LOCATING THE SOLAR WATER

HEATER” SECTION.

INSTALL THERMAL EXPANSION

TANK OR DEVICE IF WATER HEATER

IS INSTALLED IN A CLOSED WATER

SYSTEM.

6” Maximum Air Gap

Piped To An

Adequate Drain

At Least 2” Greater Than The

Diameter Of The Water Heater.

Metal

Drain

Pan

Discharge Pipe

(DO NOT CAP

OR PLUG)

Flow Direction

1 1

610

VACUUM RELIEF

VALVE

INSTALL PER

LOCAL CODES

INSTALL THERMAL EXPANSION

TANK IF WATER HEATER IS

INSTALLED IN A CLOSED

WATER SYSTEM

Item Component Function

1 Solar collector Absorbs the sun’s heat energy and transfers this to the heat transfer

uid circulating through the collector.

2 Solar storage tank Stores potable water heated by solar generated heat or installed

back-up electric resistance element.

3 Double Wall Heat exchanger (inside

Solar pump station)

Transfers the heat from the collector loop to the potable water in the

solar storage tank.

4 Solar Loop Expansion tank Allows for the expansion and contraction of the heat transfer uid 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 tempera-

ture.

6 Air vent Purges air from the collector loop uid during the installation.

7 Drain valve Used to drain the heat transfer uid from the collector loop.

8 Mixing valve Used to temper hot water from the solar storage tank with cold inlet

water to maintain appropriate temperature hot water delivered from

the system.

9 Solar pump station Controls the ow of heat transfer uid from the collectors to the tank

through the heat exchanger. For a detailed description of the solar

pump station see page 20.

10 Temperature sensor Tank and collector sensor work together to turn the circulating

pump(s) on and off at preset temperature differentials.

11 Cold Water Cut-Off Valve Isolates the tank from incoming water supply.

SYSTEM COMPONENT PART

STORAGE TANK INSTALLATION

Never operate the electrical heating element without being

certain the solar water heater is completely filled with water.

If any air is left in the top of the tank, the heating element

will burn out.

LOCAL CODES

The installation of this solar water heater must be in

accordance with these instructions and all applicable local

codes and electric utility requirements. In the absence of

local codes, install in accordance with the latest edition of the

National Electrical Code (NFPA-70).

TEMPERATURE-PRESSURE RELIEF VALVE

For protection against excessive pressures and temperatures

in this water heater, install temperature-pressure protective

equipment required by local codes, but not less than a

combination temperature-pressure relief valve certified by

a nationally recognized testing laboratory that maintains

periodic inspection of production of listed equipment or

materials, as meeting the requirements for Relief Valves for

Hot Water Supply Systems, the latest edition of ANSI Z21.22.

This valve must be marked with a maximum set pressure not

to exceed the marked hydrostatic working pressure of the

water heater (150 lbs./sq. in.).

Install the temperature-pressure relief valve directly into the

fitting of the water heater. Position the valve downward and

provide a discharge pipe that must terminate a maximum

of six inches above a oor 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.

The Discharge Pipe:

• Shall not be smaller in size than the outlet pipe size of the

temperature-pressure relief valve, or have any reducing

couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the

temperature-pressure relief valve, and the discharge pipe.

• Must terminate a maximum of six inches above a floor drain

or external to the building. In cold climates, it is recommended

that the discharge pipe be terminated at an adequate drain

inside the building.

• 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.

Figure 2.

The temperature-pressure relief valve should be manually

opened once a year. Caution should be taken to ensure that

(1) no one is in front of or around the outlet of the

temperature-pressure relief valve discharge line, and (2)

the water manually discharged will not cause any bodily

injury or property damage because the water may be

extremely hot.

If after manually operating the valve, it fails to completely

reset and continues to release water, immediately close

the cold water inlet to the water heater, follow the draining

instructions, and replace the temperature-pressure relief

valve with a new one.

If the temperature-pressure relief valve on the appliance

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.

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 temperature-

pressure relief valve operation: water discharged from the

valve due to excessive pressure build up. The temperature-

pressure relief valve is not intended for the constant relief

of thermal expansion. This condition is not covered under

the limited warranty.

A properly-sized thermal expansion tank should be installed

on all closed systems to control the harmful effects of

thermal expansion. Contact a plumbing service agency or

your retail supplier regarding the installation of a thermal

expansion tank..

LOCATING THE SOLAR WATER HEATER

If you have a choice of where to install the solar water heater,

these ideas may help you decide.

1. Put the solar water heater indoors as close as possible

to where you use the most hot water. This water heater

is not intended for outdoor installation.

2. It is handy to have a floor drain, tub or sink nearby.

That will make it easy to drain water from the water

heater. It is also a good place to end the drain line of

the temperature-pressure relief (T & P) valve.

3. The solar water heater or the pipes and the connections

may, in time, leak. Put the solar water heater in a place

where a water leak will not damage anything.

4. You must not put the water heater in an area where

it might freeze You must turn off the electricity to the

water heater before you drain it, to protect the heating

elements.

5. Make sure that you are able to reach the drain valve

and all access panels when the water heater is in place.

This will make it easy to service the water heater.

6. The water heater must be level before you begin the

piping.

WATER HEATERS EVENTUALLY LEAK. The installation

of the water heater must be accomplished in such a manner

that if the tank or any connections should leak, the flow

of water will not cause damage to the area adjoining the

water heater or to lower floors of the structure. When such

locations can’t be avoided, a suitable metal drain pan should

be installed under the water heater. Such a pan should be

no greater than 1 1/2 inches deep, have a minimum length

and width of at least two inches greater than the heater

dimensions and must be piped to an adequate drain.

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.

WATER PIPING

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.

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.

This appliance has been design certified as a solar water

heater complying with Standards for Safety - UL174 for

the U.S. and can/csa-c22.2 No 110 F379.1 and F379.2

for Canada. The particular application of this appliance

described (above paragraph) may be subject to review and

approval by local code officials.

Toxic chemicals such as used for treatment of boilers or non-

potable water heating appliances shall never be introduced

into a potable water space heating system.

Figure 3.

The solar water heater will work better if you keep the hot

water runs short. You will also get hot water faster and with

less heat loss.

The illustration shows the correct valves and fittings that you

will need to install the solar water heater. Threaded (3/4”)

water connections are supplied through the tank top.

Figure 4.

1. Buy the fittings that you need to connect the pipes.

Remember that you have to connect both the hot and

cold water pipes.

2. Apply a light covering of pipe joint compound to each

outside thread before making connection.

3. Connect the cold water supply pipe to the cold water inlet

of your solar water heater as follows:

a. Look at the top cover of the solar water heater. The

hot and cold connections are marked there.

b. A non-metallic dip tube is supplied to carry cold water

from the tank top to the bottom. Be sure that it is in

the cold water inlet.

c. If using copper tubing, solder tubing to an adapter

BEFORE you attach the adapter to the cold water

inlet. DO NOT solder the cold water supply pipe

directly to the cold water inlet connection. It might

harm the dip tube.

d. The cold water supply line must have a shut-off valve

and union.

4. Use a union to connect the hot water supply pipe to the

solar water heater’s hot water outlet.

Operating an empty or partially filled solar water heater will

result in damage to the tank.

If a solar water heater is installed in a closed water system;

such as one having a back flow preventer, check valve or

water meter with check valve in the cold water supply line,

means shall be provided to control thermal expansion.

Contact the water supplier or local plumbing contractor on

how to control this situation.

INSTALLATION IN RESIDENTIAL GARAGES

The solar water heater must be located and/or protected

so it is not subject to physical damage by a moving vehicle.

FILLING THE SOLAR WATER

HEATER WITH WATER

MIXING VALVE

HOT WATER OUTLET

SIDE SOLAR

WATER LOOP

CONNECTIONS

TOP SOLAR WATER

LOOP CONNECTIONS

TEMPERATURE-PRESSURE

RELIEF VALVE

TO SUITABLE

DRAIN

DRAIN VALVE

6” AIR GAP

DRAIN LINE

ACCESS COVER

COLD WATER

INLET

TEMPERED

WATER

OTLET

Figure 5.

Before lling the solar water heater with water, the pump

station storage tank loop must be connected to the water

heater. See “Filling The Storage Tank Loop” section of the

manual.

The solar water heater is equipped with top and side pump

station water loop connections. Cap or plug the connections

that are not used in your application.

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 and solar loop air vent after all air has been

purged and the water comes out with constant flow.

You must not turn the electricity on until the solar water

heater is full of water. IF ANY AIR IS LEFT IN THE TOP

OF THE SOLAR WATER HEATER OR IN THE PUMP

STATION STORAGE TANK LOOP THE HEATING

ELEMENT WILL BURN OUT IMMEDIATELY.

4. Check all the new water piping for leaks. Fix as needed.

WIRING OF ELEMENT

Determine voltage and wattage from the rating plate

attached to the solar water heater. All external wiring,

connection, and overcurrent protective devices must be

provided and installed in accordance with the latest edition

of the National Electrical Code, local codes, and local utility

requirements. The solar water heater must be electrically

“grounded” by the installer. A green ground screw has been

provided on the solar water heater’s junction box.

The grounding electrode conductor shall be of copper,

aluminum, or copper clad aluminum. The material shall

be resistant to corrosion, and shall be of one continuous

length without a splice or joint.

Rigid metal conduit, intermediate metal conduit, or electrical

metallic tubing may be used for the grounding means

if conduit or tubing is terminated in fittings approved for

grounding.

Figure 6.

Flexible metal conduit or flexible metallic tubing shall be

permitted for grounding if all the following conditions are

met:

1. The length in any ground return path does not exceed

6 feet.

2. The circuit conductors contained therein are protected

by overcurrent devices rated at 20 amperes or less.

3. The conduit or tubing is terminated in fittings approved

for grounding.

Never use this solar water heater unless it is completely

full of water.

SOLAR WATER HEATERS EQUIPPED FOR ONE TYPE

VOLTAGE ONLY. This solar water heater is equipped

for one type of voltage only. Check the rating plate near

the bottom access panel for the correct voltage. DO NOT

USE THIS SOLAR WATER HEATER WITH ANY VOLTAGE

OTHER THAN THE ONE SHOWN ON THE MODEL

RATING PLATE. Failure to use the correct voltage can

cause problems which can result in DEATH, SERIOUS

BODILY INJURY OR PROPERTY DAMAGE. If you have

any questions or doubts consult your electric company.

If wiring from the fuse box or circuit breaker box was alumi-

num for the old tank, replace it with copper wire. If you wish

to reuse the existing aluminum wire, have the connection

at the solar water heater made by a competent electrician.

Contact your local utility to arrange for a professional elec-

trician.

BLACK

RED

BLACK

ELEMENT

RED

C)(66 F(60 C)

C)(49

Figure 7.

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.

TEMPERATURE REGULATION

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 8 and Table 2 for information regarding thermostat

settings. In addition to using the lowest possible temperature

setting that satisfies your hot water needs, some type of

mixing device, such as a mixing valve should be used at the

hot water taps used by these people or at the solar water

heater. Mixing valves are available at plumbing supply or

hardware stores. Follow manufacturers instructions for

installation of the valves. Before changing the factory

setting of the thermostat, read the Temperature Adjustment

section. KEEPING THE THERMOSTAT SETTING AT 120°F

WILL REDUCE THE RISK OF SCALDS. Never allow

small children to use a hot water tap, or to draw their own

bath water. Never leave a child or handicapped person

unattended in a bathtub or shower.

TEMPERATURE SETTINGS

NOTE: This residential solar water heater will not supply

sanitizing hot water for dishwashers.

The thermostat is factory set at its lowest position which

approximates 120°F and is adjustable if a different water

temperature is desired. For best system savings this

temperature should not be changed. Read all warnings in

this manual and on the solar water heater before proceeding.

ADJUSTABLE

THERMOSTAT

WITH

HIGH LIMIT

CONTROL

RESET

BUTTON

Figure 8.

Water

Temperature °F

Time for 1st Degree

Burn

(Less Severe Burns)

Time for Perma-

nent Burns 2nd &

3rd Degree (Most

Severe Burns)

110

116

122

131

140

149

154

(normal shower temp.)

(pain threshold)

35 minutes

1 minute

5 seconds

2 seconds

1 second

instantaneous

45 minutes

5 minutes

25 seconds

5 seconds

2 seconds

1 seconds

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)

Table 2.

TEMPERATURE ADJUSTMENT

To adjust the temperature setting:

1. Turn “OFF” the electrical power to the water heater, at

the junction box.

HAZARD OF ELECTRICAL SHOCK! Failure to turn

“OFF” electric power to the solar water heater will result

in the possibility of DEATH, SERIOUS BODILY INJURY

OR PROPERTY DAMAGE.

2. Take off the access panel and fold away the insulation.

3. Turn the water temperature dial clockwise ( ) to

increase the temperature, or counterclockwise ( ) to

decrease the temperature.

4. Fold the insulation back in place and replace the access

panel.

5. Turn “ON” the power supply.

A non-adjustable high temperature limit control operates

before steam temperatures are reached. The high limit is

in the same area as the upper thermostat and must be reset

manually when it activates. BECAUSE THE HIGH LIMIT

ACTIVATES ONLY WHEN ABNORMALLY HIGH WATER

TEMPERATURES ARE PRESENT, IT IS IMPORTANT

THAT A QUALIFIED SERVICE AGENT BE CONTACTED

TO DETERMINE THE REASON FOR OPERATION

BEFORE RESETTING.

TANK SENSOR

The surface mount tank sensor should be attached to the

sensor stud behind the lower door by placing the hole in

the sensor over the stud provided and securing in place

with a nut. The end of the tank sensor shall be connected

to the red wires in the opening with wire nuts (with no

regard for polarity). The other ends of the red temperature

sensor extension extend from the top of the tank and shall

be connected to the controller in the tank sensor position.

DRAINING

It is recommended that the storage tank be drained and

ushed every 6 months to remove sediment which may

build up during operation. The water heater should be

drained if being shut down during freezing temperatures.

To drain the tank, perform the following steps:

1. Turn off power to the water heater.

2. Open a nearby hot water faucet until the water is no

longer hot.

3. Close the cold water inlet valve.

4. Connect a hose to the drain valve and terminate it to

an adequate drain or external to the building.

5. Open the water heater drain valve and allow all of the

water to drain from the tank. Flush the tank with water

as needed to remove sediment.

6. Close the drain valve, rell the tank, and restart the

heater as directed in this manual.

If the water heater is going to be shut down for an extend-

ed period, the drain valve should be left open.

IMPORTANT: Condensation may occur when relling the

tank and should not be confused with a tank leak.

If the solar water heater is to be shut off and exposed to

freezing temperatures, it must be drained. Water, if left in

the tank and allowed to freeze, will expand and damage

the solar water heater.

1. Turn “OFF” the electrical supply to the solar water heater.

Make sure the electrical supply to the solar water heater

is turned OFF. Failure to heed this will result in the

possibility of DEATH, SERIOUS BODILY INJURY OR

PROPERTY DAMAGE.

2. Open a nearby hot water faucet until the water is no

longer hot, then turn off the cold water supply and open

the drain valve, leaving the hot water faucet open.

3. The drain valve must be left open during the shut-down

period. Once the solar water heater is drained close the

hot water faucet.

ELEMENT

In some water areas, scale or mineral deposits will build up

on heating elements. This build up may cause a rumbling

noise. Follow the element replacement directions to remove

the elements from the tank. Soaking in vinegar and scraping

will remove the mineral deposit. Be careful not to bend the

element.

ELEMENT REPLACEMENT

Replacement elements must (1) be the same voltage and

(2) no greater wattage than listed on the model and rating

plate afxed to the solar water heater.

1. Turn OFF the electrical supply to the solar water heater.

Make sure the electrical supply to the solar water heater

is turned OFF. Failure to heed this will result in the

possibility of DEATH, SERIOUS BODILY INJURY OR

PROPERTY DAMAGE.

2. Drain the solar water heater. Follow the directions for

draining.

3. Take off the access panel and take off the access panel

and remove the insulation. Disconnect the wires from the

heating element terminals.

4. Use an element wrench to remove the element and gasket.

You should always use a new gasket when you replace the

element.

5. Install new element.

6. Reconnect the wires as they were.

7. Fill the tank , following the filling directions on page 9. Fill

the tank completely with water, BEFORE you turn on the

electric supply.

ANODE

Each water heater contains at least one anode rod, which

will slowly deplete (due to electrolysis) prolonging the life

of the water heater by protecting the glass-lined tank from

corrosion. Adverse water quality, hotter water temperatures,

high hot water usage, hydronic heating devices, and water

softening methods can increase the rate of anode rod

depletion. Once the anode rod is depleted, the tank will

start to corrode, eventually developing a leak.

Certain water conditions will cause a reaction between the

anode rod and the water. The most common complaint

associated with the anode rod is a “rotten egg smell”

produced from the presence of hydrogen sulfide gas

dissolved in the water. IMPORTANT: Do not remove this rod

permanently as it may void any warranties. A special anode

rod may be available if water odor or discoloration occurs.

NOTE: This rod may reduce but not eliminate water odor

problems. The water supply system may require special

filtration equipment from a water conditioning company to

successfully eliminate all water odor problems.

Artificially softened water is exceedingly corrosive because

the process substitutes sodium ions for magnesium and

calcium ions. The use of a water softener may decrease

the life of the water heater tank.

The anode rod should be inspected after a maximum of

three years and annually thereafter until the condition of

the anode rod dictates its replacement. NOTE: artificially

softened water requires the anode rod to be inspected

annually.

The following are typical (but not all) signs of a depleted

anode rod:

• The majority of the rod’s diameter is less than 3/8”.

• Significant sections of the support wire (approx. 1/3 or

more of the anode rod’s length) are visible.

If the anode rod shows signs of either

or both it should be replaced. NOTE:

Whether re-installing or replacing the

anode rod, check for any leaks and

immediately correct if found.

In replacing the anode:

1. Turn off power supply to the water

heater.

2. Shut off the water supply and

open a nearby hot water faucet to

depressurize the water tank.

3. Drain approximately 5 gallons

of water from tank. (Refer to

“Draining and Flushing” for proper

procedures). Close drain valve.

4. Remove old anode rod.

5. Use Teflon® tape or approved pipe sealant on threads

and install new anode rod.

6. Turn on water supply and open a nearby hot water

faucet to purge air from water system. Check for any

leaks and immediately correct any if found.

7. Restart the water heater as directed in this manual.

See the Storage Tank Repair Parts section for anode

rod location.

TEFLON® is a registered trademark of E.I. Du Pont De

Nemours and Company.

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.

WATER HEATER SOUNDS

1. The solar water heater is equipped with an immersion

heating element for fastest recovery. If the solar water

heater occasionally makes noises this is not a defect or a

safety hazard.

2. Lime or scale has accumulated on the heating element

causing a hissing sound. Element scale removal can be

accomplished by using vinegar or by scraping.

Figure 9.

Figure 10.

COLLECTOR LOCATION

Proper location and orientation of the solar collectors is

important for maximum system efciency. 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

SOLAR COLLECTOR INSTALLATION

location + 15°. A steeper angle provides better winter per-

formance as the sun is lower in the sky. The collectors

will also shed snow more effectively at the steeper angle.

Figure 10 below shows many alternatives for collector

mounting. Placing the collectors as close as possible to

the peak of the roof will make installation easier by provid-

ing increased attic access.

GENERAL CONSIDERATIONS

The contractor shall obtain all required permits and

approvals.

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 re rated assemblies.

Ensure the mounting surface is solid and able to with-

stand in excess of 330lbs / 150kg of pull force that

may be encountered during high winds. Consult a

structural engineer if in doubt.

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 Pathnder (www.solarpathnder.com) can be

used for solar site analysis.

Before the installation the contractor shall inspect the con-

dition of the roof and notify the homeowner of any existing

roof damage or necessary repairs.

COLLECTOR ORIENTATION

Proper tilt angle for solar collectors is latitude plus 15°.

This 15° additional tilt improves performance in the

winter, when the sun is weaker and at a lower angle.

The cost in performance in the summer when the sun is

high is overcome by the hours of sunlight and strength

of irradiation that occurs in the summer. Tilt mounting

accessory kits are available to set the proper collector

angle. Please call your local dealer for more information.

When the collectors are mounted one behind the other,

they should be spaced sufciently apart so that when the

sun is at its lowest altitude, the collectors will not shade

each other and cause efciency loss. See Figure 11 and

Table 3. If a collector must be installed horizontally, replace

the upper vent with a rubber plug in order to prevent rain

penetration. See Figures 12 & 13.

A”

48”

COLLECTOR TILT

Figure 11.

Figure 12. Figure 13.

LATITUDE 25° N 30° N 35° N 40° N 45° N 50° N 55° N 60° N 65° N

COLLECTOR TILT 35° 40° 45° 50° 55° 60° 65° 70° 75°

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)

CAUTION

ALL PERSONS WORKING ON ROOFS SHOULD

HAVE SUCCESSFULLY COMPLETED A FALL SAFETY

COURSE AND SHOULD BE PROPERLY EQUIPPED

WITH THE APPROPRIATE SAFETY EQUIPMENT

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.

WARNING

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 17.

Preserving the integrity of the roof membrane is the

most important roong consideration. Ensure that all roof

penetrations required to plumb and mount the solar collector

are properly ashed and sealed in accordance with standard

roong practices.

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 specic 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.

1. After locating the mounting points from Figure 14 for

vertical collector mounting, Figure 15 for horizontal

collector mounting, and Table 4, layout the roof as

specified and drill 5/16” holes between the rafters

where indicated.

2. 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 secures the all-thread to the

mounting bracket. The all-thread should extend about

4” below the roof rafters.

3. 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 16.

4. 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 16.

5. With a stainless steel nut, lock washer and fender

washer secure the all-thread to each spanner. Tighten

down until the mounting bracket is tightly secured to

the roof (approx. 97 inch pounds). Be careful not to

overtighten and dish out the roof tiles underneath the

mounting bracket.

Repeat steps 2-5 for the remainder of the mounting

bracket locations.

MOUNTING

BRACKETS

RAFTER

VERTICAL MOUNTING

HORIZONTAL MOUNTING

RAFTER

MOUNTING

BRACKET

RAFTER

Figure 14.

Figure 15.

B” B”C” C”

A”

DRILL POINTS

(CLEARANCE HOLE

for 5/16” BOLT)

RAFTER

D” BASED ON 16” CENTER RAFTERS

B” B”C” C”

A”

DRILL POINTS

(CLEARANCE HOLE

for 5/16” BOLT)

RAFTER

D” BASED ON 16” CENTER RAFTERS

4” MOUNTING BRACKET

ROOF

RAFTER

WOOD SPANNER

(2” x 4” or 2” x 6” LUMBER)

SHINGLES

PLYWOOD

SHEETING

FLASHING

STAINLESS STEEL NUT, ALL THREAD ROD

LOCK WASHER, & EPDM BONDED WASHER

CP COMPRESSION

BRACKET WASHER

DECKING/WOOD

SCREWS

FENDER WASHER

LOCK WASHER

NUT

ROOF

RAFTER

SPACER

BLOCK

Figure 16.

Table 4.

* IF MOUNTING WITH AN OPTIONAL TILT MOUNT

KIT, FOR OPTIMAL COLLECTOR ANGLE REFER TO

ITS INSTRUCTION SHEET FOR THE APPLICABLE “A”

DIMENSION.

NOTICE

COLLECTOR A B C D

Vert. 3.5’ X 7’ 86* 32 14 7-1/4

Vert. 4’ X 8’ 97* 35 16 11-3/4

Vert. 4’ X 10’ 121* 35 16 11-3/4

Horiz. 3.5’ X 7’ 42.25* 62 28 13-1/2

Horiz. 4’ X 8’ 47* 72 28 12

Horiz. 4’ X 10’ 47* 94 30 9

Figure 17.

ATTACHING COLLECTOR TO MOUNTING BRACKETS

Once all of the mounting brackets have been secured to

the roof the solar collector(s) can be installed. Refer to

Figure 17 for these instructions.

1. Insert the stainless steel channel nut w/spring inside

of the mounting bracket.

2. Fasten the solar collector mounting clip to the channel

nut with the stainless steel bolt, lock-washer, and at

washer as shown. Do not tighten. Repeat step for the

other mounting bracket locations.

3. The solar collector can now be set on the mount-

ing brackets. To aid in handling the collectors on the

roof the mounting clips may be tightened to the lower

mounting brackets prior to raising the collectors. The

collector can then be set on the lower mounting brack-

ets while the top clips are fastened over the lip on the

collector frame.

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.

5. Once the upper mounting clips are secured, the bot-

tom mounting clips can be loosened and retightened

over the collector lip as directed in step 4.

6. Repeat steps as needed for other solar collectors.

SOLAR COLLECTOR FRAME

MOUNTING CLIP

STAINLESS STEEL BOLT,

LOCK WASHER,

& FLAT WASHER

CHANNEL NUT with SPRING

(One Piece Part)

ROOF

MOUNTING

BRACKET

STAINLESS STEEL

NUT, ALL THREAD ROD

with LOCK WASHER, &

FLAT WASHER

COLLECTOR PIPING

The piping of the system should be considered before a nal

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 Solaex or equivalent.

The maximum total piping length allowed in this system is

200 equivalent ft.

Use only lead-free solder. Use of 50/50 lead solder is

expressly prohibited. Use only type “L” or “M” copper

tubing in the collector loop plumbing. Use of galvanized

steel, CPVC, PVC, PEX or any other type of plastic pipe

is prohibited.

Care should be taken in the spacing of collectors as

attachment of piping is easiest with properly aligned

collectors. The connection between the collector panels is

made with copper unions or couplings. To aid in installation

the collector array layout should be planned on the ground

and the unions or couplings soldered to the adjoining

headers prior to lifting the collectors to the roof. Similarly

the top and bottom outside header that will not be used

for the inlet or outlet (should be on opposite sides) should

be capped with the 1” copper cap provided while on the

ground. See Figure 18.

VERTICAL MOUNT

OUTLET

INLET

1” COPPER

CAPS

HORIZONTAL MOUNT

OUTLET

INLET

1” COPPER

CAPS

Figure 18.

SOLAR COLLECTOR

AIR VENT

1” COPPER

PIPE

HEADER

PIPE

ADAPTER

COLLECTOR

(OUTLET)

COLLECTOR

(INLET)

TEMPERATURE

SENSOR

Figure 19.

COLLECTOR PIPING DETAIL

The outlets of the collector are 1” copper pipe nipples. See

Figure 19. They should be piped as shown with provisions

for an air vent. The air vent must be oriented vertically as

this must be the highest point in the system in order for air

to escape. This will prevent air lock and subsequent loss of

system efciency. Teflon® tape or high temperature, high

quality pipe sealant should be used when making threaded

connections.

The collector inlets should be piped similarly but without

the air vent.

SENSOR WIRING AT COLLECTOR

The wiring used to connect the sensors to the controller

should be a minimum 18 AWG. The wiring should be two-

conductor, PVC UV resistant suitable for outdoor use. Use

Belden Wire No. 7409A or equivalent.

SENSOR MOUNTING AT COLLECTOR

The angled collector heat sensor is mounted to the outlet of

the collector. See Figure 20. The stainless steel screw clamp

should be used. The entire sensor should be wrapped

thoroughly with insulating stretch tape such as MOCAP

Silicone X-Treme Tape® so that the sensor is isolated from

the outside air. If possible route the sensor wire through the

roof with the collector piping and connect the sensor wire

to the sensor extension wire with wire nuts.

Figure 20.

PIPING THROUGH THE ROOF

Preserving the integrity of the roof membrane is the

most important roong consideration. Ensure that all roof

penetrations required to plumb and mount the solar collector

are properly ashed and sealed in accordance with standard

roong practices.

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).

PIPE INSULATION

The collector loop piping (exterior and interior) must be

well insulated with a high quality exible EPDM closed

cell insulation to minimize heat loss. The wall thickness

of the pipe insulation should not be less than ¾”. A 1” wall

thickness is required in all areas prone to annual hard

freeze conditions. When it comes to pipe insulation the

rule is simple: thicker is better. The specied insulation

material is Armacell UT Solaex or equivalent. As part of

the insulation requirements the nal 5 ft of the cold water

inlet to the storage tank must be insulated.

To the extent possible, slide the insulation material over

the pipe without cutting or taping. All butt joints must be

sealed with high temperature contact adhesive. The use

of rigid polyethylene pipe insulation is prohibited. All

outdoor insulation should be protected from moisture and

Ultraviolet deterioration by either paint or foil tape.

PUMP STATION

The following instructions describe the installation, start-

up, 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 specied

in these instructions must be observed. Improper usage

excludes any liability claims.

The wrapping materials that form the outer shell of the

pump station are made of recyclable materials and can be

disposed of with recyclable materials.

The solar station is a premounted valves and ttings group

checked for leakage used to circulate the solar uid in the

solar circuit.

SAFETY INSTRUCTIONS

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

qualication such as a tter for plumbing, heating and air

conditioning technology, or a profession requiring a com-

parable level of knowledge [specialist]. The following must

be observed during installation and start-up:

• Relevant local and national codes

• Accident prevention regulations of the professional

association

• Instructions and safety instructions mentioned in this

manual

PUMP STATION INSTALLATION

Figure 21.

With cover on:

a. Front Cover

b. Differential temperature

controller

Primary (solar) loop with cover

removed:

a. Ball valve with integrated

temperature gauge and

check valve, solar supply

b. Ball valve with integrated

temperature gauge and

check valve, solar return

c. Pressure relief valve for

avoiding over-pressure

condition

d. Fill valve

e. Pressure gauge and

connection for expansion

tank

f. Solar loop circulation pump

g. Flow meter to display the flow

rate

h. Drain valve

i. Double wall heat exchanger

j. Air scoop

SOLEX PUMP STATION COMPONENTS

Secondary (storage tank) loop

with cover removed:

A. Storage tank loop air vent

B. Water heater circulation pump

C. Temperature sensor supply

D. Temperature sensor return

The solar ball valves (a and

b) are equipped with spring-

charged check valves to prevent

gravity circulation.

SAFETY EQUIPMENT

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 oor. 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 uid in quantities should circumstances

demand. If the discharge pipe is not connected to a drain

or other suitable means, the uid may cause property

damage.

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.

When following the ‘PUMP STATION INSTALLATION’ see

Figure 21.

WALL MOUNTING THE SOLAR PUMP STATION

1. Choose the position to install the solar pump station

next to the storage tank .

2. Mark the location of the hanging holes on the wall (15”

apart vertically)

CAUTION

DUE TO THE WEIGHT OF THE SOLEX PUMP STATION THE

HANGAR ANCHORS MUST BE ATTACHED TO A STRUCTURAL

SUPPORT LIKE A STUD

3. Pre-drill holes and insert the enclosed 4.5” hanging

screws so that about 1” of each screw still stick out..

4. Remove the front cover of the solar station and hang

the station onto the screws then tighten the screws.

5. Mount the solar safety group to the connection above

the return ball valve.

CONNECTION FOR

EXPANSION TANK

CONNECTION FOR

DISCHARGE LINE

DRAIN

VALVE

CONNECTION SET

WITH EXPANSION TANK

Figure 22.

6. Connect a discharge line to the pressure relief valve

in the solar circuit

7. Connect the stainless steel corrugated hose to the

safety group. Do not forget to insert the seal.

8. Choose the position for the expansion tank bracket

on the wall beside the solar pump station. Fasten the

bracket to the wall with the enclosed hardware (masonry

or drywall).

9. Unscrew the tank connector to separate the two halves.

The top half should be pushed onto the mounting

bracket and the lock ring tightened. The bottom half

should be attached to the ¾” threads on the expansion

tank.

NOTE: The tank connector allows you to isolate the

expansion tank from the solar circuit. See Figure 23. 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. Do

not forget to insert the seal.

The expansion tank should not be connected to the system

until it has been flushed and charged.

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.

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.

12. 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.

PUMP STATION INSTALLATION

Installing the ½” copper to and from the collector using

the compression fittings.

1. Push the union nut  and

the cutting ring  onto the

copper pipe . The pipe

must protrude at least 3/8”

(3 mm) from the cutting ring

in order to ensure the force

transmission and the sealing.

2. Insert the support sleeve  into

the copper pipe.

3. Insert the copper pipe with the

plugged-on individual parts (,

 and ) all the way into the

housing of the compression

fitting .

4. First screw the union nut 

manually.

5. Tighten the union nut  by

rotating one full turn. Hold the

housing of the compression

fitting  to avoid rotation in order

to avoid damaging the sealing

ring.

Figure 24.

PLUMBING CONFIGURATION

1 2

3 4

1. ½” copper tube - from

the collector outlet

(top) to the collector

return compression

fitting.

2. ½” copper tube –

from the collector

inlet (bottom) to

the collector supply

compression fitting.

3. ¾” copper tube –

from the upper tank

inlet marked “from

collector” to the tank

supply threaded fitting.

4. ¾” copper tube – from

the lower tank outlet

marked “to pump”

to the tank return

threaded fitting.

Figure 25.

FUNCTION

Check valves

The solar station is equipped with check valves in the supply

and the return ball valve (J, Q).

For filling, venting and flushing of the installation the check

valves must be turned to the correct position. To set the

proper position for the check valves take off the temperature

gauges (C, E), remove the top cover (D) and turn the ball

valves into the proper position using a wrench. See Figure

26. In the 45° position the balls in the ball valves push the

check valves open.

During operation the ball valves must be in 0° position.

0° 45° 90°

Check valve is

operating, flow

only in flow

direction

Check valve is not

operating, flow in

both directions.

Ball valve

closed,

no flow.

Figure 26.

FLOWMETER

The flowmeter serves to measure and display flow volume

of the system in a range of 0.5-5.0 US gpm.

In order to guarantee the flawless function of the measuring

device the installation must be flushed and free from foreign

substances.

The flowmeter must be mounted vertically.

LEFT SCALE:

0.5 - 3.5 GAL/MIN

READING EDGE =

TOP EDGE OF THE

TURBINE

EXAMPLE:

ABOUT 2 GAL/MIN

RIGHT SCALE:

4 - 5 GAL/MIN

READING EDGE =

BOTTOM EDGE OF

THE TURBINE

Figure 27.

START-UP AND OPERATION OF THE SOLAR

PUMP STATION

Observe the following safety instructions when starting up

the solar thermal installation:

CAUTION

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).

LEAK DETECTION

1. Disconnect the expansion tank from the solar system by

unscrewing the nut on the tank connector. This prevents

the access of dirt particles present in the pipes from

entering the expansion tank.

2. Remove the front cover of the solar station and the

temperature gauges from the ball valves (a, b)

3. Turn the two isolation ball valves (a,b) to 45° using an

appropriate wrench to allow flow in both directions.

4. Close the drain valve (h).

5. Be sure the air vent at the collector array is closed.

6. Connect an air pressure hose to the fill valve (d) above

the pressure gauge (e) and open this valve.

7. Using an air compressor or pressurized air tank fill the

system with pressurized air until the pressure gauge

(e) reads 40 psi then close the fill valve (d).

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 (h) to release

the air pressure on the system.

FLUSHING

9. Disconnect the air pressure hose from the fill valve (d)

10. Connect a water hose from a water source with at least

40 PSI supply pressure to the fill valve (d).

11. Connect a discharge hose to the drain valve (h) and

open this valve. Place the other end of the discharge

hose into an appropriate drain.

12. Turn the supply ball valve (b) to 90° (horizontal) so that

the valve is closed.

13. Turn on the supply water and open the fill valve (d)

then leave running for 15 minutes to flush debris out

of the solar loop

14. 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 (d)

15. Close the drain and fill valves (d & h) on the pump

station and disconnect the water source hose.

FILLING

The storage tank loop is filled with potable water by means

of the valves and fittings of the storage tank.

16. Fill the storage tank following the procedures in the tank

section of this manual.

17. Vent the storage tank loop by opening a nearby hot

water faucet and the storage tank loop ball valve (A)

to avoid trapped air in the storage tank loop of the

pump station and burn out of the water heater heating

element.

18. Close the faucet and solar loop air vent (A) after all

air has been purged and the water comes out with

constant flow.

PREPARATION OF THE HEAT TRANSFER FLUID

19. Pour 100% Propylene Glycol into a large clean bucket.

Add an equivalent amount of distilled or de-mineralized

water for a 50/50 solution by volume.

The use of regular tap water as a mixing agent is

prohibited. Distilled or de-mineralized water is often

available from grocery stores and drugstores. This

solution provides freeze protection down to -30° F and

burst protection down to -60° F.

Use of heat-transfer uid 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 uid other than that specied by the appliance

manufacturer will void warranty, and may result in poor

performance, equipment damage, or risk to health and

safety.

FILLING THE SOLAR LOOP

20. Connect a discharge hose to the drain valve (h) and

place the discharge end of the hose into the glycol

solution container.

21. Turn the return ball valve (a) to 0° (vertical) so that flow

is only allowed in the proper direction.

22. 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 (d) then open this valve.

23. Turn on the transfer pump to fill the system with the

glycol solution and allow to circulate for 15 minutes in

order to flush as much air as possible from the system.

24. Open the air vent at the top of the collector array until

all of the air has been dispersed then close the air vent.

25. Open the vent on the air scoop (j) with a flat head

screwdriver. This will release air that has been captured

by the system during circulation. Cover small outlet

port with a rag as fluid will be ejected after the air is

evacuated.

26. Turn the supply ball valve (b) to 0° (vertical) so that flow

is only allow in the proper direction.

27. With the transfer pump still running close the drain valve

(h) and allow the 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 the slowly open the drain

valve (h) and relieve pressure until the pressure gauge

reads 30 psi. then close the drain valve.

28. Connect the expansion tank and verify the system

pressure. If it has dropped open the fill valve (d) and

turn on the transfer pump. Repeat system pressure

setting in step 27.

29. Remove the fill and drain hoses and close the fill and

drain valves (d, h) 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.

Figure 28.

30. Plug in the solar pump station to a 115V outlet and

turn the pump on using the manual mode (see control

operation section).

31. Switch on the pumps using the manual mode.

32. Adjust the solar pump speed using the pump speed

selector on the side of the pump (f). Set the speed to

the lowest level possible to achieve the recommended

system flow rate. See Table 5.

NUMBER OF COLLECTORS

1234

COLLECTOR

SIZE

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.

Adjust the storage tank pump speed using the pump

speed selector on the side of the pump (B). Set the speed

to be one level lower than that of the solar pump.

Cycle the pumps 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. Again check the

installation for leaks and ensure both ball valves are

open completely.

33. Re-insert the temperature gauges and replace the

front cover.

34. Set both pumps on the controller to operate in automatic

mode. See control operation section.

35. After the system has been running for several days

open the air vent at the top of the collector array until

all of the air has been dispersed then close the air vent.

DRAINING

1. 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 (a,b) by turning the ball valves to position 45°

with an appropriate wrench

3. Place a temperature-resistant container under the drain

valve (h)

4. Connect a temperature resistant hose to the drain

valve (h) with the discharge end placed in the collection

container

5. Open the drain valve.

6. Open the air vent 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.

ATTENTION: Upon completion of the pump station

installation and prior to the pump station start-up the

included pump station valve diagram label must be attached

to the pump station piping so that it is in plain view.

PUMP STATION CONTROL INSTRUCTIONS

CONTROL INSTRUCTIONS

WARNING

ESD SENSITIVE

Electrostatic discharge can lead to

damage of electronic components.

Prior to operation of the control on the solar pump station

the collector and tank temperature sensors must be prop-

erly connected. Remove the control cover and connect

the sensors to the proper terminals.

COVER

CABLE CONDUITS

WITH STRAIN RELIEF

DISPLAY

PUSHBUTTONS

CAN FUSE 4A

Figure 29.

FUSE

Figure 30.

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 (lower heat exchanger sensor - pre-installed)

5 / 6 = sensor 3 (tank sensor)

7 / 8 = sensor 4 (upper heat exchanger sensor - pre-installed)

9/10 = VBus (see VBus note)

The power supply is connected to the following terminals:

19 = Neutral - N

20 = Line power - L

12 = Ground

The control is equipped with two relays, one for the solar

loop pump (upper - primary) and one for the water loop

pump (lower - secondary)

• Relay 1 (primary pump)

18 = Line power - R1

17 = Neutral - N

13 = Ground

• Relay 2 (secondary pump)

16 = Line power - R2

15 = Neutral - N

14 = Ground

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.

SYSTEM DESCRIPTION

The DeltaSol® BS Solex US controller is used in solar thermal

systems with an external heat exchanger which separates

the solar loop from the domestic hot water loop.

The controller calculates the temperature difference between

the collector sensor S1 and the tank temperature sensor

S3. If this temperature difference reaches the switch-on

temperature difference, the primary loop pump is switched

on. If the temperature difference falls below the switch-off

difference the pump is switched off.

If the switch-on temperature difference between the upper

heat exchanger sensor S4 and the tank temperature sensor

S3 is reached, the secondary loop pump will be switched on.

Figure 31.

SENSOR DESCRIPTION

S1 Collector sensor

S2 Secondary loop heat exchanger sensor

S3 Tank sensor

S4 Primary loop heat exchanger sensor

RELAYS DESCRIPTION

R1 Primary loop pump

R2 Secondary loop pump

OPERATION AND FUNCTION

12 3

OPERATION

CONTROL LAMP

BACKWARDS FORWARDS

SET

(SELECTION / ADJUSTMENT MODE)

Figure 32.

The controller is operated by 3 push buttons below the display. The forward key (1) is used for scrolling forward through

the indication menu or to increase the adjustment values. The backwards key (2) is used for scrolling backward through

the indication menu or to decrease the adjustment values.

For system settings adjustment press the forward key to reach the last display channel. Then hold the forward button

down for 2 seconds and the system setting screens can then be shown. If an adjustable value is shown on the display

is indicated. To change the set value press the Set button (3) so that flashes. Adjust the value using button 1

or 2 until the desired value is shown then press button 3 so that permanently appears. The adjusted value is now

saved.

System Monitoring Display

System screen with toolbar

Channel display

The system monitoring display consists of 3 blocks: channel indication, the toolbar, and

system screen.

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

The symbols in the toolbar indicate the current system status:

STATUS STANDARD FLASHING

An adjustment value is being changed - SET MODE

Relay 1 active

Relay 2 active

Maximum tank temperature reached

Tank Emergency shutdown active

Collector emergency shutdown 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 error

Blinking control symbols

• Pump is blinking while running

• Sensors are blinking if the respective sensor indication channel is selected

• Sensors are quickly blinking if there is a sensor error

Operation control lamp indication

Constantly green: system operation normal

Red/green blinking: initialization phase / manual operation

Red blinking: sensor error

STARTUP / SYSTEM SETTINGS

The AC power cord should be plugged in to an appropriate 115V outlet. The controller will enter an initialization phase

in which the operating control lamp will flash red and green

When the controller is commissioned for the first time or after a system reset, it will run a commissioning menu. The

commissioning menu leads the user through the most important adjustment channels for operating the system.

Commissioning Menu:

Unit:

Adjust the unit in which the

temperatures and temperature

difference shall be displayed

Time:

Adjust the current time for the

real time clock.

The hours and minutes have

to be adjusted separately, rst

the hours, then the minutes.

Time format is 24 hours, e.g.

15:00h = 3 pm

Switch-on difference of

primary loop

Adjust the switch-on differ-

ence

Switch-on difference of

secondary loop

Adjust the switch-on differ-

ence

Switch-off difference

Adjust the switch-off differ-

ence

Target temperature

Adjust the target temperature

Completing the commis-

sioning menu

After the last channel of the

commissioning menu has

been adjusted and conrmed,

the controller asks for conr-

mation of the adjustments.

To conrm the adjustments

made in the commissioning

menu, press button 3

The controller is now ready for operation with typical settings to suit the system layout

The settings made in the commissioning menu can be changed later on in the corresponding adjustment channels. Ad-

ditional functions and options can be individually set by accessing the system adjustment channels.

Display Channels:

COL:

Collector Temperature

Display range: -40 to +482 °F

Shows the current collector temperature.

TST:

Tank temperature

Display range: -40 to +500 °F

Shows the current tank temperature (from tank bottom sensor).

TPRI:

Flow temperature of the pri-

mary loop

Display range -40 to +500 °F

Indicates the current ow temperature of the primary loop in

the Solex station.

TSEC:

Flow temperature of the sec-

ondary loop

Display range -40 to +500 °F

Indicates the current ow temperature of the secondary loop in

the Solex station.

n1%, n2%:

Current pump speed

Display range 30 to 100%

Indicates the current pump speed of the corresponding pump:

- n1%: current pump speed pump 1 – primary loop

- n2%: current pump speed pump 2 – secondary loop

h P1, h P2

Operating hours counter

Display channel

The operating hours counter adds up the solar operating hours

of the respective relay (h P1, h P2). Full hours are shown on

the display.

The total operating hours can be reset. When the operating

hours channel is selected the symbol is permanently

shown in the display. The set button (3) must be pressed for

approximately 2 seconds in order to go into the reset mode

for the counter. The display symbol will be ashing

and the operating hours will be set to 0. In order to nish the

reset procedure the set button (3) must be pressed in order to

conrm.

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.

kWh/MWh:

Heat quantity value shown

in the kWh and MWh display

channels. The sum of both

channels form the total heat

output.

The total heat quantity value can be reset. When one of the

heat quantity display channels is selected the symbol is

permanently shown in the display. The set button (3) must be

pressed for approximately 2 seconds in order to go into the

reset mode for the counter. The display symbol will be

ashing and the value for heat quantity will be set to 0. In order

to nish the reset procedure the set button (3) must be pressed

in order to conrm.

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.

TIME:

Current time based on 24

hour clock, e.g. 15:00 = 3 pm

To set the current time:

Press button 3 for two seconds to adjust the hours

Set the hours by pressing buttons 1 and 2

Press button 3 again to set the minutes

Set the minutes by pressing buttons 1 and 2

Press button 3 in order to save the adjustments

Once the nal 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:

Adjustment channels:

DT1O / DT20:

Switch-on temperature diff.

Adjustment range

2.0 to 40.0 °F

Recommended setting: 10.0

The controller works as a standard differential controller. It

calculates the temperature difference between the collector

sensor S1 and the tank temperature sensor S3. If this

temperature difference reaches the switch-on temperature

difference DT1O, the primary loop pump is switched on. If

the temperature difference falls below the switch-off difference

DTF, the pump is switched off.

DT F:

Switch-off temperature diff.

Adjustment range

1.0 to 39.0 °F

Recommended setting: 4.0

If the switch-on temperature difference between the upper heat

exchanger sensor S4 and the tank temperature sensor S3 is

reached (DT2O), the secondary loop pump will be switched on.

TMN:

Minimum runtime

Adjustment range

1 to 10 min

Recommended setting: 2

min

Solar loading will be carried out for the adjustable minimum

runtime TMN during which the switch-off condition will be ig-

nored to stabilize the system.

If the temperature difference between the upper heat exchang-

er sensor S4 and the lower heat exchanger temperature sen-

sor S2 falls below the switch-off temperature difference DTF

both loops will be switched off.

Note: The switch-on temperature difference must be at least 1°

higher than the switch-off temperature difference.

TAR:

Pump speed control target

temperature

Adjustment range

70 to 210 °F in steps of 2 °F

Recommended setting: 140

°F

The primary and secondary pump speeds are controlled based

on the target temperature of the upper heat exchanger sensor

S4.

The primary and secondary loop pumps will run at minimum

speed until the target temperature at S4 is reached. If the tar-

get temperature is exceeded by 5°, the speed of the primary

loop pump will increase by one step (10%). This state will be

held for 2 min even if the sensor temperature decreases. If,

during this time, the S4 temperature increases by more than

5°, the pump speed of the secondary pump will also increase

by 1 step.

This state will be held for 2 min each time the pumps increase

a step unless the temperature increases further by 5° and the

speed is increased another step. If the temperature decreases

the secondary pump will decrease by 1 step followed by the

primary pump.

n1MN, n2MN:

Minimum pump speed

Adjustment range

30 to 100%

Recommended setting: 30%

A relative minimum pump speed that can be allocated to the

outputs R1 (primary pump) and R2 (secondary pump) via the

adjustment channels n1MN and n2MN.

S MX:

Maximum tank temperature

Adjustment range:

100 to 160 °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 fur-

ther. A xed hysteresis of 4 °F is set for the maximum tank

temperature.

When the maximum tank temperature setting is reached the

symbol will be shown on the display.

EM:

Collector temperature limit

Adjustment range:

170 to 390 °F

Recommended setting: 270

°F

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). A hyster-

esis of 20 °F is set for the collector temperature limit.

If the collector temperature limit setting is exceeded the

symbol will be shown ashing on the display.

OCN:

Minimum collector limit

Adjustment: OFF / ON

Recommended setting: OFF

The minimum collector temperature is a minimum switching

temperature, which must be exceeded before the solar pump

(R1) is switched on. The minimum temperature will avoid short

cycling of the solar pump at low collector temperatures. If the

collector temperature is lower than the minimum collector tem-

perature set point the symbol will be shown ashing on the

display.

CMN:

Minimum collector temp.

Adjustment range:

50 to 195 °F

Recommended setting: 50 °F

Channel only available when

OCN is active

This function is unnecessary if the system backup heating ele-

ment has a set point maintained at 120 °F.

OCF:

Antifreeze function

Adjustment: OFF / ON

Recommended setting: OFF

This function is used to transfer heat from the storage tank to

the collector in order to avoid freezing of the heat transfer me-

dium in some system types.

Note: Since this function uses the limited heat quantity of the

tank, the antifreeze function should only be used in regions

with a few days of temperature around the freezing point. The

antifreeze function will be suppressed if the tank temperature

falls below 40 °F in order to protect the tank from frost damage.

If the system uses a 50/50 solution of propylene glycol and

water it is freeze resistant to -30 °F; therefore, this function is

not necessary.

There is an automatic antifreeze function for the heat exchanger

that activates R2 (100%) if the heat exchanger temperature

falls below 40 °F.

CFRO:

Antifreeze temperature on

Adjustment range:

38 to 48 °F

Recommended setting: 39

°F

Channel only available when

OCF is active

CFRF:

Antifreeze temperature off

Adjustment range:

40 to 50 °F

Recommended setting: 41

°F

Channel only available when

OCF is active

O TC:

Tube collector function

Adjustment: OFF / ON

Recommended setting: OFF

The tube collector function is only needed for systems that use

vacuum tube solar collectors.

This function is not necessary for this system.

OHQM:

Heat quantity measurement

Adjustment: OFF / ON

Recommended setting: OFF

If enabled a heat quantity measurement is possible for this

system in conjunction with the ow meter.

FMAX:

Volume ow in gal/min

Adjustment range:

0.0 to 5.0 gal/min in steps of

0.2 gal/min

Recommended setting: pump

station ow meter reading.

Channel only available when

OHQM is active

For OHQM to give an accurate reading the volume ow readable

at the owmeter (l/min) must be adjusted in the channel FMAX.

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

uid 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 uid

in this system may cause damage to the system or present a

health hazard

MED%:

Concentration of antifreeze by

volume %

Adjustment range: 20 to 70%

Recommended setting: 50

Channel only available when

OHQM is active.

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.

MAN1:

Operating mode R1

Adjustment range:

OFF / AUTO / ON / n1LO

MAN2:

Operating mode R2

Adjustment range:

OFF / AUTO / ON / n2LO

For system setup and service work the operating mode of the

pump can be manually adjusted by selecting the adjustment

value for MAN1, MAN2 as follows:

Operating mode:

OFF: relay off (ashing) +

AUTO: relay in automatic operation

ON: relay on (ashing) + +

n1(2)LO: minimum speed

Note: Always adjust the operating mode back to “Auto” when

the control and service work is completed. Normal operation is

not possible in manual mode.

UNIT:

Temperature units

Adjustment: FAH, CEL

Recommended setting: FAH

The temperature unit can be adjusted in this channel:

FAH: °Fahrenheit

CEL: °Celsius

RESE:

System reset

If the reset is selected, the controller will revert back to the fac-

tory settings and the commissioning assistant will be displayed

for new start-up.

The nal channel indicates the current version number for the controller. To exit out of the system setting mode press

the backward button (2) repeatedly until you reach the rst display channel (COL).

TROUBLESHOOTING

PROBLEM CHECK THIS POSSIBLE CAUSE CORRECTIVE ACTION

No hot water 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.

Not enough hot water Storage water heater 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.

Differential Controller Improper operation (cycling,

late turn on)

Check sensor placement

and insulation from ambient

conditions

Faulty sensor

is shown and control

reads 888.8 instead of

temperature

Sensor line break. Check the

line and repair or replace

Faulty sensor

is shown and control

reads -88.8 instead of

temperature

Short circuit. Check the line

for breaks, metal contact,

water exposure and corrosion.

PROBLEM CHECK THIS POSSIBLE CAUSE CORRECTIVE ACTION

Not enough hot water (cont.) Differential Controller Improper wiring or loose

connections)

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.

Piping Insufcient 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 ow

direction

Flow blockage Flush system. Check efuent

for debris.

Low system pressure Check pressure gauge. Set

system pressure to correct

setting, check for leaks.

Pump No power Check breaker, pump cord,

and controller fuse. Repair or

replace

Flow rated too high or too low Adjust ow 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

No hot water in the morning 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

Water too hot 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.

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

PROBLEM CHECK THIS POSSIBLE CAUSE CORRECTIVE ACTION

Pump does not start Electrical power supply 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

Pump starts, but cycles

continuously

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

Pump cycles after dark 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

Pump runs continuously Differential controller Off temperature differential set

too low

Reset off differential according

to recommendation

Controller set to “on” position Set system operation to

“Auto”

Pump operated but no uid

ows from collectors

Air Scoop System air-locked Purge air from air scoop in

solar pump station by opening

valve slowly. Caution: after air

is evacuated uid will ow out

in a small stream and may be

hot. Cover port with a rag to

catch any uid.

Air vent System air-locked Open air vent on the top of the

system and purge excess air.

Close after purging.

Fluid Loss of uid 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

Noisy system 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

uid will ow out in a small

stream and may be hot.

Cover port with a rag to catch

any uid.

Pump Bearings are dry or have

excessive wear

Lubricate or replace

Impeller loose Tighten or replace impeller

SYSTEM MAINTENANCE

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.

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

On an annual basis, all piping should be checked for leakage

at joints, and unions. Any damaged external insulation

should be repaired or replaced.

WIRING AND CONNECTIONS

On an annual basis, check wiring and connections, including

sensor wiring and splices. Look for signs of overheating,

discoloration, corrosion or loose connections. Any damaged

wiring should be repaired or replaced.

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.

EXPANSION TANK

Annually check condition of the solar expansion tank. Check

to see if it is waterlogged by quickly pressing Schrader valve

stem at bottom of the tank. You should get a quick burst of

air. If fluid is discharged, the tank may be waterlogged and

need replacement. Contact a qualified solar installer if the

tank needs replacement.

VACATION

For extended periods with no hot water usage such as

vacation it is recommend that the power to the pump station

be disconnected and that the solar collectors are covered

with a blanket or other means to prevent heat gain from

the sun to prevent system overheating and breakdown of

the glycol solution.

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 per loop. See Figure 33. The inlet water

shut-off to the unit itself shall also be closed. This will isolate

any electricity or fluids from entering the unit.

Figure 33.

REPAIR PARTS

REPAIR PARTS SCHEDULE

ORDERING REPAIR PARTS

The following parts may be ordered through the store or dealer from whom you purchased the solar water heater, or direct

from the factory listed on the model & rating plate located on the lower front of the solar water heater and by phone at

1-800-433-2545. Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be

billed accordingly. When ordering repair parts always give the following information: (1) Part description, (2) Model serial

number, (3) Element wattage, (4) Voltage, (5) Part number.

ITEM PART DESCRIPTION SERVICE

PART #

WATER HEATER SERVICE PARTS

1Primary Anode 9003892005

2 Anode Outlet 9006827005

3Primary Dip Tube 9002549005

4 Element w/Gasket 9003950115

5 Thermostat Bracket 9003898215

6 Thermostat w/High Limit 9007623015

7 Terminal Cover 9003914015

8Access Panel 9003900005

9 Sensor Mounting Plug 9007309005

10 Solar Loop Dip Tube 9006789005

11 Solar Loop Dip Tube w/Nipple 9006790005

12 Plastisert Nipple 9003976015

13 T&P Valve 9000728015

14 Drain Valve 9003906015

SOLEX DWHX PUMP STATION SERVICE PARTS

15 Temperature Gauge-Supply (Red) 9007789005

16 Temperature Gauge-Return (Blue) 9007788005

17 Pressure Gauge 9007454005

18 Resol BS Solex US Controller 9007785005

19 Solex Flowmeter 9007782005

20 Wilo Star S 21U-15 Primary Pump 9007783005

21 Wilo Star S 21BU Secondary Pump 9007784005

ITEM PART DESCRIPTION SERVICE

PART #

22 Pressure Relief Valve 9007460005

23 Temperature Sensor (Plug-In) 9007786015

24 Temperature Sensor (Screw-In) 9007787015

25 Sealing Cap 9007792015

26 Solex Gasket Kit (Not Pictured) 9007793015

MISCELLANEOUS SYSTEM SERVICE PARTS

27 Chromagen CR110 AP Solar Collector

(Not Pictured) 9007447005

28 Chromagen CR130 AP Solar Collector

(Not Pictured) 9007712005

29 Chromagen CR140 AP Solar Collector

(Not Pictured) 9007724005

30 Water Tempering (Mixing) Valve (Not

Pictured) 9007448005

31 Propylene Glycol HTF (DOWFROST)

5 Gallon (Not Pictured) 9007645005

32 Air Vent (Not Pictured) 9007451005

33 Solar Loop Expansion Tank (Not Pic-

tured) 9007456005

34 Collector Temperature Sensor (Not

Pictured) 9007461015

35 Tank Temperature Sensor (Not Pictured) 9007462015

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 aking and softening of skin.

Skin Absorption: Prolonged skin contact is unlikely to result in absorption of harmful amounts.

Inhalation: At room temperature, exposure to vapor is minimal due to low volatility. Mist may cause irritation of upper respiratory tract (nose and throat).

Ingestion: Very low toxicity if swallowed. Harmful effects not anticipated from swallowing small amounts.

Effects of Repeated Exposure: In rare cases, repeated excessive exposure to propylene glycol may cause central nervous system effects.

Component CAS # 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 ushing for several additional min-

utes. 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 specic 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 prop-

erly 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 brous insulations may lead to lowering of the autoig-

nition temperatures possibly resulting in spontaneous combustion.

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 materi-

als 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 appli-

cable 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

Specic 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/Provin-

cial 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 dened 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

320009

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