HTP FP-26SC, Installation And Maintenance Manual

Page 1: ...the right to make product changes or updates without notice and will not be held liable for typographical errors in literature This manual must be used by a qualified installer service technician Read all instructions in this manual before installing Perform steps in the given order Failure to comply could result in substantial property damage severe personal injury or death ...

Page 2: ... documents included with this system and additional publications such as Solar Water Heating System Design and Installation Guidelines be reviewed in their entirety before beginning any work The solar energy system described in 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 pro...

Page 3: ...ion 85 John Street New York NY 11038 The latest version of the National Electrical Code NFPA No 70 In Canada refer to Canadian Electrical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5N6 TABLE OF CONTENTS INTRODUCTION 6 ABOUT YOUR FLAT PLATE SOLAR COLLECTOR 6 PART 1 GENERAL SAFETY INFORMATION 6 A METALLIC COMPONENTS 6 B FLAT PLATE COLLE...

Page 4: ...ECTOR ANGLE TILT 14 3 COLLECTOR PLANE HORIZONTAL OR VERTICAL 14 I AVOID SHADE 15 J LOCATION 15 K EXPANSION TANK 15 1 OPEN LOOP SYSTEMS 15 2 CLOSED LOOP SYSTEMS 15 3 DRAIN BACK SYSTEMS 15 L LIGHTNING PROTECTION 15 M PIPE SIZING AND CONNECTIONS 15 N CONNECTION OF MULTIPLE COLLECTORS 16 O POTABLE WATER 16 P MOUNTING FRAME 16 Q GALVANIC REACTION 16 PART 4 MOUNTING INSTALLATION 16 A MOUNT TYPES 16 1 TI...

Page 5: ...OOP 24 3 CLOSED LOOP 24 D PLUMBING CHECK 24 E GLYCOL FREEZE PROTECTION 24 F INSULATION 24 G PUMP SELECTION 25 PART 7 SYSTEM PIPING DIAGRAMS 26 A REVERSE RETURN 26 B BALANCE FLOW VALVES WITH METERS 27 C PRESSURE SYSTEM PLUMBING PANEL ATTACHMENT 28 PART 8 MAINTENANCE 28 A CLEANING 29 B INSULATION 29 C OTHER COMPONENTS 29 D STAGNATION 29 PART 9 TROUBLESHOOTING 29 A NO HOT WATER 30 B REDUCED SOLAR CON...

Page 6: ... LOCAL CODES Only use this solar hot water system as intended and described in this installation manual Any use other than described will void warranty and may lead to fire property damage personal injury or death Install all system components and piping in such a way that does not reduce the performance of any fire rated assembly Failure to do so may lead to fire property damage personal injury o...

Page 7: ...ntil the affected component has been inspected by a qualified serviceman 1 FIRE 2 DAMAGE 3 SUBMERSION IN WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Use of lead solder is expressly prohibited Use of galvanized steel CPVC PVC PEX or any other type of plastic pipe is prohibited E TEMPERATURE LIMITATION To prevent s...

Page 8: ...d in open loop systems An open loop system may allow the solar collectors to stagnate to prevent overheating of the storage tank In the event of component failure the pressure relief valve must be able to release the increased pressure and should be rated to meet the maximum possible pressure output of the solar collector s Please see Part 3 for sections regarding overheating 2 CLOSED LOOP SYSTEMS...

Page 9: ...side the solar collector Scale deposits will reduce collector efficiency and eventually plug the collectors In such regions it is advisable to install a water softening device to ensure the long term efficient operation of the collector or consider a closed loop system In order to meet health and safety regulations glycol used should be food grade propylene glycol FDA rated as generally recognized...

Page 10: ... on the upper and 2 on the lower track each with a minimum pull strength of 150 kg 330 lbs If this cannot be achieved additional attachment points must be made to achieve minimum strength levels It is the responsibility of the installation contractor to ensure that the frame mounting is of suitable strength Where applicable inspection by building department officer or equivalent should be complete...

Page 11: ...l larger than 1 in diameter The ability of collectors to withstand hail impact is greatly influenced by the angle of impact so installing the collectors at low angles does reduce their impact resistance PART 3 INSTALLATION INFORMATION A TRANSPORT UNPACKING AND INSPECTION Solar collectors are normally transported in a protective crate Boxes containing the mounting assemblies will generally accompan...

Page 12: ...RONTAL AREA FT 2 23 6 29 9 37 4 ABSORBER PLATE AREA FT 2 23 2 25 7 36 9 FLUID CAPACITY gallons 90 1 05 1 22 NOMINAL FLOW RATE GAL MIN 0 8 1 5 gallons per collector 0 8 1 5 gallons per collector 0 8 1 5 gallons per collector Table 2 C TOOLS AND MATERIALS Make sure you have all necessary tools materials and accessories before beginning work on the solar system Following is a list of minimum tools re...

Page 13: ...ating the collector and plumbing in close proximity may reach temperatures greater than 395 o F components that may be exposed to these high temperatures such as valves plumbing or insulation should be suitably rated If the system is designed to allow stagnation of the collector when the tank reaches a set maximum level steam may form in the collector s In such a system temperature relief valves o...

Page 14: ...ce heating Subtract 15 o from the latitude to optimize for summer performance pool heating Given the formula above a solar collector installed at 30 o N latitude should face due south at an angle of 45 o for wintertime advantage and 15 o for summertime heating Preventing Overheating To reduce summer heat output angle the collector for optimal winter absorption This is achieved by installing the co...

Page 15: ...umping of water it is required to install a potable water expansion tank on open loop systems 2 CLOSED LOOP SYSTEMS Closed loop systems should always be installed with a solar expansion tank Refer to the solar expansion tank manufacturer s guidelines regarding correct sizing 3 DRAIN BACK SYSTEMS Expansion tanks are not required in drain back system design L LIGHTNING PROTECTION To avoid lightning ...

Page 16: ... that frame attachment points and externally supplied fasteners are of suitable structural strength and corrosion resistance Be sure to tighten all hardware securely Q GALVANIC REACTION Zinc galvanized components should NOT be installed in direct contact with stainless steel or aluminum as galvanic reaction between metals can cause premature oxidation of the zinc coating as well as the steel and a...

Page 17: ...ble to withstand in excess of 150 kg 330 lbs of pull force that may be encountered during high winds Consult a structural engineer if in doubt C TILT MOUNTS HTP Part FP SM The tilt mount package contains enough hardware to secure one collector Each set contains 6 Tilt hinges each with 20 stainless steel set screws pre installed 4 Triangle mounting feet 4 1 x 3 8 16 stainless steel bolts 2 4 x 3 8 ...

Page 18: ... 3 REAR MOUNTS Fully loosen the tilt hinge set screws Slide the tilt hinges to desired location along the top side of the collector Figure 7 Leave a 1 space between the tilt hinges Tighten set screw with a 7 16 wrench to a maximum of 10 foot pounds to lock the flush mount into position See Figure 8 Position the E1022 struts between the two tilt hinges on each side and align the hole in the strut w...

Page 19: ...h E E 115 Strut length E E 60 o 100 Strut length E E 124 Strut length E E C C of holes subtract 1 C C of holes subtract 1 E E end to end C C center to center Table 3 Rear strut length chart D FLUSH MOUNTS HTP Part FP FM The flush mount package contains enough hardware to secure one collector Each set contains 4 Flush mounts 20 stainless steel set screws pre installed per flush mount INSTALLATION L...

Page 20: ...ly dangerous Plan the installation carefully such that a safe distance from the edge can be maintained Sure footing is also required Be sure to wear sturdy rubber soled shoes NO SANDALS OR FLIP FLOPS Harnessing equipment for fall prevention is mandatory Be sure that the roof is dry before beginning installation Be sure that any ladders are set firmly against the side of the building and mounted pr...

Page 21: ...attaching to the roof surface it is important to ensure proper sealing to prevent water penetration It is also important to consider the building structure and roof construction type to ensure the structure is adequate for the collector s weight and can withstand wind loads as determined by local codes For commercial buildings it is especially recommended to consult a structural engineer Figure 18...

Page 22: ...boarding stainless steel screws that can penetrate into the wall framework may be suitable for mounting If the strength of these screws is a concern use bolts that run directly through the wood with a large washer or metal plate positioned before the nut Always consider the weight of the collector and the structural integrity of the wall before installation HTP requires that installations be inspe...

Page 23: ...n glycol based systems Tighten using two wrenches taking care not to stress the copper pipe Do not over tighten Brazing Sweating Soldering to the collector is acceptable but not recommended as doing so can damage the header grommet Care must be taken to avoid exposing the silicone rubber seal to the torch flame Ideally place a wet cotton cloth against the rubber seal to prevent heat damage C AIR P...

Page 24: ...te any possible points of heat loss Insulations should have a temperature rating of 250 o F Ensure the insulation is tight against the collector casing thus minimizing heat loss from the inlet and outlet High quality silicone sealant should be used to prevent water from entering the temperature probe port and or in between the piping and insulation foam Insulation foam exposed to direct sunlight s...

Page 25: ...ly Determine the vertical lift from the water level in the drain back tank to the top of the solar panels vertical lift is the same as head loss Refer to the chart below for pressure drop figures with a 40 glycol solution When using distilled water as HTF there is a further 20 reduction in pressure drop NOTE To convert psi to head feet multiply psi by 2 31 and divide total by specific gravity 1 fo...

Page 26: ...ll reduce or fail to deliver solar contribution To further increase solar production use a variable speed solar pump controller HTP part 8600 047 PART 7 SYSTEM PIPING DIAGRAMS Figure 23 System Piping Concepts A REVERSE RETURN Below you will find suggested collector piping diagrams utilizing reverse return for balanced flow NOTE Landscape or horizontal examples not recommended for drain back system...

Page 27: ...sted collector piping diagrams using balance flow valves and meters for balanced flow The following configurations may not work in drain back systems These drawings can be applied to various system configurations but may not meet certain requirements Figure 25 Balance flow meter suggested plumbing ...

Page 28: ... is maintenance free Other system components such as the pump and glycol if used may require periodic inspection and changing maintenance Please refer to the documentation provided by the manufacturers of these components NOTE Apart from those maintenance items outlined below any system inspection maintenance or repair should only be completed by authorized persons The solar collector warranty cov...

Page 29: ...ing the drain valve Failure to do so could result in property damage or serious injury C OTHER COMPONENTS Other parts of the system such as the pump and storage tank should be serviced inspected according to the manufacturer s maintenance guidelines D STAGNATION Drain back systems These systems may be stagnated Pressure glycol systems If left unattended for a significant length of time greater tha...

Page 30: ...m with your solar heating system This may be due to an incorrectly configured controller pump malfunction or problem with the boosting system In such cases please contact the company who supplied and installed the system INVESTIGATION H 1 Does the circulation pump appear to be operating In sunny weather the circulation pump should come on for 1 2 minutes ever 3 5 minutes The pump may run very quie...

Page 31: ... PLUMBING PIPE RUNS ARE WELL INSULATED Y N 9 INSULATION ABOVE ROOF LEVEL IS PROTECTED AGAINST SUNLIGHT WITH FOIL WRAP OR EQUIVALENT Y N 10 CONTROLLER IS CONFIGURED CORRECTLY WITH FREEZE SETTING ON IF REQUIRED Y N 11 SYSTEM IS FITTED WITH PRESSURE RELIEF VALVE ON THE COLLECTOR OUTLET AND OR STORAGE TANK Y N 12 PRESSURE RELIEF VALVE WILL DUMP ONLY ONTO HIGH TEMPERATURE RESISTANT MATERIAL AND WILL NO...

Page 32: ...32 MAINTENANCE NOTES ...

Page 33: ... Date of Installation Installer s Code Name Product Serial Number s Comments Installer s Phone Number 1 Signed by Installer Signed by Customer 2 IMPORTANT Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make contact please con...