Sol-R-Therm NEW PRODUCT LINE - Home | NTI Boilers COMMISSIONING AND OPERATION ... The Sol-R-Therm Installation and Operation Manual included ... Check shipment contents against Sol-R-Therm

Sol-R-Therm Model Numbers: SRT-Pk1 & Pk2 and

SRT-Pk1E & Pk2E Version Date: 2013-04-05

65 Drury Cove Road Saint John, NB E2H 2Z8 Canada

PACKAGED SOLAR DOMESTIC HOT WATER SYSTEM INSTALLATION AND OPERATION INSTRUCTIONS This manual to be read in conjunction with the "TRI N & STOR Installation and Operation Manual" included with the solar tank.

TABLE OF CONTENTS Certifications and Approvals...............................................................................................................3

1.0 SOL-R-THERM SYSTEM OVERVIEW ...........................................................................................4 System Configuration..........................................................................................................................6 Solar Preparation.................................................................................................................................6 Equipment Installation ........................................................................................................................6 Commissioning and Operation............................................................................................................6

2.0 SOLAR ASSESSMENT .....................................................................................................................8 Site Solar Evaluation...........................................................................................................................8 Finding True South .............................................................................................................................9 Obstructions and Shading..................................................................................................................10 Tilt and Latitude................................................................................................................................11 Clearances .........................................................................................................................................13

3.0 SOLAR INDIRECT WATER HEATER ..........................................................................................14 4.0 PUMP STATION..............................................................................................................................15

FlowCon B Pump Station..................................................................................................................16 Expansion Tank Connection Set .......................................................................................................16 Solar Expansion Tank .......................................................................................................................17

5.0 FLUSH MOUNT SYSTEM..............................................................................................................18 Roof Preparation ...............................................................................................................................18 Collector Layouts ..............................................................................................................................19 Installing FastJack.............................................................................................................................21

6.0 COLLECTORS.................................................................................................................................23 Hardware...........................................................................................................................................23 Rail Sets ............................................................................................................................................23

7.0 SOLAR PLUMBING........................................................................................................................27 Solar Circuit ......................................................................................................................................27 Collectors to Pump Station................................................................................................................30 Pump Station Connections ................................................................................................................32 Pump Station to Solar Tank Heat Exchanger ....................................................................................32 Solar Tank Connections by System Configuration ...........................................................................32

8.0 FIELD WIRING................................................................................................................................34 9.0 CONTROL MODULE......................................................................................................................35

System Configuration........................................................................................................................35 Controller Options.............................................................................................................................42

10.0 HEAT TRANSFER FLUID ..............................................................................................................48 Recommended Use and Restrictions .................................................................................................48

11.0 COMMISSIONING AND OPERATION .........................................................................................52 Filling the System .............................................................................................................................52 Commissioning the System...............................................................................................................53 Draining the System..........................................................................................................................53

12.0 MAINTENANCE AND TROUBLESHOOTING ............................................................................56

Installation Instructions - The Sol-R-Therm Installation and Operation Manual included with the system must remain at the site where the Sol-R-Therm system is installed.

Approved Heat Transfer Fluid - Recommended minimum concentration is Dowfrost mixed 40/60 with de-ionized water, freezing point -20.1°C (-4.2°F). Refer to Dowfrost

Production Information Sheet for environmental conditions and different freeze protection by volume %. Substitution of any other heat transfer fluid can cause irreparable damage and create a health and safety hazard.

\\\\ NEW PRODUCT LINE Solar Domestic Hot

Water System

Sol-R-Therm Installation and Operation Instructions Packaged SDHWS

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ICONS AND CHECKLISTS

Certification When you see this icon, look for applicable standards, certifications, performance ratings, and approvals for the Sol-R-Therm system.

Supplies A minimum list of supplies required to install the Sol-R-Therm system.

Pre-Installation Checklist When you see this icon, look for the checklist beside it listing preparation tasks or installation prerequisites to be completed prior to the installation checklist.

Tools Recommended list of tools required by installing Contractors to mount collectors, fill the system, and install the solar piping.

Installation Checklist This icon indicates there is an installation checklist and steps to be completed in sequence. Refer to the figures referenced, as they show assembly procedures or the finished assemblies.

Trade Tip Guidelines or trade tips specific to the NTI Sol-R-Therm system or best practice when installing solar domestic hot water systems.

Safety Equipment Be smart, stay alive and use the necessary safety equipment when working on ladders, roofs, lifting heavy equipment, or working with electrical power. Hazard Symbols in the manual indicate potential hazards and how to avoid them.

Supplemental Instructions Indicates that there are additional instructions or guidelines specific to a particular piece of equipment or system component that should be read in conjunction with the NTI Sol-R-Therm manual.

HAZARD SYMBOLS AND DEFINITIONS

Danger Sign: Indicates a hazardous situation which, if not avoided, will result in serious injury or death.

Warning Sign: Indicates a hazardous situation which, if not avoided, could result in serious injury or death.

Caution Sign plus Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Caution Sign without Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in property damage. Notice Sign: Indicates a hazardous situation which, if not avoided, could result in property damage. Important Sign: Indicates a hazardous situation which, if not avoided, could result in property damage.

Instructions

Trade Tip

Tools

Supplies

Safety

�� Check List

�� Check List

Approvals

Packaged SDHWS Installation and Operation Instructions Sol-R-Therm

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\\\\ Certifications and Approvals The Sol-R-Therm system can be used for large scale commercial applications or as a certified packaged solar domestic hot water system for residential applications. There are several packaged systems listed in this manual; however, only the ones listed on this page are certified to the residential certification standards. There is currently no certification standard for commercial solar thermal systems. NTI recommends the following design guidelines. For more information about Sol-R-Therm including downloadable pdfs or certification listings, visit the NTI website at www.nythermal.com.

Residential Solar Water Heating

United States Standard Description Product Classification Certification # SRCC OG-100 Solar Collectors SRT-215 Flat Plate, Glazed 100-2012-051A

SRCC OG-300 Packaged SDHWS SRT-Pk1, SRT-Pk2 Pre-heat System Pending

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.

Canada Standard Description Product Classification Certification # CAN/CSA F-378-87 Solar Collectors SRT-215 Flat Plate, Glazed 031285_0_000

CAN/CSA F-379.1-09 Packaged SDHWS SRT-Pk1, SRT-Pk2 Pre-heat System Pending

EEV Mark - This marking indicates that the product is in compliance with the requirements of CSA energy efficiency and performance standards, as verified under the CSA Energy Efficiency Verification program. Collector SRT-215 is listed by CSA International as complying with the Energy Efficiency Verification Service requirements

Commercial Solar Water Heating There is currently no certification standard for large scale commercial solar thermal systems. The American Society of Heating, Refrigeration and Air Conditioning Engineers, also known as ASHRAE, has three (3) solar system guideline documents which are the most comprehensive commercial solar system guidelines available at this time. To view these documents, visit http://www.solar-rating.org/commercial/index.html or contact NTI directly at 1-800-688-2575 for more information on commercial applications.

� Active Solar Heating System Design Manual � Active Solar Heating Systems Installation Manual � Guideline for Preparing Active Solar Heating Systems Operation and Maintenance Manuals

Engineered Rack Mount Systems - A rack mount system suitable for commercial applications or flat roof installations; available with stamped engineered drawings for anywhere in North America and optional roof anchors. Contact NTI for more details.

Approved Heat Transfer Fluid

DowFrost™ inhibited propylene glycol concentrate is provided with each Sol-R-Therm system. Substitution of any other heat transfer fluid can cause irreparable damage and

create a health and safety hazard.

Regulatory Information - Refer to Dowfrost ™ MSDS, Section 15 for Regulatory Information regarding Toxic Substances, Domestic Substances List, Hazardous Products Act.

US Food and Drug Administration (USFDA) - Dowfrost ™ ingredients meet AWWA GRAS requirements, an acronym for "generally recognized as safe" and are listed as such by the U.S. FDA under regulations 21 CFR 182.6285 and 21 CFR 184.1666 as per Standard SRCC OG-300 requirements. The FDA has approved the individual chemicals used in Dowfrost ™ but does not approve the products of any manufacturer.

Canadian Food Inspection Agency (CFIA) - All ingredients are rated as non-toxic and listed as "food grade" by the Canadian Food Inspection Agency as per Standard CSA F-379 requirements.

Approvals


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1.0 SOL-R-THERM SYSTEM OVERVIEW Sol-R-Therm systems are the optimum sustainable domestic hot water heating system, in that they combine advanced renewable energy technology from the solar industry with energy efficient, state-of-the-art NTI heating products. The benefit of purchasing a packaged system is that the design work has been done in advance which saves a lot of time during installation. Simply unpack the Sol-R-Therm system then review the 4 major installation stages at the end of this section: 1) System Configuration, 2) Solar Preparation, 3) Equipment Installation, and 4) Commissioning and Operation.

Unpacking the System Pre-installation and Inspection 1. Remove plastic wrap from equipment. 2. Inspect equipment for shipping damage upon delivery. 3. Check shipment contents against Sol-R-Therm Systems (Table 1-1). 4. Verify both manuals are included, Sol-R-Therm and Trin & Stor. 5. Do not pick up or carry collectors by cardboard-corner packaging. 6. See The Big Picture and 4 major installation steps (Table 1-2). 7. Go to Master Reference Guide for a list of tools/supplies (Table 1-3).

Parts and Service NTI Sol-R-Therm systems and parts are available from participating wholesalers who sell to installers and service contractors in the area. Refer to Tables 1-1 for a list of standard components included with each Sol-R-Therm System or Table 1-2 for a list of individual replacement parts or accessories. To locate an NTI wholesaler visit our website at www.nythermal.com. To enquire about parts contact NTI Inside Sales or call 1-800-688-2575.

Technical and Training If you are a wholesaler wanting to host an NTI Sol-R-Therm training workshop or an installer requiring technical assistance, contact NTI Technical Support at [email protected] or call our toll free number 1-800-688-2575.

Warranty Registration

The Sol-R-Therm Warranty and Trin & Stor Warranty are shipped with the system and tank respectively and describe warranty coverage, actions required to obtain coverage, and how to register the warranty on line.

Table 1-1 Sol-R-Therm Systems Part No. Description SRT-Pk11 �� SRT-Pk2

1 �� SRT-Pk1E 2 �� SRT-Pk2E

2 ��

S80SR Trin & Stor 80gal Solar Indirect WH 1 - - - - - - S120SR Trin & Stor 119gal Solar Indirect WH - - 1 - - - - SL80SRE Trin & Stor 80gal Solar Indirect WH - - - - 1 - - SL120SRE Trin & Stor 120gal Solar Indirect WH - - - - - - 1 84169 FlowCon S21u-15 Pump Station 1 1 1 1 84323 Expansion Tank, Extrol S-60 1 1 1 1 84176 Expansion Tank Connection 1 1 1 1 84177 Roof Mount Legs, 4.5" FastJack 6 8 6 8 84221 Roof Flashing, 1/2"-1" Oatey 6 8 6 8 84159 SRT-215 Collector, Flat Plate 2 3 2 3 84161 SMP-SHS2 Rail Set (2 Col.) 1 - - 1 - - 84162 SMP-SHS3 Rail Set (3 Col.) - - 1 - - 1 84165 Hooks-clamps x 2C 1 - - 1 - - 84166 Hooks-clamps x 3C - - 1 - - 1 84168 SVP-WR Quick Connection Set 1 2 1 2 SRT-Kit2 Collector Adapter Kit 1 1 1 1 84172 Pre-insulated Line Set, 5/8" SS, 50′ 1 1 1 1 SRT-Kit1 Solar Plumbing Accessory Kit 1 1 1 1 84174 DowFrost Glycol pure, 5gal (20L) 1 1 1 1 81313 Relay, R8285A 1048 Control Center - - 1 1

�� Check List


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\\\\ Table 1-2 Optional Parts and Accessories Part No. Description Comments

- Amtrol Expansion Tank, 30 gal Note 2

- UT/Solaflex High Temp Pipe Insulation Note 3 - HT 625 Adhesive Note 3 - Armacell Solar Tape (UV resistant) Note 3 - FKP6 Sensor/High Temp Blk Cable, 5’ Note 1 - FRP6 Sensor/PVC White Cable, 8’ Note 1 - Positive Displacement Fill Pump w/ Filter Note 3 - Overvoltage Protection (RESOL SP1) Note 3 - Sol-R-Therm Toolbox Note 3 - Engineered Rack Mount System 3 Note 4

Notes: 1 - Standard replacement parts for Sol-R-Therm packaged systems. 2 - Permitted on 2 collector systems only if installed with a vertical

height ≤30’ and total lineset length ≤150’. (NTI P/N 84171). 3 - Optional parts, supplies, or accessories available upon request.

Contact NTI for more information at 1-800-688-2575. 4 - Commercial rack mount systems c/w stamped engineering drawings

are special order. Contact NTI for more information.

Table 1-3 Sol-R-Therm Specifications (complete for SRCC OG-300) Part No. Description Rating Characteristics / Comments

Electrical Wiring Specifications - Sensor Wiring, FKP6 Pt1000, Black, 5’ - 356oF Weather/temp resistant silicone wire insulation.

- Sensor Wiring, FRP6 Pt1000, White, 8’ - 356oF PVC wire insulation.

- Sensor Wiring, Solar Piping, Red/Blue, 50’ - 392oF PVC wire insulation.

- Power Wiring, Line Voltage, 120V 90oF 194oF Controller to Solar Pump

- Power Wiring, Line Voltage, 120V 60oF 1401oF Controller to Outlet

x

x

x

x

x

Notes: 1 Tanks for Systems SRT-Pk1 & Pk2 have an extra heat exchanger coil in the top of the tank for auxiliary boiler backup. 2 Tanks for Systems SRT-Pk1E & Pk2E come standard with an electric element for auxiliary backup.


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\\\\ System Configuration Section 9.0: Select the best system configuration for the application. There are five types described under System Configurations in Section 9.0: 1-basic preheat, 2-preheat with auxiliary storage, 3-preheat with surplus heat distribution, 4-supplemental with boiler backup, or 5-supplemental with electric backup. See Figure 1-1 for an example of a system configuration diagram.

Solar Preparation Sections 2.0 - 4.0: Before installing a solar thermal system, the building should be "Solar Ready". There are three (3) main areas which should be prepared or planned out before installation begins, these are: roof, typically where collectors are installed; utility room, typically where the solar tank and pump station are installed; pipe chase (easiest route) to connect collectors and pump station. Ensure building materials adjacent to solar components are not exposed to elevated temperatures. Solar piping, tank, pump station and back of collector are insulated to minimum R-5.0.

On the Roof - Listed below are some important points to consider when preparing to install a solar thermal system on the roof. The Solar Assessment section guides you through the site assessment process and explains key factors used to determine the most suitable location for the collector installation and what preparation is need prior to installation. NTI recommends having an experienced installer or solar professional assess your site prior to installation to determine if your site or is optimal for solar. 1. Assess the site for solar potential and determine the best location for collectors as per Section 2.0. 2. Verify roof slope. If less than 20o, roof slope is too shallow for collectors to vent. See Table 2-2 for options. 3. Evaluate if the roof area selected is large enough for the collector array. 4. Locate collectors so they can be accessed for service and maintained with minimal effort. 5. The solar thermal system should blend with the building architecture or landscaping. 6. Check that the roof structure conforms to current building codes for loading.

In the Utility Room - Determine the room where the solar tank, pump station and controls will be installed. Typically this is the utility room. There are some basic things to consider before installing equipment. 1. Locate solar tank and pump station in a room that is dry and where temperature is never below 50oF (10oC). 2. Install domestic plumbing as per Section 3.0. 3. Mount pump station to wall near solar tank as per Section 4.0.

Routing Piping - Determine the best solar piping route: 1. If routing line sets through attic roof, use PVC pipe and a 90o elbow to

protect line sets. Elbow must NOT be pointing up or it will collect water. 2. Inside the attic, support line sets with pipe hangers so that insulation is not

compressed. Support the PVC pipe where it exits the roof, 4" PVC will take both lines. Feed line sets through the PVC conduit in the roof, slide elbow over line sets, then attach elbow to PVC conduit. Flash and seal all roof penetrations (Fig. 1-2). Complete firestopping during install (if required).

3. If routing down the building facade, ensure all wall penetrations are weatherized and solar piping is adequately supported by the building.

4. Approximate the distance between the collectors and pump station in the utility room and determine if more solar piping will be needed. If total distance is greater than 50’, refer to Section 4.0, "Expansion Tank". The vertical height between the top the collector air vent and top of the pump station must be known to set the expansion tank pressure prior to filling the system (Table 4-2).

5. If the solar piping run is less than 15’ or stagnation is frequent, a cooling loop may need to be installed. For more information, contact NTI at [email protected] or call our toll free number 1-800-688-2575.

Equipment Installation Sections 3.0 - 10.0: Once the three (3) main areas have been prepared, the next sections of the manual will guide you through the installation procedure for each piece of equipment in the Sol-R-Therm system from pump station to collectors, including step-by-step installation instructions, illustrated assembly procedures, and system configuration setup. Follow the installation procedure sequence to avoid component damage and personal injury.

Commissioning and Operation Section 11.0: This section guides installers through the operation and commissioning process. It is important to note that the white collector covers should not be removed until the system is ready to be commissioned. Installing contractors requiring assistance can contact NTI Technical Support directly by calling 1-800-688-2575.

_Figure 1-2 Roof Penetration _

Figure 1-1 Configurations


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\\\\ Table 1-3 Master Reference Guide

Symbols Description Itemized List

De-ionized water

Container for mixing glycol

Thread tape and paste

Hose with NPT fitting for filling the system

High temp closed-cell pipe insulation, R-2.6 (pump station>tank)

Cold water pipe insulation, R-2.6 (last 5 feet to tank)

Pipe hangers to support solar piping (attic or building exterior)

Minimum list of supplies required to install the system.

PVC - 4" pipe, 2' length, 4" elbow, 90 degree (

Fill pump with filter

Wire cutter and/or stripper

Standard tube cutter

Channel locks, 1-1/2" minimum jaw capacity

Adjustable wrenches (2)

Phillips screw driver

5/16" drill bit (mounting pump station to wall)

Utility knife (hooked blade recommended)

Ratchet with extension and 9/16" (15mm) socket

Stud finder

Chalk line and/or lumber crayon

3/8" masonry drill bit (for breaking through asphalt shingles)

3/16" drill bit (for FastJack pilot hole)

Impact wrench and 1/2" (15mm) socket

Suggested list of tools and equipment that will be needed to mount collectors, fill the system, and install the solar piping.

Multimeter

Use a combination of thread tape and thread paste on solar fittings.

Mix DowFrost™ glycol concentrate with de-ionized water only, available at most wholesalers or pharmacies (DO NOT mix glycol with distilled water or tap water). Determine freeze protection required, then add extra 9oF (5oC) of freeze protection for safety.

Trade Tips specific to the Sol-R-Therm system and/or solar domestic hot water system installations.

DowFrost™ is a propylene glycol with food grade corrosion inhibitors that meet the requirements of Standards CSA F-379 and SRCC OG-300 for use with solar single wall heat exchangers.

FlowCon B Booklet

Amtrol Solar Extrol Installation and Operation Instructions

DeltaSol BS Plus Booklet

DowFrost Product Information Sheet

DowFrost MSDS

Supplemental instructions may be provided with specific components and are to be read in conjunction with the NTI Sol-R-Therm and Trin & Stor manuals. Note NTI manuals are specific to the system and take precedence over generic supplemental instructions.

Ladder and/or crane

Fall arrest equipment

Safety glasses

Sturdy footwear with good grip

Recommendation of safety procedures and equipment required when working at heights, climbing ladders, electrical power, and high water temperatures.

Lightning Protection - unless local codes state otherwise, it is not required for collectors that are bonded to ground via copper plumbing, meaning the water main entering the building must be copper and below grade (i.e. in direct contact with the earth).

Tools

Trade Tip

Supplies

Reference

Safety


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2.0 SOLAR ASSESSMENT Site Solar Evaluation This section explains basic site assessment concepts and rules-of-thumb for orientation, identifying obstructions, and impacts of collector tilt angles. Not all homes and properties have good solar access due to roof orientation or obstructions that shade the roof, so before installing a solar hot water system have a qualified solar installer visit the site to figure out what you have to work with. A site evaluation prior to installation is an investment that can save you money, especially if your site is not suitable for solar. By the same token, proper solar orientation can dramatically lowered domestic water heating expenses.

If applying for solar hot water incentives, check with your solar incentive program provider to verify rebate requirements. For incentive programs requiring shading analysis, isolation patterns, and sun path charts, consult a professional solar site evaluator.

Figure 2-1 Sun Chart

Terminology

Altitude Sun’s angle above the earth that changes with the seasons. Azimuth Angle Horizontal angle or orientation with respect to True South. (i.e. True South, Azimuth =0). Horizon The line or circle that forms the apparent boundary between earth and sky. Inclination Angle The angle of the collector above the horizontal plane; collector tilt angle. Magnetic Declination The azimuth offset between True and Magnetic North, expressed in degrees east or west. Magnetic North Earth's magnetic north pole, direction the north-seeking magnetic needle points. Solar Noon The time when the sun is at its highest; half way through its daily journey across the sky;

same azimuth location every day; solar noon is not to be confused with 12 o’clock noon. Sun’s Path rises in the east (sunrise), journey’s across the sky, sets in the west (sunset). True Bearing Used in navigation; grid lines on a map are the true bearing; due north and due south. True North Direction from an observer’s position to the geographic north pole or north meridian. True South The azimuth when the sun is highest (solar noon); 180o from True North. Zenith The point in the sky directly above you; 90 degrees above the horizon.

Evaluation

Solar Noon

The Big Picture - The sun’s altitude changes constantly during the year, climbing higher or lower in the sky, as it transitions between seasons. Optimize the collector tilt angle for a specific season. Solar Noon, the time when the sun is strongest, occurs when the sun is at the highest point in its daily path, the same time it’s horizontal angle aligns with True South (Azimuth=0). Optimize collector orientation by pointing collectors True South.

Zenith 90 o

Sunset

Sunrise


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MB = Magnetic Bearing TB = True Bearing D = Declination MN = Magnetic North = True North

East Declination

West Declination

Finding True South Solar thermal collectors should be aimed directly at "True South" , whenever possible. The colder the climate the less hours of daylight and the more important it is to point collectors True South, as the sun is strongest in that direction, specifically at solar noon. True South can be located by using any of the following rule-of-thumb methods: • solar noon method • smartphone compass apps • compass bearing

Solar Noon Method (Figure 2-1) When east and west horizon are approximately at the same elevation, sunrise and sunset times can be used to determine the time and direction of solar noon and True South, respectively.

1. Sunset - Sunrise = Total Daylight Hours 2. Total Daylight Hours ÷ 2 = Midpoint of Sun’s Path 3. Sunrise + Midpoint of Sun’s Path = Solar Noon 4. At Solar Noon the sun will be at the True South azimuth.

Smartphone Compass Apps A word of caution about smartphonee GPS. Older generation smartphones use vector analysis and in-motion based coordinates which are often inaccurate. A more reliable method is a 3GS compass app that augments the phones GPS with the local magnetic declination and automatically converts it to the True Bearing.

Compass Bearing and Declination (Figures 2-2 and 2-3) 1. Find the Declination for your city or zip/postal code using the on-line magnetic declination calculators listed below. 2. Find the magnetic bearing for Magnetic North on your compass. Hint: red end of the needle points toward magnetic north. 3. Adjust declination of magnetic bearing for True North. Hint: Magnetic bearing +/- declination = True Bearing 4. True North + 180o = True South.

While facing the building, align the True North bearing so it points directly at the potential collector location. True South will be the direction the collectors are facing which should be directly behind you. If collectors are not facing True South, then determine if they are in the preferred orientation zone and enough solar access.

Figure 2-3 Reading the True Bearing

Figure 2-2 Adjusting for Declination

A compass bearing can be affected by the presence of iron or magnetic objects, so stay clear of railway tracks, big trucks, or power lines. Personal items such as oversize belt

buckles and cell phone cases with self-closing magnetic clasps can affect a compass bearing if held too close to it.

Magnetic Declination Calculators Canada http://geomag.nrcan.gc.ca/apps/mdcal-eng.php United States http://www.ngdc.noaa.gov/geomagmodels/struts/calcDeclination

Orientation

MN MN

East Declination

West Declination

read True bearing here


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\\\\ Obstructions and Shading The collectors performance is dependent on how much solar exposure it gets, so before deciding on location and orientation, look around for any permanent objects that could obscure the sun, cause excessive shading of collectors, or create mutual shadowing. Shading can be tolerated in the morning and evening, and is to be avoided during times of maximum solar gain, typically solar noon + 2 hours. Obstructions can be on the roof, such as chimneys, satellite dishes, and dormers or seemingly far away, like buildings or trees. Site specific permanent weather patterns that habitually obscure the sun should be treated as obstructions.

Preferred Orientation Zone Although the optimum solar orientation is True South, there is a preferred orientation zone. If collectors are oriented within 30o of solar noon (+ 2 hours), only 18% of the total solar gain available will be lost (Figure 2.4). The zone should be un-shaded by any permanent obstacles. If trees or tall objects are located within the zone, see Figures 2.5 and 2.6 to check if obstructions will shade collector during solar noon + 2 hours.

Site Specific Weather Take note if the local latitude is subject to specific weather patterns such as extended periods of afternoon cloud or rain (i.e. Honolulu, HI). If a good portion of afternoon solar gain is typically lost due to weather, the collectors may need to be optimized for the 2 hours just before solar noon. Places along the coast that typically experience poor solar exposure in the mornings due to fog (i.e. Saint John, NB) may need to orient collectors to take advantage of the afternoon sun or the first 2 hours after solar noon.

Estimating the Height of Obstructions The relationship between elevation and distance can be used to determine if trees in the preferred orientation zone will obstruct collectors (see Figure 2.5).

A - Elevation: Use a pencil to estimate the height of the tree as show. Align pencil so the eraser end is level with the tree top and thumb position is level with the tree base. The pencil represents the height of the tree.

B - Distance: Turn pencil sideways. Have someone measure the distance as they walk from the base of the tree to the end of the pencil. The distance walked is the height of the tree.

Half-Height Rule Once you know the height of trees, existing buildings or other tall objects on or near your site, you can determine which ones will be obstructions by using a 2:1 ratio or the half-height rule illustrated in Figure 2.6.

Figure 2-6 Half-Height Rule

Figure 2-4 Preferred Orientation Zone

Figure 2 -5 Estimating the Height of Obstructions

A

B

Shading

Full grown trees or tall objects within the Preferred Orientation Zone of the building should be no higher than half their distance from the collectors or they will become obstructions and shade collectors during solar noon + 2 hrs. Trees can easily grow 20” (0.5m) in a year.

Maritime Solar Shelter Manual

1h

2h


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\\\\ Tilt and Latitude Latitude (north-south) and Longitude (east-west) are how your site location is defined on the surface of the earth. The amount of energy a solar collector receives depends on the angle the suns rays make with its surface and is greatest when the sun’s rays are perpendicular to the collector. Being at right angles to the sun’s rays may provide more energy then you need in some seasons and not enough at other times of the year. In cases like these, the collector tilt angle can be optimized for the specific season desired depending on the mounting system used and available clearances at the desired collector location.

Collector Tilt Angle The angle of inclination refers to the angle the collector is tilted above the horizontal (Figure 2-7). To optimize for a season, the collectors should be perpendicular to the sun’s rays. It is important not to confuse altitude with the tilt angle. In the summer when the altitude of the sun is higher in the sky the collector tilt angle should be lower. Like wise in the winter, the sun’s altitude is lower because it is farther south, and so the collector tilt angle should be higher above the horizon than the local latitude to be more at right angles to the sun’s rays. This is desirable but not always practical as the collector tilt angle may or may not be adjustable depending on the mounting system. Refer to Flush Mount vs Racking for more details. Optimizing for Specific Seasons

The sun’s altitude above the horizon changes from one season to another (Figure 2-8) and can be used to determine the best collector tilt angle, which is perpendicular (⊥) or 90o to the sun’s rays. During Spring/Fall Equinox, Mar 21th and Sep 21st, the sun passes over the equator. Collectors with tilt angles equal to the local latitude are optimized for these seasons.

In the summer, the sun travels due north (True North) of the equator until it reaches 23.5o on Jun 21st (Summer Solstice). The altitude of the sun above the horizon at this time is: zenith angle (90o) - latitude + 23.5o. The collector tilt angle typically used to optimize for summer is: latitude -15o, or roughly the middle of the summer season rather than just the longest day of the year.

During the winter season, the sun travels due south (True South) of the equator until it reaches 23.5o on Dec 21st (Winter Solstice). The altitude of the sun above the horizon at this time is: zenith angle (90o) - latitude - 23.5o. The collector tilt angle typically used to optimize for winter is: latitude +15 o, or roughly the middle of the winter season rather than just the shortest day of the year. Refer to Table 2-1 for an example of how to calculate Collector Tilt Angle.

Table 2-1 Optimizing for Specific Seasons Season Collector Tilt Angle Example at 40o Local Latitude Tilt Angle (ββββ) Spring/ Fall zenith angle – local latitude 90o – 40o 50.0o

Summer zenith angle – local latitude – 15o 90o – 40o – 15 o 35.0o

Winter zenith angle – local latitude + 15o 90o – 40o + 15 o 65.0o

Latitude

Figure 2-8 Sun’s Seasonal Path

Note: This diagram shows the altitude of the sun at Equinox, Summer Solstice, and Winter Solstice for a Latitude equal to 40 degrees in the Northern Hemisphere.

Figure 2-7 Inclination

ββββ = Tilt Angle horizontal ββββ

Solar Collecto r


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\\\\ Flush Mount vs Racking The maximum energy collection over the course of the year is typically obtained when the tilt angle is equal to the latitude of the location. This would optimize solar gain for the spring/fall seasons. Flush roof mount systems align collectors with the slope of the roof which essentially determines the collector tilt angle. In comparison, rack systems allow the angle of the solar collectors to be adjusted to the desired inclination. With the right roof mount system almost any roof can be used to obtain the desired collector slope. Regardless of the system used, the collector shall be installed on a mount capable of maintaining tilt and azimuth to design conditions.

Each Sol-R-Therm system includes a flush mount system to secure collectors to the roof. For flush mount systems on a sloped roof, the collector tilt angle is fixed and will be the same as the pitch or slope of the roof. This type of roof mounting system does not lend itself to optimizing for a specific season unless a tilt up kit is used in combination with it. If the local latitude and roof slope are known, then the resultant tilt angle of the collector and optimized season can be identified as per Table 2-3.

For ground or roof racking installs, the collector tilt angle can be optimized for the latitude or specific season by using an adjustable mounting system that permits the angle above horizontal to be set by the installer. Table 2-3 can be used to find the collector tilt angle for a given season or latitude.

Table 2-2 Slope of Roof Mounted Collectors

Finding the Existing Roof Pitch Pitch (") Slope ( o)

12 / 12 45.0

11 / 12 42.5

10 / 12 39.8

9 / 12 36.9

8 / 12 33.7

7 / 12 30.2

6 / 12 26.6

5 / 12 22.6

4 / 12 18.0

3 / 12 14.0

2 / 12 9.5

1 / 12 4.8

Acceptable collector inclination is between 20-70º on a sloped or flat roof. Shaded boxes in Table 2-2 indicate roof slopes which are too shallow to flush mount collectors on. Collector tilt angles must be greater than 20º (4/12 pitch) in order for collectors to vent. Rack mount systems with adjustable tilt angles must still maintain the minimum 20º above horizontal or warranty is void (see Tilt Angle in Figure 2-7). Failure to follow these instructions will damage collectors and result in serious personal injury.

Table 2-3 Resultant Angle and Optimized Season Roof Slope (Collector Tilt Angle) North

Latitude 45.0 o 42.5 o 39.8 o 36.9 o 33.7 o 30.2 o 26.6 o 22.6 o Season Legend

20 o 25 22.5 19.8 16.9 13.7 10.2 6.6 2.6

25 o 20 17.5 14.8 11.9 8.7 5.2 1.6 -2.4 W Winter

30 o 15 12.5 9.8 6.9 3.7 0.2 -3.4 -7.4

35 o 10 7.5 4.8 1.9 -1.3 -4.8 -8.4 -12.4

40 o 5 2.5 -0.2 -3.1 -6.3 -9.8 -13.4 -17.4 F Spring/Fall

45 o 0 -2.5 -5.2 -8.1 -11.3 -14.8 -18.4 -22.4

50 o -5 -7.5 -10.2 -13.1 -16.3 -19.8 -23.4 -27.4

55 o -10 -12.5 -15.2 -18.1 -21.3 -24.8 -28.4 -32.4 S Summer

60 o -15 -17.5 -20.2 -23.1 -26.3 -29.8 -33.4 -37.4

Notes: 1 The shading indicates the season collectors are optimized for with respect to a given latitude and roof slope (see legend). 2 The resultant angle represents the degrees that collectors are tilted + latitude (e.g. + fall/winter; - spring/summer). 3 Unshaded resultant angles indicate slopes at which seasonal solar gain will be noticeably reduced.


13

\\\\ Clearances Maintain the following clearances around collector arrays installed on a roof. Clearances are indicated by the shaded perimeter along the roof (Figure 2-9) and shows the importance of sufficient roof space (Figure 2-10). Note that rack mounted collectors on flat roofs will experience greater wind loading and may require increased structural support.

Minimum clearances 0.3m (1’) from roof edge and corners due to wind loading Recommended clearances 0.5m (2’) around all sides of the array for service and access

Figure 2-9 Collector Mounting and Clearances

Figure 2-10 Roof Space

Collector Mounting Do’s and Don’ts

� Leave white covers on collectors until commissioning. � Weatherize roof/wall penetrations required for mounting. � Do not mount collectors flat or at a slope less than 20o.

Vertical Mounting Install field supplied flashing material between vertical wall surface and top edge of collectors to prevent water from entering collector vents.

Ground or Flat Roof Recommend that collectors with adjustable rack systems, mounted on the ground or a flat roof, be elevated off the mounting surface with sleepers. In areas of heavy snow or rainfall, sleeper height should be 6-12” above recorded rainfall or snow levels. Check local codes.

Clearances To reduce turbulence and minimize wind loading effects on solar collectors, maintain a minimum perimeter of 0.3m (1’) from ridge line (peak, roof edges and corners. Recommended clearance for access around collector arrays is 0.5m (2’). For sloped roofs, mount collectors as close to the peak as possible within the specified clearances to allow for a simpler installation.

Flush vs Rack Mounting A flush roof mount system call "FastJack is packaged with each Sol-R-Therm system. Installer/Owner assumes all liability for field supplied rack mount systems. Contact NTI for Engineered Rack Mount System. Basic calculations for rack row spacing are illustrated in Figure 2-11.

A - Flush Mount B - Vertical Mount C - Rack Mount

A

B

C

C

Insufficient clearance

Good roof clearance

�

�

Good clearance 10’x12’ with 2′ perimeter from roof edge.

Insufficient clearance due to protrusions.

CanSIA Solar Ready

Figure 2-11 Rack Row Spacing

Shadows are longest when collectors are perpendicular to the sun’s rays and the sun is at its lowest altitude (winter solstice). Use the formulas above to calculate the minimum distance required to avoid shadowing from adjacent collectors.

h

ββββββββ αααα

d

Formulas: d = h ÷ Cos β, where α = 90 - latitude - 23.5o β = 90 - α

d = distance between rows h = height of collector (82” ) α = angle of the sun β = collector tilt angle

Clearances


14

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3.0 SOLAR INDIRECT WATER HEATER

Supplemental Instructions The Solar Indirect Water Heater Installation and Operation Instructions, included with the tank, is to be read in conjunction with this manual, which focuses on the closed loop solar circuit while the Tank manual focuses on domestic plumbing.

Trin & Stor Tank Models Total Volume (usg) Packaged with

Tank Model Total Volume (usg) Packaged with

S-SR 79,119 SRT-Pk1/Pk2 SL-SRE 80,120 SRT-Pk1E/Pk2E

Domestic Plumbing Specific details pertaining to domestic plumbing for the Solar Water Heater are covered in the Trin & Stor Indirect Water Heater Manual included with the tank. As a minimum, a properly installed domestic hot water system will follow the instructions in the solar tank manual. It is the responsibility of the installing contractor and system designer to consider all aspects of a proper system design including compliance with local codes, additional components required for prevention of thermal-siphoning (i.e. heat traps), isolation valves, drain and purge valves, etc. Permanent maintenance accessories shall be left in place for service and maintenance of the tank (i.e. hose bibs, drains valves). All domestic plumbing and solar tank plumbing connecting the solar tank to the auxiliary water heater, are to be completed prior to commissioning the solar collectors.

Reference

Trin & Stor Manual

Sol-R-Therm Manual

Sol-R-Therm Manual

NTI Manuals - Which manual covers what?

Sol-R-Therm - Solar plumbing and solar equipment installation instructions for the closed-loop system are covered in the Sol-R-Therm manual which is included with the packaged solar domestic hot water system.

Trin & Stor - Domestic plumbing for the solar water heater is covered in the Trin & Stor manual which is included with the solar indirect water heater (tank).


15

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4.0 PUMP STATION

Supplemental Instructions This section deals with installing the pump station. For additional details regarding the pump station, refer to the FlowCon B booklet included with the pump station. The controller is integral to the pump station and will be covered under Control Module in Section 9.0 of this manual.

FlowCon B

Safety Valve, 4 bar (58 psi) Solar Pump Controller Thermometers Pressure Gauge Check Valves Flow Meter 0.5-3.5gpm

The pump station comes fully pre-assembled with all the necessary plumbing for the solar circuit including solar pump (SRT-S21u) and control module (DeltaSol BS Plus). Figure 4-1 illustrates the individual components included in FlowCon B pump station which comes fully assembled. There are two (2) additional attachments that need to be connected to the pump station: the expansion tank connection bracket (item 15) and the solar expansion tank (item 16). Both are packaged separately from the pump station and will have to be field installed.

Figure 4-1 Pump Station Components and Attachments

Pump Station Components * Pump Station Attachments ** 1. Wall mount bracket 2. NPT Adapter 3. Ball valve with integrated check valve (supply) 4. Air eliminator (de-aerator) 5. Safety group (PRV, pressure gauge, fill/drain valve) 6. Ball valve with integrated check valve (return) 7. Gasket 8. Circulator pump (Wilo Star S21u15) 9. Nut for cable connection 10. Flow meter c/w fill/drain valve 11. Red thermometer 12. Blue thermometer 13. Pump Station Insulation (front and back) 14. Controller module (DeltaSol BS Plus)

15. Expansion tank connection set 16. SolarExtrol expansion tank * Pump Station comes fully assembled. ** Attachments are packaged separately.

Reference

13

15

Refer to numbered list below for a description of pump station components

and attachments. 16

All components on the pump station are accessible for service and maintenance.


16

\\\\ FlowCon B Pump Station The FlowCon B pump station control module, DeltaSol BS Plus, continuously monitors all aspects of the solar circuit using the. The control displays the current operational status and is easily programmed to obtain optimal system efficiency. See Section 10.0 for more details pertaining to functions and settings.

Installation Checklist 1. Determine location of pump station, preferable

within 6' of 120VAC/15A electrical outlet. 2. Remove the two thermometers, then the front

insulation cover from the pump station. 3. Mark and drill holes at a center distance of 6" for

alignment with the wall bracket. Drill holes using a 5/16" (8mm) drill bit.

4. Put the enclosed dowels (S8) into the holes, use the enclosed fixing screws (6 x 60 mm) and a Phillips screwdriver to secure the pump station in place.

Expansion Tank Connection Set The connection set contains a wall bracket to support the tank and a stainless steel flex line to connect the expansion tank to the pump station. Refer to Figures 4-2 and 4-3 for a list of components and connection instructions.

Installation Checklist 1. Assemble expansion tank connection set, attach stainless flex line (Figures 4-2 and 4-3). 2. Mount wall bracket so it supports the isolation 3. DO NOT insulate the expansion tank connection set.

Figure 4-3 Connecting to the Pump Station

The arrow indicates the location on the pump station where the expansion tank stainless steel flex line must attach. The expansion tank connects to the bottom of the expansion tank connection set at the brass bushing (4). Consult NTI before attaching a larger expansion tank 1-800-688-2575.

Figure 4-2 Expansion Tank Connection Set

1

2

5

3

3

4

1

Components 1 – Gasket

2 – Stainless Flex Line

3 – Isolation Check with nut 4 – Brass bushing, ¾” x ½”

5 – Wall bracket

�� Check List

�� Check List


17

\\\\

Supplemental Instructions The Amtrol SolarEXTROL Installation and Operation Instructions, included with the expansion tank, are to be read in conjunction with this manual. Note that the Sol-R-Therm manual is specific to the packaged solar domestic hot water systems featured in it.

SolarEXTROL

Model Total Volume (usg) Accept. Volume (usg) Height Diameter Connection

S-60 7.6 2.5 23" 11" ½"

Solar Expansion Tank The SolarEXTROL expansion tank provided with the Sol-R-Therm System has been sized for thermal expansion and stagnation based on the components included with the packaged Sol-R-Therm systems.

System Design Limits – Maximum Height = 45’ head; Maximum Line Set Length = 50’; Maximum Glycol Mix Ratio = 50%; Maximum Number of Collectors = 3.

Upsized Expansion Tank - If additional line sets are required to extend solar piping beyond the maximum 50’ feet provided with the packaged Sol-R-Therm system, a larger

expansion tank may be required. Solar thermal systems have additional safety requirements and are consequently sized differently than hydronic systems; therefore, consult NTI technical support before extending line sets or using another expansion tank. Unauthorized increases in the predesigned total system volume or maximum height specified under System Design Limits may compromise personal safety and exceed component operational limits and failure to follow instructions may result in personal injury and void the warranty.

Expansion Tank Connection Set - The expansion tank must be connected to the location shown in Figure 4-3. If a larger expansion tank is required, it can be plumbed directly to

the pump station using the NPT adaptor (part #84283) or to the bottom of the expansion tank connection set. Note that the wall bracket is not designed to support a larger expansion tank and a floor mount model may be required.

Pre-installation Checklist 1. Visually inspect SolarEXTROL for any damage. 2. Adjustment to pre-charge must be done at time of initial installation before filling tank. 3. Adjustment to pre-charge must be done at ambient temperature only. 4. Adjust pre-charge to equal the system fill pressure specified in Table 4-2. 5. Replace and tighten plastic cap on air fitting.

Table 4-2 Expansion Tank Pre-charge Fill Pressure Vertical Height 1 Feet of Head ≈ PSI 2 Pressure at Collector 3 Pre-charge Pressure 4

20′ 10 psi 15 psi 25 psi

30′ 14 psi 15 psi 29 psi

40′ 18 psi 15 psi 33 psi

45′ 22 psi 15 psi 37 psi

Notes: 1 Total vertical height from top of expansion tank to top of collector air vent. 2 A foot of head (1 foot of vertical height) equals 0.45 psi or 4.5 psi per building story, at 10′ per story. 3 Pressure at the top of collector air vent must be 15 psi to ensure the system maintains a positive pressure. 4 Factory set pre-charge on Solar Extrol expansion tank is 25 psi.

Installation Checklist 1. Ensure Pump Station is securely fastened to the wall. 2. Install the wall bracket designed to support the expansion tank flex line. 3. Install the SolarEXTROL at the location shown in Figure 4-3. 4. Mount expansion tank in the vertical position only. 5. Failure to properly seal will result in loss of pre-charge and cause expansion tank failure.

�� Check List

�� Check List

Reference


18

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5.0 FLUSH MOUNT SYSTEM

Flush Mount System for Sloped Roofs Each packaged system comes with a flush mount roof system, Oatey Flashing and FastJacks, designed to secure collectors to sloped asphalt roofs. FastJack maintains a low profile for aesthetics and eliminates direct contact with hot collectors that could result in softening or deterioration of non-

metal roof material at temperatures ≥ 60-80

oF (140-180

oC).

FastJack & Flashing

Oatey Flashing 4.5" FastJack (2359lbs pull-out force)

The quantity of FastJacks and Oatey Flashing in the flush mount system is enough for the "Alternate Layout" in Figure 5-5.

Roof Preparation Pre-installation Checklist 1. Select Layout from Figures 5-4 or 5-5. 2. Locate rafters beneath roof sheathing. 3. Mark collector rail placement with a chalk line as shown (Figure 5-1). Note collectors

extend 6" beyond the bottom rail and have an overall height of 2m (82"). 4. Review Building Penetration Requirements in Table 5-1 before installing Fast Jacks. 5. Determine if layout spacing allows FastJack to be fastened directly to rafters (Figure 5-2).

If not, install blocking between rafters and fasten to blocking (Figure 5-3).

6. Secure FastJack as per section "Installing FastJack" (Figure 5-7).

Figure 5-1 Roof Preparation

FastJack

Figure 5-2 Rafter Detail Figure 5-3 Blocking Detail

How to Mount Collectors 1. Mount FastJack to roof. 2. Mount rails to FastJack. 3. Mount collectors to rails

(steps 2 and 3 are covered in Section 6.0)

�� Check List

DO NOT space rails in between 70" and 75", choose one dimension or the other.


19

\\\\

Collector Layouts Layout options for collector arrays should be decided based on rafter locations and loading requirements prior to Roof Preparation. Refer to Figures 5-4 to 5-5 for suggested collector array layouts, dimensions and spacing.

Figure 5-4 Standard Vertical Layouts

2 collector east - west layouts require extra clamps and a different rail set. Contact NTI for more details.


20

\\\\

Figure 5-5 Alternative Vertical Layouts

Loading The minimum distribution shown in the standard layout covers a portion of the potential wind and snow load. Note that actual dimensions may deviate due to local circumstances and must be adjusted. The alternative layouts show additional FastJacks for improved load distribution. Horizontal Arrays Horizontal installations are not covered in this manual. If considering installing a horizontal array or end-to-end collectors, contact NTI directly regarding special instructions for plumbing, mounting, and venting. .


21

\\\\

Installing FastJack Once that location has been determined, collector layout should be decided based on rafter location and loading requirements. Refer to Figure 5-6 for a breakdown of flush mount components and the applicable installation checklist and illustrations for the roofing application (i.e. existing roof, new roof, flashing installation).

Figure 5-6 Flush Mount System Components Table 5-1 Building Penetrations

• Building - Penetrations through which piping or wiring is passed shall not reduce or impair the function of the enclosure.

• Pests - Penetrations through walls /other surfaces shall not allow intrusion by insects or vermin.

• Roof - Penetrations for solar system installation shall be made in accordance with applicable codes and also by practices recommended by the National Roofing Contractors Association.

• Structural - Support penetrations by solar system components to comply with local building codes.

• Fire Resistance - Penetrations through fire rated assemblies shall not reduce the fire resistance of the building as required by applicable standards, ordinances and local codes.

Installation Checklist – Existing Roof Retrofits 1. Refer to Figure 5-7 when installing FastJack on an existing asphalt roof. 2. Locate rafter center, drill/break shingle w/ masonry bit, drill pilot hole w/ regular 3/16" bit. 3. Insert the 5/6" stainless steel lag bolt and washer through the FastJack base. 4. Use the flashing template provided with the roof mount system to properly cut in flashing. 5. Temporarily hold post in place by inserting upwards into flashing. 6. Insert flashing beneath shingles, aligning post and base. 7. Tighten post onto base as shown.

Figure 5-7 FastJack and Existing Roof Retrofits

STEP 1 STEP 2 STEP 3

STEP 4 STEP 5 STEP 6

FastJack Installation Manual

�� Check List

3/8” x 3/4“ s.s. bolt

3/8” s.s. flat washer

1“ dia. solid aluminum post

5/16“ x 3-1/2“ s.s. lag bolt

5/16“ s.s. flat washer 1-1/2“ aluminum base

FastJack Components

Oatey Flashing

Assembled Flush Mount

System


22

\\\\ Installation Checklist - New Roof Installations 1. Refer to Figure 5-8 when installing FastJack on a newly constructed roof. 2. Locate rafter center, drill pilot hole with regular 3/16" bit. Insert the 5/6" stainless steel lag bolt and washer through the FastJack base. Install roof paper and/or ice and water shield over roof sheathing, notch out around base. 3. Temporarily hold post in place by inserting upwards into flashing, aligning post and base. Position flashing over roof paper and tighten post onto base using channel locks. 4. Shingle around flashing to optimize water shedding. Use the flashing template provided

with the roof mount system to properly cut in flashing.

Figure 5-8 FastJack and New Roofs Installations

STEP 1 STEP 2 STEP 3 FastJack Installation Manual

Trade Tip - Flashing It is extremely important to properly flash and weatherize roof penetrations. The arrows in Figure 5-9 indicate typical water flow direction on a pitched roof and flashing performance.

Properly installed flashing will: � shed water from the roof without allowing water beneath the flashing � minimized the risk of roof leaks � result in less warranty servicing and liability � protect lag bolt connections from the elements � prevent dry rot

Correct Flashing Installation A correct installation locates the lag bolt inside the cut-in-area of the shingle. In this method the flashing placement provides both top and side water protection keeping water away from the lag bolt connection and minimizes the potential for roof leaks or dry rot. Proper flashing placement specified as specified in the FastJack Installation Instructions is illustrated in Figure 5-9.

Incorrect Flashing Installation Figure 5-9 illustrates incorrect flashing placement as specified in the FastJack Installation Instructions. In both examples, flashing is placed on top of the shingles or not cut into the shingle area, leaving roof penetrations un-weatherized and allowing water to flow beneath the edge of the flashing and into the lag bolt connection. Improper flashing installations are susceptible to roof leaks, damage to interior spaces, and structural dry rot.

Figure 5-9 Oatey Flashing Placement

FastJack Installation Manual

Trade Tip

�� Check List

Post

Base

Roof Paper

Oatey Flashing

Shingles


23

\\\\

6.0 COLLECTORS Flat Plate Collector The SRT-215 has a high optical efficiency with optimal fluid hydraulics for low head loss. The one piece, extruded aluminum frame provides superior strength and corrosion resistance and top edge serves as a handle for easy maneuvering during installation.

SRT-215

Height Width Depth Weight Stagnation Max Pressure Unit Volume

82-1/4" (2.088 m) 36-3/8" (1.031 m) 3-1/4" (0.081 m) 70.5 lb (32 kg) 376ºF (191.2ºC) 145 psi (10 bar) 0.44 usg (1.65 L)

Hardware Once the FastJacks and Oatey Flashing are secured to the roof and weatherized, the rails and collectors can be installed. Refer to Figure 6-1 for an overview of components required to mount the collectors.

Figure 6-1 Collector Installation Hardware

Rail Sets Fasten the rail sets to the FastJacks. Refer to checklist below and Figures 6-2 and 6-3 for rail mounting procedure.

Installation Checklist 1. Remove the 3/8" stainless steel bolt and washer

from the top of FastJack (Figure 6-1). 2. Center the mounting rails over the FastJack. 3. Insert the 3/8" bolt down through the washer

and slot in the rail and tighten to FastJack. 4. Thread bolt back into top of the FastJack and

tighten until snug. 5. Position two hooks per collector on bottom rail.

Rail Joiner (3 Collectors) Rail sets for three (3) collector systems come with 2 long rails, 2 short rails and 2 rail joiners. For the top rail, connect a short rail to a long rail using the rail joiner and hardware. Repeat for the bottom rail. Rail joiner locations should be offset from one another when installed so they are at opposite ends of the top and bottom rails. Rails must be securely joined together prior to attaching the rails to the roof mount system.

�� Check List

Figure 6-2 Attaching the Rails

Collectors

Hooks-Clamps (p/n 84165 shown)

End Clamps

Center Clamps

Hooks

Rail Set (p/n 84161 shown)

Quick Connection Set (p/n 84168 shown)

Retaining Clips

Compensators

(2 collector system shown)


24

\\\\

First Collector

Installation Checklist 1. Do not remove white collector covers until the system has been commissioned. 2. Insert tee nuts on end of rails, both top and bottom, with metal wings aligned with the rails

short axis and plastic wings parallel with its long access (Figure 6-4 and 6-5). 3. Position first collector on the rails ensuring the bottom lip is inserted into the groove of the

two hooks. 4. Side collector over to the edge leaving the tee nut’s threaded insert exposed. (Figure 6-6).

Figure 6-4 Clamp to Rail Assembly

�� Check List

Figure 6-3 Rail to Fast Jack Assembly

Hooks Step 4

FastJack Steps 1-3

Rail Set

Oatey Flashing

tee nut

Center Clamp cap screw washer clamp (double sided)

tee nut

End Cap cap screw washer clamp (single sided)

Hooks

top rail

bottom rail

Rail Set

Collectors Collectors are held in place with end and center clamps (Figure 6-1), where a washer and cap screw sandwich the collector to the rail, anchoring it with a tee nut. All collectors are to be installed with the collector sensor well located at the top of the collector. Refer to the check list and Figures 6-4 to 6-10 for step-by-step instructions.


25

\\\\ Connecting Collectors

Installation Checklist 5. Install the two end clamps, ensure

clamp grooves align with ridges on collector lip, finger tighten the bolts.

6. Position tee nut and center clamp on other side of first collector, finger tighten the bolts.

7. Place compensators into the manifold ports of the first collector (Figure 6-7).

8. Position second collector on rails ensuring the bottom lip inserts into the groove of the two hooks (Figure 6-8).

Figure 6-6 Installing the First Collector

�� Check List

End Clamp (tee nut shown)

Figure 6-5 Hooks and Clamps

Hook

1st Collector

End Clamp

Compensator

Compensator

Center Clamp

Top Rail

Bottom Rail

Hooks

Hooks

Center Clamp


26

\\\\ Third or Final Collector

Installation Checklist 9. Slide the second collector to the

first, ensure the compensator inserts into the upper/lower manifold ports, and collector lip slides under the open side of the double sided center clamp.

10. Slide retaining clips over middle of compensators to secure header connectors in place, ensuring the retaining clips are capturing the flared ends of each collector manifold pipe (Figures 6-8 to 6-10).

11. For a 3 collector system, repeat Steps 7 to 10 before proceeding to the next step. 12. Center collector array on rails, install the tee nuts at end of rail, tighten all clamps ensuring clamp grooves

align with ridges on collector lip.

Figure 6-8 Two Collector System Installation

Figure 6-7 Connecting Collectors

Center Clamp (double sided)

Hook

Compensator

1st Collector

�� Check List

Figure 6-9 Compensator Retaining Clip Figure 6-10 Joined Collectors

Center Clamp (double sided)

Compensator

Retaining Clip (installed)

Retaining Clip

Compensator Retaining Clip

Inlet Sub-assembly

Retaining Clip

Outlet Sub-assembly

Plug

End Clamp

Retaining Clip

Retaining Clip and Plug

Compensator Retaining Clip

End Clamp

Retaining Clip

1ST COLLECTOR

2ND COLLECTOR


27

\\\\

7.0 SOLAR PLUMBING

Closed Loop System This section focuses on closed loop solar plumbing. A highly innovative connection system allows for easy connection to collectors and insulated solar piping. Two kits are required to complete the solar plumbing: ▫ SRT-Kit1 Solar Plumbing ▫ SRT-Kit2 Collector Adaptors

Armacell DuoSolar Piping

50′ Insulated Dual Line Set Insulation temp rating of 300oF, R-value 5.5, thickness ¾”, high temperature closed-cell. Solar Piping - 5/8" Corrugated Stainless Steel Tubing Integral Collector Sensor Wire Lines separate /combine easily UV and weather resistant

Solar Circuit The solar circuit is the closed loop connecting the solar collectors to the solar tank heat exchanger. The NTI solar package includes all plumbing (line sets and adaptors) associated with interconnecting the solar collectors and connecting them to the pump station. Figure 7-1 illustrates the solar circuit which must be understood prior to proceeding with the installation. Plumbing required to connect the pump station to the solar tank heat exchanger is not included and must be sourced separately, see Figure 7-1 and "Pump Station to Solar Tank Heat Exchanger" for more details. (Note: Figure 7-1 shows the recommended reverse return collector plumbing, while Figure 7-2 shows an alternative method along with the legend for the solar plumbing schematics).

Figure 7-1 Solar Plumbing Schematic Reverse Return Configuration (Recommended)

Piping

(System SRT-Pk2 shown)

Factory Supplied Piping / Adaptors

Field Supplied Piping / Adaptors

Factory Supplied Piping / Adaptors


28

\\\\ Figure 7-2 Solar Plumbing Schematic

Alternative Configuration

Liquid Pockets The life expectancy of collectors and glycol mixtures are greatly impacted by liquid pockets (Figure 7-3). During stagnation, the glycol in the collectors can become super heated and vaporize, forcing the remaining liquid glycol out of the collectors. Collector "A" shows solar piping terminated downward for easy evacuation of super heated glycol. In contrast, Collector "B" shows solar piping terminated upward within 12" (300mm) of the manifold ports, which creates liquid pockets. This situation prohibits the glycol from exiting the collectors during stagnation and should be avoided, as it can damage collectors and cause glycols to break down.

Collector A Without Liquid Pockets

Collector B With Liquid Pockets

Figure 7-3 The Liquid Pocket Dilemma

� � Inlet

Inlet

Outlet

Outlet

General Notes

Figures 7-1 and 7-2 Sensor S1 must be installed in the last collector in the array with respect to flow direction. This is the same collector and location where the outlet sub-assembly is be installed.

Sensor FKP6 c/w black wire must be used as S1. It has a high temperature rating and weather resistant insulation.

Do not remove white covers from flat plate collectors until the solar domestic hot water system is completely installed and ready for commissioning.

(System

SRT-Pk2 shown)


29

\\\\ Factory Supplied Fittings

Plumbing Sub-assemblies Using the components included in SRT-Kit1 and SRT-Kit2 (Figures 7-4 and 7-5), assemble the collector inlet and outlet plumbing assemblies. Refer to pre-installation checklist and Figures 7-6 and 7-7 for details.

Pre-installation Checklist 1. Prepare fittings for sub-assembly

by wrapping with thread tape, then apply thread paste.

2. Completely tighten sub-assembly fittings together in a bench vise prior to connection to the collector. Do not over tighten.

3. Do not remove the cap from the collector plugs and NPT adaptors until immediately before connection to the collector. The caps protect the speciality lubricant on the adaptor o-rings.

NTI recommends using a combination of thread tape and paste when preparing fittings for the sub-assemblies shown in Figures 7-6 and 7-7 as it provides a better seal between the fittings. Lightning Protection - Recommended only for collectors that are not bonded to ground via copper plumbing components. If lightning protection is deemed necessary, check with the Local Authority Having Jurisdiction regarding local codes requirements.

Protection Against Auto-ignition of Combustibles - Combustible materials used in solar equipment and adjacent structures shall not be exposed to an elevated temperature that

could cause ignition. Failure to following instructions could result in injury or damage to property and equipment.

Figure 7-6 Collector Outlet Sub-assembly

Air Vent

Isolation Valve

Line Set Adaptor (M)

Cap

Bushing

Brass Tee, 3/4”

Collector NPT Adaptor

Do not over tighten the 1/8” NPT fittings (valve and vent) in the collector outlet sub-assembly.

Figure 7-5 Collector Adaptor Kit

(SRT-Kit2 shown)

Collector NPT Adaptors

Plugs

Safety Clamps

Figure 7-4 Solar Plumbing Accessory Kit

(SRT-Kit1 shown)

Line Set Adaptors (F)

Line Set Adaptor (M)

Air Vent

Bushing

Brass Tee 3/4”

Isolation Valve

Line Set Adaptor (F)

Collector NPT Adaptor

Cap

Figure 7-7 Collector Inlet Sub-assembly

�� Check List

Trade Tip


30

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Collectors to Pump Station

Collector Connections Connect the plumbing sub-assemblies to the collectors as detailed in the installation checklist and Figures 7-8 and 7-9. The outlet assembly is installed on top and the inlet assembly at the bottom as illustrated in Figure 6-8.

Installation Checklist 1. Remove cap from end of collector NPT adapter. 2. Install sub-assembly by pushing the collector NPT adapter (o-ring end) into the appropriate

port of an end collector. 3. Secure in place by sliding retaining clip over the collector NPT adapter until it seats

(Figure 7-8). 4. Install plugs at unused ports in the same manner. 5. Installed sub-assemblies and clips should look similar to Figure 7-9.

The retaining clip must sandwich the flanges of the adapter and collector port together, i.e. both flanges must be held together by the slot in the retaining clip.

Line Sets The 5/8" corrugated stainless steel line sets provided with the Sol-R-Therm system are pre-insulated and will need to be cut and insulation stripped backed during the piping installation process. Refer to the installation checklist and Figure 7-10, (1) to (4) for instructions on removing line set insulation and cutting the tubing.

Installation Checklist 1. Locate the octagon box with the coiled preinsulated corrigated stainless steel tubing. 2. Line sets split / re-join easily, Sensor wire tube goes to collector outlet. 3. Using a utility knife, cut back insulation where required and expose tubing. 4. Using a standard tube cutter, cut tubes to length.

Figure 7-10 Line Set Preparation

Figure 7-8 Connecting a Sub-assembly

Outlet Sub-assembly

Outlet Port

Safety Clamp

Figure 7-9 Installed Sub-assembly

�� Check List

�� Check List

STEP 4 STEP 3 STEP 1 STEP 2


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\\\\ Installing Line Sets and Sensor Wire

Installation Checklist 1. Prepare line sets as required

during installation (Figure 7-10). 2. Run the line set with the sensor

wire to the outlet port of the collector (Figure 7-11).

3. Loosen the line set adapter swivel nut on the outlet sub-

assembly and insert tubing until it bottoms out (Figures 7-11 and 7-12).

5. Hold the tubing in place, tighten using two wrenches until threads are no longer showing.

6. Do not leave bare tubes exposed. Recover with insulation, seal seams with armacell tape.

4. Tighten adapter until no threads show (Figure 7-12).

5. Remove cap from collector sensor well and cut off the tip (Figure 7-13). 6. For best temperature measurement, fill bottom half of collector sensor well with heat conduction paste. 7. Slide sensor tip backwards through small end of cover, place sensor in well until it bottoms out, slide cover

down over top of well and sensor wire. 8. Splice together sensor pigtail and lineset sensor wire with marretts or quick disconnects. Make connections

weather tight using a weather-UV resistant tape to avoid corrosion by the elements (i.e. Armaflex solar tape). 9. Repeat steps 3 and 4 for the inlet sub-assembly.

�� Check List

Figure 7-12 Installed Outlet Supply Piping

Line Set Adaptor

Sensor Wire

Figure 7-13 Connecting Outlet Sensor

Collector sensor well

Sensor well cap

Sensor (S1)

Sensor Pigtail (black)

Sensor Wire

Small end of cap

Figure 7-11 Connecting Outlet Supply Piping

Line Set c/w Sensor Wire

Collector Outlet Sub-assembly

Loosen swivel nut


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\\\\ Pump Station Connections Connect line sets to fittings at top of pump station to complete the collector loop (see checklist and Figure 7-14).

Installation Checklist 1. Prepare upper fitting ends on pump

station with thread tape and thread paste, tighten a line set adapter (F) to each.

2. Connect line sets to appropriate pump station fittings (collector supply and return) and tighten (see instructions above).

3. Connect S1 sensor wire to DeltaSol BS Plus controller (see section on field wiring).

Pump Station to Solar Tank Heat Exchanger

Indoor Piping Insulation (solar) - Hydonic hot water pipe insulation

available at the local hardware store is typically rated for a maximum temperature of 200oF (93oC). DO NOT use this to insulate high temperature solar piping as the insulation will melt. Instead, insulate solar piping using approved hot water closed cell high temperature insulation rated up to 300oF (150oC), recommended insulation thickness of ¾”. Failure to follow these instructions may result in fire or serious personal injury. The NTI Trin & Stor "S-SR" line of high efficiency Solar Indirect Water Heaters is intended to be heated by a solar thermal system where a propylene glycol mixture, heated by the solar collectors, is circulated through the internal heat exchanger coil in the tank. Piping connecting the pump station and the solar tank heat exchanger should be made with standard type M, ¾" copper pipe. Solar heat exchanger and Pump Station fittings are ¾" NPT (M). Compression or quick connect fittings are not recommended for this application as fluid in piping can reach temperatures in excess of 200oF (93oC). Insulate piping connecting pump station and the solar tank with high temperature insulation. Refer to Figure 7-15. Solar Tank Connections by System Configuration The controller settings and tank connections depend on the system configuration selected. This section summarizes the basic operation and tank connections required for each general configuration. Refer to Section 9.0 of this manual for applicable control features, operating parameters of the controller, sensor inputs, and load outputs for each configuration. See Trin & Stor Manual, Figure 2-4 and Table 2-1 respectively for location and sizes of connection ports for applicable solar models. Pre-heat Configurations - The most common configuration or application is when the solar water heater is plumbed in series with an auxiliary water heater which is used as the primary storage tank (see Solar Indirect Water Heaters and Auxiliary Water Heaters section below for more information regarding auxiliary water heaters). The hot water out (connection port 2) of the solar indirect water heater is connected to the cold water inlet of the auxiliary water heater. So when there is a demand for domestic hot water, the auxiliary water heater

�� Check List

Return to bottom of collector (inlet manifold)

Adaptor Sensor Wire

Adaptor

Supply from the top of collector (outlet manifold)

Figure 7-14 Pump Station Hook Up

Field Supplied 3/4” copper pipe

Pump Station 3/4” NPT Male Adaptors (2)

WARNING: Do not use compression / quick connect fittings when piping pump station to solar tank heat exchanger.

Figure 7-15 Heat Exchanger Connections

Field Supplied Pipe Insulation closed cell, temp 300oF, 3/4” thick


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\\\\ immediately brings in pre-heated water from the solar tank to replace it instead of cold water directly from the potable water system. In this configuration the upper heat exchanger coil is not required so connection ports 4 and 5 should be left capped. Any unused ports, such as the recirculation (connection port 3), should be capped/plugged before filling the tank with water. Interconnection of the auxiliary system to the solar energy system shall be made in a manner which will not result in excessive temperature or pressure in the auxiliary system or bypassing of safety devices of the auxiliary system. Domestic side piping for solar thermal can be done in a number of configurations depending on the application. Since solar tanks are specifically designed for high temperature applications in the event of collector stagnation and overheating, tank sensors specifically designed for these high temperature applications must be used instead of the TPI.

Solar Indirects and Auxiliary Water Heaters: 1. Two tank systems - Pre-heat systems use two-tanks, a solar indirect tank and an auxiliary water heater. 2. Packaged Systems - The auxiliary water heater is not included as part of the packaged Sol-R-Therm system. 3. Listed Auxiliary - The auxiliary water heater should be listed and labeled by an accredited listing organization. 4. Adaquate Capacity - The auxiliary water heater should be of adequate capacity and/or similar size as the solar

indirect water heater included with the packaged Sol-R-Therm system. 5. Normal Service - Plumb the solar tank so its cold water inlet can be shut off without interrupting normal cold

water service. 6. Solar Tank Bypass Valve - The cold water inlet isolation valve can be used as the solar tank bypass provided it

allows the auxiliary water heater to operate without the solar tank when the valve is close and the solar is bypassed. Refer to Trin & Stor Manual, Figure 2- 4.

7. Auxiliary System - Make connections between solar and auxiliary tanks in such a manner so as not to result in excessive temperature or pressure in the auxiliary system or bypass the auxiliary system safety devices.

8. Accessible Connections - All connections to the solar tank and auxiliary tank must be accessible for service. 9. Cold Water Pipe Insulation - Last 5' of cold water piping into the tank must be insulated to R-2.6 (minimum).

10. Solar Pipe Insulation - Solar piping between the tank and pump station must be protected with a closed-cell insulation rated for temperatures up to 300oF (150oC) and have a minimum insulating value of R-2.6. (i.e. UT SolaFlex).

Back Up Configurations - This option is used when the solar water heater is the primary storage tank and solar water heating alone is not enough to meet the domestic hot water demand. Hot water supplied from the boiler is connected to ports 4 and 5 on the solar water heater and circulated through the upper heat exchanger coil in the tank. See Trin & Stor Manual, Figure 2-4. Refer to the Installation and Operation Manual included with the boiler for detailed instructions on connecting boiler system piping to the indirect water heater. Storage Configurations - This option is used when the solar water heater is the primary storage tank and is connected to an additional storage tank for use as extra storage or as a dump zone for excess heat. In this method, hot water from the solar water heater is transferred to the secondary storage tank using connections 4 and 5. Note that flow direction is reversed for this application compared to the back up option. See Trin & Stor Manual, Figure 2-4.


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8.0 FIELD WIRING

Wiring the Controller Terminate the sensor wires and control wiring to the controller terminal strip as per Figure 8-1 and Table 8-1. Coordinate wire terminations, inputs and outputs with the System Configuration selected from Section 9.0.

DeltaSol BS Plus

Sensor inputs (4) Relay outputs (2) Integral fuse, T4A Line voltage termination VBus connection

Read Warnings below before starting installation.

ESD Damage - Electrostatic discharge can result in damage to electronic components. Take care to properly discharge static by touching a grounded surface such as a radiator,

metal tap, or copper piping before touching the inside of the control device.

Overvoltage Protection Device - Recommended to avoid damage to sensitive components during lightning storms. Check if required by local codes, USA only. See Table 1-2 for p/n.

Electric Shock Disconnect power

from pump station before opening the controller housing and/or connecting any equipment to the controller terminal strip, removing the cover will expose live parts.

Table 8-1 Wiring Instructions Connection Location Description

1 S1

2 Collector Outlet Temperature Sensor – Input for temperature sensor installed in drywell nearest the collector outlet (top) (S1=FKP6 sensor with black wire).

3 S2

4 Lower Solar Tank Temperature Sensor – Input for temperature sensor installed in solar tank lower drywell (S2=FRP6 sensor with white wire).

5 S3

6 Upper Solar Tank Temperature Sensor – Input for temperature sensor installed in the solar tank upper drywell. Install with S2 in lower drywell for solar electric tank (S2=FRP6).

7

S4

8

Collector Return Temperature Sensor – Input for temperature sensor installed on or in the return line between the Solar Tank and Pump Station. Optional for the purpose of Energy Metering for applicable systems. Or….

Auxiliary Tank Temperature Sensor – Input for temperature sensor installed in the lower drywell of an Auxiliary Storage Tank as per Figure 9-2 (S4=FKP6 sensor with black wire).

9 VBus

10 Data Communication/ Bus – Allows interconnection to optional devices such as large displays, data-loggers, interface adaptors. See DeltaSol® BS Plus booklet for more details.

12 13

14 Ground – Terminals for grounding power supply and loads connected to R1 and R2.

N 15 Neutral Relay 2 – Neutral for load powered by 120VAC output R2.

R2 16

Relay 2 – 120VAC semiconductor relay output for a pump, valve, relay or other load, see Figures 9-1 to 9-5. Maximum capacity of 1 Amp.

NOTICE: The minimum pump speed (n2MN) must be set to 100% when R2 is used to power a valve or relay (i.e. a load requiring full output).

N 17 Neutral Relay 1 – Neutral for load powered by 120VAC output R1.

R1 18 Relay 1 – 120VAC semiconductor relay output for the Solar Pump, see Figures 9-1 to 9-5. Maximum capacity of 1 Amp.

N 19 Neutral – Location for connecting the neutral of the 120VAC power supply.

L 20 Line – Location for connecting line voltage of the 120VAC power supply. Note: It is necessary to install a service switch to break line voltage prior to the control.

Fuse - Fuse – MSTU T4A/ 250V

Hook Up

Figure 8-1 Controller Terminal Strip


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9.0 CONTROL MODULE

Supplemental Instructions This section covers several basic system layouts and corresponding controller settings and options. For more complicated layouts and control settings, refer to the controller manual (DeltaSol BS Plus booklet) included with the pump station.

DeltaSol BS Plus

-Pump Speed Control -Thermostat Function -Frost Protection -Emergency Shutdown -Priority Logic/Parallel Loading -Cooling Feature -Thermal Disinfection -Energy Metering Option

System Configuration The NTI DeltaSol® BS Plus controller offers a large number of control features. The use of many of these features will depend on the overall system layout being employed in the given application. This manual identifies five of the most common (and basic) types of system configurations (layouts). Figures 9-1 to 9-4 are specific to NTI Solar packages SRT-Pk1 and Pk2, while Figure 9-5 is specific to packages SRT-Pk1E and Pk2E. There are many application specific variables that need to be considered with each layout when setting the operating parameters of the controller and connecting to the controller sensor inputs and load outputs. This section covers the basic operation common to each system and the layouts and settings for the various systems profiled. For setup information of more advanced system layouts, consult the NTI DeltaSol® BS Plus booklet included with the Pump Station. For more information tank connections for the various configurations, refer to "Solar Plumbing" (section 7.0 in this manual) and to the Trin & Stor Manual, Figure 2-2 and Table 2-4.

Basic Operation The following describes the basic operational features common to all systems illustrated in this section. In each application, the pump station circulates heat transfer fluid from the outlet of the solar collectors to the inlet of the lower coil in the solar tank, where heat is transferred to the domestic hot water stored in the tank. Refer to Table 9-1 for more details on the basic operations. See Table 9-2 Display Channels and Table 9-3 Common Adjustment Channels for information on navigating and setting the adjustment channels.

Table 9-1 Basic Operation Quick Reference Table Item Type Operation Control Sequence

Diff

On: Solar Pump (R1) turns on when the Collector Temperature (S1) is greater than the Solar Tank Temperature (S2) by the Switch-on Temperature Differential (DTO).

R1 on when S1 > (S2 + DTO)

Diff

Off: Solar Pump (R1) turns off when the Collector Temperature drops below the Solar Tank Temperature (S2) plus the Switch-off Temperature Difference (DTF).

R1 off when S1 < (S2 + DTF)

Safety

Off: All normal solar loading of the tank stops (solar pump turns off) when the Solar Tank Temperature (S2) reaches the Solar Tank Set point (S MX)

R1 off when S2 > SMX

Safety

Off: All solar loading of the tank stops (solar pump turns off) when the Collector Outlet Temperature (S1) reaches the Emergency Shutdown Temperature setting (EM).

Emergency R1 off when S1 > EM

Solar Pump

Speed

Pump Speed: Solar Pump (R1) is increased when the Collector Outlet Temperature (S1) goes above the Solar Tank Temperature (S2) by more than the Nominal Temperature Difference setting (DT S).

Speed increases when S1 > (S2 + DTS)

Layout 1 (Arr = 1)

1 - Basic Preheat Figure 9-1 illustrates the general system layout and terminal allocation for the most basic solar thermal application. In this configuration, the solar tank is only heated by the solar collectors (no supplemental heat) and solar heat is only stored in the solar tank (no auxiliary storage). This system’s purpose is to preheat the water for a separate hot water heater. For the controller to anticipate this configuration and respond accordingly, adjustment channel Arr must be set to 1.

Reference


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\\\\ For the purpose of optional Energy Metering, S4 can be connected to a sensor installed in a well in the return line between the outlet from the tank coil and the inlet of the pump station. To activate the Energy Metering function, OHQM must be set to on, see Energy Metering for more details. Sensor S3 can be installed in the upper tank thermostat well for observation purposes only, however it serves no function for basic preheat configurations.

Figure 9-1 Basic Preheat Layout 1 (Arr = 1)

S1 Collector Outlet Sensor (Top) S4 Collector Return Sensor S2 Lower Solar Tank Sensor R1 Solar Pump (within Flow Station) S3 Upper Solar Tank Sensor

Layout 2 (Arr = 2)

2 - Preheat with Auxiliary Storage Figure 9-2 illustrates the general system layout and terminal allocation for an application incorporating an auxiliary storage tank. The auxiliary storage tank is connected to the solar tank’s upper coil; energy is transferred from the solar tank to the auxiliary tank by activating a recirculation pump. Sensor S3 is installed in the upper well of the solar tank and sensor S4 is installed in a well in the auxiliary tank. The auxiliary tank can be used to store DHW for preheating the potable water inlet to the solar tank, or as energy storage of non-potable water, such as a hydronic heating system. Like the basic preheat system in Figure 9-1, preheat w/auxiliary storage systems provide preheated water to a separate hot water heater. For the controller to anticipate this configuration and respond accordingly, adjustment channel Arr must be set to 2.

Since sensor S4 is allocated to the auxiliary storage tank, the Energy Metering Function is not an option for configurations using Layout 2 (Arr = 2).


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\\\\ Advanced Operation (Auxiliary Storage) - The Recirculation Pump (R2) turns on when the Upper Solar Tank Temperature (S3) rises above the Auxiliary Tank Temperature (S4) by the Switch-on Tank Temperature Difference (DT3O). The Recirculation Pump (R2) turns off when the Upper Solar Tank Temperature (S3) drops below the Auxiliary Tank Temperature (S4) plus the Switch-off Tank Temperature Difference (DT3F). Loading of the auxiliary tank stops (Recirculation Pump turns off) when the Auxiliary Tank Temperature (S4) reaches the Maximum Auxiliary Tank Temperature setting (MX3O) or when the Upper Solar Tank Temperature (S3) drops below the Minimum Tank Temperature (MN3O).

R2 on when S3 > (S4 + DT3O) R2 off when S3 < (S4 + DT3F) S3 < MN3O or S4 > MX3O During auxiliary tank loading the speed of the Recirculation Pump (R2) is increased when the Upper Solar Tank Temperature (S3) goes above the Auxiliary Tank Temperature (S4) by more than the Nominal Tank Temperature Difference setting (DT3S). See Table 9-4, Adjustment Channels Specific to Layout 2 (Arr = 2), for more detailed instructions.

Figure 9-2 Preheat with Auxiliary Storage Layout 2 (Arr = 2)

S1 Collector Outlet Sensor (Top) S4 Lower Auxiliary Tank Sensor S2 Lower Solar Tank Sensor R1 Solar Pump (within Flow Station) S3 Upper Solar Tank Sensor R2 Recirculation Pump


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\\\\ Layout 3 (Arr = 3)

3 - Preheat with Surplus Heat Distribution Figure 9-3 illustrates the general system layout and terminal allocation for an application using surplus heat distribution. Surplus heat is removed from the solar tank’s upper coil and supplied to a hot water distribution system such as a hydronic heating zone, storage tank or other. Sensor S3 is installed in the upper well of the solar tank while sensor S4 is optionally installed in the collector return line to permit the use of the Energy Metering function. Like other preheat configurations, this one is generally used to provide preheated water to a separate hot water heater. For the controller to anticipate this configuration and behave accordingly adjustment channel Arr must be set to 3 and AH O must be set greater than AH F.

Advanced Operation (Surplus Heat Distribution) - The controller operates a Circulating Pump (R2) to transfer surplus solar energy stored in the solar tank to a hot water distribution system. The Circulating Pump (R2) turns on when the Solar Tank Temperature (S3) rises above the Thermostat Switch-on Temperature (AH O) and turns off when the Solar Tank Temperature (S3) drops below the Thermostat Switch-off Temperature (AH F).

R2 on when S3 > AH O R2 off when S3 < AH F AH O > AH F

The controller is also equipped with three separate timers that can be set to allocate specific times during the day that the thermostat function can activate to deliver surplus heat. See Table 9-3, Adjustment Channels Specific to Layout 3 (Arr = 3), for more detailed instructions.

Figure 9-3 Preheat with Surplus Heat Distribution Layout 3 (Arr = 3) AH O > AH F


R2 Hot water boiler circulating pump, or relay providing end-switch for boiler DHW demand.


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\\\\ 4 - Supplemental with Boiler Backup Figure 9-4 illustrates the general system layout and terminal allocation for application using a back-up boiler. The boiler system uses the solar tank’s upper coil to provide supplementary heat to the solar tank, much the same way a boiler would heat a traditional indirect fired hot water heater (“sidearm tank”). Sensor S3 is installed in the upper well of the solar tank while sensor S4 is optionally installed in the collector return line to permit the use of the Energy Metering function. Unlike a preheat system, supplemental w/boiler back-up is a stand alone system that does not require a separate hot water heater. For the controller to anticipate this configuration and behave accordingly, adjustment channel Arr must be set to 3 and AH O must be set lower than AH F.

Advanced Operation (Boiler Back-up) - Relay R2 is wired to a field supplied boiler circulator (or isolation relay generating a domestic hot water demand from a back-up boiler, see CAUTION below). When the Solar Tank Temperature (S3) drops below the Thermostat Switch-on Temperature (AH O), R2 generates a DHW demand for the back-up boiler. When the Solar Tank Temperature (S3) rises above the Thermostat Switch-off Temperature (AH F), the demand to the back-up boiler is turned off.

R2 on when S3 < AH O R2 off when S3 > AH F AH O < AH F

The controller is equipped with three separate timers that can be allocated to specific times for the thermostat function to activate the boiler back-up. These times can be programmed to allow the tank to operate cooling preceding times of anticipated solar gain. See Table 9-5 for Adjustment Channels Specific to Layout 3 (Arr = 3).

Figure 9-4 Supplemental with Boiler Backup Layout 3 (Arr = 3) AH O < AH F


R2 Hot water circulating pump to provide surplus

heat to a distribution system.


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Most boiler models incorporate a dry contact input to activate a DHW demand and a 120VAC relay output intended to operate the DHW circulator; therefore, the Delta Sol R2

relay must activate a 120VAC relay employing an issolated end switch to be connected to the boiler DHW input.

5 - Supplemental with Electric Backup Figure 9-5 illustrates the general system layout and terminal allocation for an application incorporating a solar storage tank with a back-up electric element (SRT-PK1E and SRT-PK2E). The solar storage tank incorporates a 4500W element to provide supplementary heat to the solar tank when the solar thermal system is unable to meet the application demands. Sensor S3 is installed in the allocated well located in the solar tank, along with sensor S2. Sensor S4 is optionally installed in the collector return line to permit the use of the Energy Metering function. This is a stand-alone system that does not require a separate hot water heater. For the controller to anticipate this configuration and behave accordingly adjustment channel Arr must be set to 3 and AH O must be set lower than AH F.

Advanced Operation (Electric Element Back-up) - Relay R2 is wired to the factory supplied isolation relay (Honeywell R8285A 1048 Control Center), field installed at the solar-electric tank junction box. When powered, the isolation relay makes the 240VAC power supply to the electric element. When the Solar Tank Temperature (S3) drops below the Thermostat Switch-on Temperature (AH O), the electric element is turned on. When the Solar Tank Temperature (S3) rises above the Thermostat Switch-off Temperature (AH F), the electric element is turned off.

R2 on when S3 < AH O R2 off when S3 > AH F AH O < AH F

The controller is also equipped with three separate timers that can be set to allocate specific times during the day that the thermostat function can activate the electric element. The timers can be programmed to allow the tank to operate cool preceding times of anticipated solar gain. See Table 9-5, Adjustment Channels Specific to Layout 3 (Arr = 3), for more detailed instructions. (Note: the thermostat in the solar-electric tank must be calling for the element to turn on.)

The factory supplied isolation relay (Honeywell R8285A 1048 Control Center) is rated for a resistive load of up to 20Amps at 240VAC; therefore it must not be used with solar-

electric tanks that use more than one element or an element larger than 4500W. A jumper must be placed between terminals R and G (24VAC) on the factory supplied isolation relay (Honeywell R8285A 1048 Control Center).


41

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Figure 9-5 Supplemental with Electric Backup Layout 3 (Arr =3) AH O < AH F


R2 Hot water circulating pump to provide surplus heat to a distribution system.


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\\\\ Controller Options Cooling Options The Delta Sol BS Plus features four (4) cooling options designed to help prevent collector overheating which can occur during times of high solar gain and/or low hot water usage. Each cooling function is factory set to OFF; before turning ON it is important to understand how each work and what precautions need to be observed. The cooling options are accessed via the adjustment channels, see Table 9-3 and 9-6.

Collector Cooling (OCC) – When the Solar Tank Temperature (S2) is above the Solar Tank Set Point (SMX) solar loading of the solar tank ends. If this scenario occurs during periods of solar gain the collector temperature will increase; when the Collector Temperature (S1) rises above the Maximum Collector Temperature (CMX), the Solar Pump (R1) turns on, cooling the collector. Note: Collector Cooling (OCC) takes priority over System Cooling (OSYC). R1 on when S1 > CMX / R1 off when S1< (CMX - 10oF). System Cooling (OSYC) – When the Solar Tank Temperature (S2) is above the Solar Tank Set Point (SMX) solar loading of the solar tank ends. If this scenario occurs during periods of solar gain the collector temperature will increase; when the Collector Temperature (S1) rises above the Solar Tank Set Point (SMX) by the System Cooling Switch-on Temperature Differential (DTCO), the Solar Pump (R1) turns on, equalizing the system temperature. The Solar Pump (R1) turns off once the Collector Temperature (S1) drops below the Solar Tank Set Point (SMX) plus the System Cooling Switch-off Temperature Differential (DTCF). Note: the DTCO setting must be greater than the DTCF setting.

R1 on when S1 > (SMX + DTCO) R1 off when S1 < (SMX + DTCF)

Tank Cooling (OSTC) – Normally used in combination with collector or system cooling, this function prepares the solar tank for subsequent collector or system cooling. The Solar Pump (R1) turns on when the Solar Tank Temperature (S2) is greater than the Collector Temperature (S1) by the Switch-on Temperature Differential (DTO). The Solar Pump (R1) turns off when the Solar Tank Temperature (S2) drops below the Collector Temperature (S1) plus the Switch-off Temperature Differential (DTF). Note: the Tank Cooling function does not operate when the Solar Tank Temperature (S1) is less than or equal to the Solar Tank Set Point (SMX).

R1 on when S2 > (S1 + DTO) and SMX R1 off when S2 < (S1 + DTF) or SMX

Cooling functions are not permitted when the Collector Temperature (S1) is above the Emergency Shutdown Temperature (EM). Collector and system cooling will not function

when the Solar Tank Temperature (S2) is above 200ºF.

Collector and system cooling function will permit the solar tank temperature to rise above the programmed set point, up to a maximum of 200ºF; therefore, it is necessary to install

an approved thermostatic mixing valve prior to routing hot water to fixtures. Failure to follow this warning may cause personal injury or death.

Holiday Tank Cooling (OHOL) – Same as normal Tank Cooling (OSTC), with the exception it replaces the normal Solar Tank Set Point (SMX) with Holiday Tank Set Point (THOL). This permits the solar tank to cool beyond the normal temperature. This function would normally only be used when the occupants are going to be away for extended periods of time.

R1 on when S2 > (S1 + DTO) and THOL R1 off when S2 < (S1 + DTF) or THOL

Thermal Disinfection (OTD) Thermal disinfection of the solar storage tank is only possible when there is a form of supplemental heat (i.e. boiler or electric element back-up) which, when called upon can work to raise the temperature of the solar tank to a level sufficient to disinfect the tank. Thermal disinfection is factory set to off, to activate it set OTD to ON. See Table 9-7 for a description of the thermal disinfection specific adjustment channels.

For thermal disinfection to be effective, the temperature set point of the supplemental heat source must be set high enough (i.e. boiler control or solar electric thermostat).


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\\\\ Energy Metering (OHQM) When sensor S4 is installed in the collector return line (Figures 9-1, 9-3, 9-4, and 9-5), the controller can be configured to approximate the energy transferred from the solar collectors to the solar storage tank. Note: the energy metering function is not an option with Layout 2 (Arr = 2). By inputting the Maximum Collector Flow Rate (FMAX), Heat Transfer Fluid Type (MEDT) and Glycol Concentration (MED%), the controller is able to calculate the energy captured by comparing the collector inlet and outlet temperatures, S4 and S1, respectively.

To determine the Maximum Collector Flow Rate (FMAX), set MAN1 to ON, this will force the Solar Pump (R1) to operate at 100%. Note: the collector requires FMAX to be inputted in units of liters per minute (l/m), so multiply the measured flow rate of gallons per minute (gpm) by 4.

Once the Maximum Collector Flow Rate (FMAX) has been observed, it is necessary to set MAN1 back to AUTO. Failure to follow these instructions may result in unexpected tank

overheating, component failure or personal injury.

Scroll through the display channels by depressing the minus (-) or positive (+) buttons.

Table 9-2 Display Channels Channel Layout Sensor Description

COL 1,2,3 S1 Collector Temperature – Indicates temperature at S1 sensor located in the collector well nearest the outlet.

TST 1 TST1 2 TSTB 3

S2 Lower Solar Tank Temperature – Indicates temperature at S2 sensor located in the lower well of the solar storage tank.

S3 1

TSTT 2,3

TDIS 1 3

S3

Upper Solar Tank Temperature – Indicates temperature at S3, sensor location is upper well of the solar storage tank; not required for Layout 1 (Arr = 1). During the Heating Period (DDIS) of Thermal Disinfection (OTD), TDIS replaces TSTT, see Table 9-7. (S3 is installed with S2 in the lower well of the solar electric tank).

S4

TR2 1,3

Collector Return Temperature (Optional) – Indicates temperature at S4 sensor located in the return line to the collector. For Energy Metering (OHQM), S4 is displayed as TR, see Table 9-8.

TST2 2

S4 Auxilary Tank Temperature – Indicates temperature at S4 sensor located in the lower well of a second (auxiliary) solar storage tank; Layout 2 (Arr = 2) only.

n% 1 n1% 2,3

Pump Speed R1 – Indicates speed of solar pump.

n2% 2 Pump Speed R2 – Indicates speed of re-circulation pump between primary and secondary (auxiliary) solar tanks; Layout 2 (Arr = 2) only.

hP1 1,2,3 Operating Hours R1 – Indicates the number of hours that the solar pump has operated.

hP2 2,3 Operating Hours R2 – Indicates the number of hours that relay contact R2 has been engaged (re-circulating pump, boiler or electric backup).

kWh

MWh 1,3

Heat Quantity kWh/MWh (Optional) – Indicates an approximation of the amount of energy that has been collected in the solar storage tank. Requires S4 to be installed in the return line to the collectors and for OHQM to be set ON. Option not available for Layout 2 (Arr = 2).

CDIS1

Countdown Monitoring Period (dd:hh) – Indicates the amount of time left in the Thermal Disinfection monitoring period (PDIS), time before forced thermal disinfection occurs. Counter resets if the Upper Tank Temperature (S3) exceeds the Disinfection Temperature (TDIS) continuously for a period equal to the Heating Period (DDIS).

SDIS1 Disinfection Start Time (o’clock) – Displays once the CDIS has counted down, indicates the precise time when Thermal Disinfection will begin.

DDIS1

3

Disinfection Heating Period (hh:mm) – Replaces the CDIS once it has counted down, indicates the amount of time left in the Thermal Disinfection process. Counter resets if the Upper Tank Temperature (S3) drops below the Disinfection Temperature (TDIS).

TIME 1,2,3

N.A.

Time (o’clock) – Indicates the time of day – 24 hour clock. Notes: 1 Thermal disinfection is only available for Layout 3 (Arr = 3); to activate set OTD (Optional Thermal Disinfection) to

ON, see Table 9-7 for more details. 2 Energy metering is only available for Layout 1 and 3 (Arr = 1 and 3); to activate set OHQM to ON, see Table 9-8.


44

\\\\ Upon power up, the most important adjustment channels (LANG, UNIT, TIME, Arr, S MX and nMN) will be displayed, followed by “OK” prompting the user to accept the setting. To access these and other adjustments at anytime, depress and hold the minus (-) and positive (+) buttons simultaneously until Arr is displayed on the screen. Note: depress the minus (-) button first.

Scroll through the adjustment channels by depressing the minus (-) or positive (+) buttons. Make adjustments by depressing the OK button (this will cause “set” to flash on the screen), followed by adjustment up or down with the positive (+) or minus (-) button respectfully.

Table 9-3 Common Adjustment Channels Channel Description Factory

Arr 1 Arrangement – Determines the system layout of the specific application. 1

DT O Switch-on Temperature Difference – Temperature difference required between the collector (S1) and the solar tank (S2) to activate the solar pump relay R1. 12ºF (6oC)

DT F Switch-off Temperature Difference – Temperature difference between the collector (S1) and the solar tank (S2) where the solar pump relay R1 is deactivated.

Note: The DT F must be at least 1ºF lower than the DT O. 8ºF (4oC)

DT S Nominal Temperature Difference – Temperature difference between the collector (S1) and solar tank (S2) where the controller increases relay R1 output (solar pump speed) by 10%. 20ºF (10oC)

RIS Temperature Rise – Temperature difference, in excess of the DT S, where the controller increases relay R1 output (solar pump speed) in increments of 10%. 4ºF (2oC)

nMN or n1MN

Minimum Pump Speed (R1) – Establishes the minimum pump speed allocated to relay R1 – Solar Pump. 30%

S MX

Solar Tank Set Point – Establishes the desired Lower Tank Temperature (S2). During normal operation the Solar Pump (R1) will turn off once the S MX setting is reached.

Note: During optional Collector or System Cooling (OCC or OSYC), the Solar Pump (R1) may continue to operate after the S MX setting is exceeded, hence heating the tank beyond the S MX setting.

140ºF (60oC)

EM

Emergency Shutdown Temperature – Collector temperature (S1) where the controller overrides all operating parameters and forces the Solar Pump (R1) off to help prevent overheating. Normal operation will commence once the collector temperature has dropped 20ºF below the EM setting.

250ºF (130oC)

OCC Collector Cooling Option – See Table 9-6. OFF OSYC System Cooling Option – See Table 9-6. OFF OSTC Tank Cooling Option – See Table 9-6. OFF

OCN Collector Minimum Temperature – When switched on, establishes a minimum collector temperature threshold, adjustable via CMN (default = 50ºF), for Solar Pump (R1) operation. Function avoids unnecessary Solar Pump cycling at low temperatures.

OFF

OCF

Antifreeze Function – When switched on, establishes a minimum collector temperature threshold, adjustable via CFR (default = 40ºF), where the Solar Pump (R1) activates to send heat from the Solar Tank to the collectors to help prevent freezing or coagulating of the heat transfer fluid.

Note: NTI highly recommends mixing the heat transfer fluid according to the local climate to avoid the possibility of freezing and coagulating.

OFF

O TC Evacuated Tube Option – Not Applicable, leave this function turned OFF. OFF OHQM Energy Metering Option – See Table 9-8 OFF ODB Drain Back Option – Not Applicable, leave this function turned OFF OFF

MAN1 Manual R1 Operation – Allows for manual operation of relay R1 (Solar Pump) during commissioning and service work. AUTO

MAN2 Manual R2 Operation – Allows for manual operation of relay R2 (Recirculation Pump, Boiler or Electric Backup Demand – Figure 9-2 to 9-5) during commissioning and service work. AUTO

LANG Language – Allows the user to select between English and German. En UNIT Units – Allows the user to select temperature units. ºC RESE1 Reset Function – When selected the controller reverts back to the factory default settings. - W005 Version Number -

Notes: 1 When this channel is selected (OK) or modified, the user will be prompted to SAVE the setting, if YES is selected then

all old setting will be lost.


45

\\\\ When Arr = 2 is selected, the controller is anticipating a system Layout as illustrated in Figure 9-2.

Table 9-4 Adjustment Channels Specific to Layout 2 (Arr = 2) Channel Description Factory

n2MN Minimum Pump Speed (R2) – Establishes the minimum pump speed allocated to relay R2 – recirculation pump (set to 100% if the load connected to R2 requires full output).

30%

DT3O Switch-on Tank Temperature Difference – Temperature difference required between the Solar Tank (S3) and the Auxiliary Tank (S4) to activate the Recirculation Pump (R2).

12ºF (6ºC)

DT3F

Switch-off Tank Temperature Difference – Temperature difference between the Solar Tank (S3) and the Auxiliary Tank (S4) where the Recirculation Pump (R2) is deactivated. Note: DT3F must be at least 1ºF lower than DT3O.

8ºF (4ºC)

DT3S Nominal Tank Temperature Difference – Temperature difference between the Solar Tank (S3) and Auxiliary Tank (S4) where the controller increases the Recirculation Pump (R2) speed by 10%.

20ºF (10ºC)

RIS3 Temperature Rise 3 – Temperature difference, in excess of the DT3S, where the controller increases the Recirculation Pump (R2) speed in increments of 10%.

4ºF (2ºC)

MX3O / MX3F

Maximum Aux. Tank Temperature – Establishes the desired Auxiliary Tank Temperature (S4). Recirculation Pump (R2) operation is prevented above MX3O and allowed below MX3F.

140ºF / 136ºF (60ºC / 80ºC)

MN3O / MN3F

Minimum Tank Temperature – Establishes a minimum Solar Tank Temperature (S3) for Recirculation Pump (R2) operation. R2 operation is prevented below MN3O and allowed above MN3F.

40ºF / 50ºF (5ºC /10ºC)

When Arr = 3 is selected, the controller anticipates a system Layout as illustrated in Figure 9-3, 9-4, and 9-5.

Table 9-5 Adjustment Channels Specific to Layout 3 (Arr = 3) Channel Description Factory

AH O / AH F

Thermostat Switch-on/off Temperature AH O < AH F, Supplemental with Boiler or Electric Backup (Figures 9-4 and 9-5) – Relay R2 functions as a thermostat to activate supplemental heating of the solar tank when the Upper Solar Tank Temperature (S3) drops below AH O and deactivates when it rises above AH F. If AH O > AH F, Preheat with Surplus Heat Distribution (Figure 9-3) – Relay R2 functions as a thermostat to distribute excess heat for the solar tank to a distribution system (i.e. hydronic heating zone). Circ Pump (R2) activates when the Upper Solar Tank Temperature (S3) rises to AH O and deactivates it when it drops below AH F.

110ºF / 120ºF (40ºC / 45ºC)

t1 O t1 F t2 O t2 F t3 O t3 F

Thermostat Timers 1, 2 and 3 (hh:mm) – There are three separate timers that can be programmed to allocate specific times during the day where the thermostat relay R2 can activate. These can be used to prevent heating of the solar tank by the Backup Boiler or Electric Elements preceding times of anticipated solar gain.

E.g. Settings t1 O and t1 F establish the thermostat switch-on and off times respectfully for timer 1.

Note: if the timers are set to 00:00, they will not block the operation of the thermostat.

00:00

OTD Thermal Disinfection Option – See Table 9-7. OFF


46

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Table 9-6 Adjustment Channels for Optional Cooling Functions Channel Description Factory

OCC

Collector Cooling Option – When set to ON, works to help keep the collector temperature at an operable level (i.e. below stagnation). When the Collector Temperature (S1) rises above CMX, the Solar Pump (R1) is activated until the temperature at the collector drops below CMX by 10ºF. Collector cooling is overridden if the Lower Solar Tank Temperature (S2) goes above 200ºF or the Collector Temperature (S1) goes above the EM setting.

OFF

CMX Maximum Collector Temperature – Collector Temperature (S1) where collector cooling commences. Only displayed when OCC is set to ON

230ºF (110ºC)

OSYC

System Cooling Option – When set to ON, works to help keep the system temperature at an operable level (i.e. below stagnation). The Solar Pump (R1) turns on when the Collector Temperature (S1) is greater than the Solar Tank Set Point (SMX) by the System Cooling Switch-on Temperature Differential (DTCO). When the Collector Temperature drops to the Solar Tank Set Point (SMX) plus the System Cooling Switch-off Temperature Differential (DTCF), the Solar Pump (R1) is turned off.

OFF

DTCO System Cooling Switch-on Temperature Differential – Temperature above SMX where the Solar Pump (R1) turns on. Only displayed when OSYC is set to ON

40ºF (20ºC)

DTCF System Cooling Switch-off Temperature Differential – Temperature above SMX where the solar pump (R1) turns off. Only displayed when OSYC is set to ON.

Note: DTCF must be set lower than DTCO. 30ºF (15ºC)

OSTC

Tank Cooling Option – When set to ON, works to cool the Solar Tank to normal operating temperature (SMX) during the night in order to prepare for solar loading the following day. Solar Pump (R1) turns on once the Lower Solar Tank Temperature (S2) exceeds the Solar Tank Set Point (SMX) and the Collector Temperature (S1) by the Switch-on Temperature Differential (DTO). When the Lower Solar Tank Temperature (S2) drops below the Solar Tank Set Point (SMX) by 4ºF and the Collector Temperature (S1) by the Switch-off Temperature Differential (DTF), the Solar Pump (R1) turns off.

OFF

OHOL

Holiday Tank Cooling Option – When set to ON, works to cool the Solar Tank to lower than normal operating temperature (THOL ) during anticipated extended periods of no DHW usage (i.e. Holidays). Works the same as OSTC, except the Solar Tank Set Point (SMX) is replaced with THOL .

OFF

THOL Holiday Tank Set Point – Only displayed when OHOL is turned ON. Replaces the normal Solar Tank Set Point (SMX) for the purpose of Tank Cooling.

110ºF (40ºC)

Collector and system cooling functions will permit the solar tank temperature to rise above the programmed set point, up to a maximum of 200ºF; therefore, it is necessary to install

an approved thermostatic mixing valve prior to routing hot water to fixtures. Failure to follow this warning may cause personal injury or death.


47

\\\\ Thermal Disinfection is optional for system Layout 3 (Arr = 3), when configured with a supplemental boiler backup or electric element backup (Figures 9-4 and 9-5).

Table 9-7 Adjustment Channels for Optional Thermal Disinfection Channel Description Factory

OTD

Thermal Disinfection Function –Used to protect the upper tank zone against Legionella by activating the Backup Boiler (R2). Thermal Disinfection is considered complete or satisfied when the Upper Tank Temperature (S3) exceeds the Thermal Disinfection Temperature (TDIS) continuously for a period equal to the Heating Period (DDIS) every Monitoring Period (PDIS).

OFF

PDIS

Monitoring Period (dd:hh) – A user defined period where the Upper Tank Temperature (S3) is monitored for disinfecting; temperature in excess of the Disinfection Temperature (TDIS). Establishes the maximum amount of time where the system does not force Thermal Disinfection; activation of the Backup Boiler (R2).

01:00 (1-day)

DDIS

Heating Period (hh:mm) – User defined length of time of Thermal Disinfection. Thermal Disinfection, for a given Monitoring Period (PDIS), is not considered complete until the Upper Tank Temperature (S3) has been above the Disinfection Temperature (TDIS) continuously for a period equal to the Heating Period (DDIS).

01:00 (1-hour)

TDIS Disinfection Temperature – Temperature requirement of the Upper Tank Zone (S3) during Disinfection.

140ºF (60ºC)

SDIS Disinfection Start Time (o’clock) – Allows the user to delay the start of the disinfection process, Heating Period (DDIS), until a specific time of day; Start Time (SDIS). 00:00

Optional Energy Metering only available for system Layouts 1 and 3 (Figures 9-1, 9-3, 9-4 and 9-5), when sensor S4 is installed in the collector return line.

Table 9-8 Adjustment Channels for Optional Energy Metering Channel Description Factory

OHQM

Energy Metering Option –When turned on, determines the approximate energy gained from the solar collectors by observing the temperature gain across the collectors (S4 to S1) given the Maximum Collector Flow Rate (FMAX), Heat Transfer Fluid Type (MEDT) and Glycol Concentration (MED%).

OFF

FMAX Maximum Collector Flow Rate – Only displayed when OHQM is set to ON. Set to the observed collector flow rate during maximum pump speed (multiply observed value by 4, i.e. 2 gpm x 4 = 8 l/min).

6.0

MEDT

Heat Transfer Fluid Type – Only displayed when OHQM is set to ON. Set to the appropriate value for the corresponding heat transfer fluid. Note: NTI systems are provided with Propylene glycol (1). o 0 – Water o 1 – Propylene glycol o 2 – Ethylene glycol o 3 – Tyfocor® LS / G-LS

1

MED% Glycol Concentration – Only displayed when OHQM is set to ON and MEDT is set to 1 or 2. Set to the percentage of glycol being used. 45%


48

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10.0 HEAT TRANSFER FLUID Supplemental Instructions The Product Information Sheet, included in this manual and with the heat transfer fluid, lists the Freeze Tolerance Limits for a given mix ratio by volume. Dowfrost inhibited propylene glycol is listed with the USFDA as "generally recognized as safe" (GRAS) and the Canadian Food Inspection Agency (CFIA) as "food grade".

Dowfrost

Non-toxic Propylene Glycol, pure concentrate Pail, 20L (5 usg)

Max Working Pressure (solar) is 58 psi (400kPa)

Meets SRCC and CSA standards for solar single wall heat exchangers

Approved Heat Transfer Fluid (HTF) - Recommended minimum concentration is Dowfrost mixed 40/60 with de-ionized water, freezing point -20.1°C (-4.2°F). Refer to

Dowfrost Production Information Sheet for environmental conditions and different freeze protection by volume %. Substitution of any other heat transfer fluid can cause irreparable damage and create a health and safety hazard.

Recommended Use and Restrictions Dowfrost is approved for incidental contact with food and water and shall be used in a manner consistent with the intended use specified in the Dowfrost Product Information Sheet and this manual. Dowfrost is used extensively in the food manufacturing industry, such as chocolate manufacturers, to control heating and/or cooling processes as well as in solar domestic hot water systems with single-wall heat exchangers. Fluid pH levels should be checked and maintained annually. Maximum design life of HTF is 5 years from time of commissioning.

Installation Checklist 1. Identify the temperature range for your Climate Zone (Figure 10-1). 2. Select a temperature at least 9

oF (5oC) below the lowest expected ambient temperature (Freeze Tolerance Limit) to provide an addition degree of safety against climate change.

3. Freeze Tolerance Limits are based upon an assumed set of environmental conditions. 4. Mix pure glycol by volume % with de-ionized water (field supplied) to the expected freeze

level c/w safety margin as per the DowFrost_ Product Information Sheet. 5. Fill the system with the glycol mixture prior to commissioning the system.

Reference

�� Check List

Figure 10-1 Climate Zones of North America

January Temperature s by Climate Zone *

United States 1 80 to 128oF 2 64 to 80oF 3 55 to 64oF 4 48 to 55oF 5 32 to 48oF 6 24 to 32oF 7 0 to 24oF 8 -35 to 0oF *

* Alaska is mostly Zone 7, Boroughs >62o N are Zone 8.

D

C

A

B D C

B

B

January temperatures represent the mean minimum / maximum temperatures in each climate zone. Check with your local weather office regarding the coldest recorded temperature for that latitude, as elevation and micro climates can result in colder or warmer temperatures than the mean. Mix glycol to freeze protection required c/w safety margin of 9oF (5oC). See DowFrost Product Info Sheet.

Canada A -10 to 5oC B -25 to -10oC C -30 to -25oC D -35 to -30oC *

* Latitudes > 50o N in Nunavut, and > 60o N in the Yukon and NW Territories post temperatures of -40oC or colder.

7 7

3

2 3

3

2

6

4

7

7 6

* Sol-R-Therm system are designed to operate in cool to moderate climates.


49

\\\\ Handling Instructions - Refer to Table 10-1 for handling instructions and recommended precautions. For more details refer to the Dowfrost Material Safety Data Sheet included with the system and attached to the glycol.

Dilution Requirements - Refer to Dowfrost Product Information Sheet on the next 2 pages for glycol dilution requirements and freeze protection concentrations and freezing and boiling points.

Table 10-1 Handling Instructions for Dowfrost Reduce the Risk of Exposure Precautions and Recommended Personal Protective Equipment Handling

• Recommend using safety glasses to avoid incidental contact with eyes. • No special precautions required.

Storage

• Store in original unopened container. • Do not store in galvanized steel containers, opened or unlabeled containers. • Avoid exposure to elevated temperatures, direct sunlight, or ultravoilent sources that

can cause glycol to decompose. • Gas generated during decomposition can increase pressure in closed systems.

First Aid Measures

If irritation persists after implementing first aid measures consult a physician. • Skin - Wash with water. Prolonged contact nonirritating. • Eyes - Flush with water for several minutes. Remove contacts (if applicable). • Inhalation - Move to fresh air; mist may irritate upper respiratory track (nose/throat) • Ingestion - No harmful effects anticipated. No emergency treatment necessary.

Disposal • All displosal practices must be in compliance with Federal, State/Provincial, and local regulations.

• DO NOT dump any glycol, including glycols "generally recognized as safe", into the sewer, ground, or a body of water unless that is an approved disposal method sanctioned by the authority having jurisdiction.

• Decomposed glycol can be often be acidic and is typically subject to the same rules and similar disposed methods as used motor oil.

• Contact your local licensed, permitted recycler, waste management company, or hazardous waste depo to inquire what chemicals and fluids they reclaim and reprocess.

Table 10-2 NFPA 704 Requirements

Hazard Classification Diamond Substance: Propylene Glycol Hazard Rating Diamond Rating Health Blue 0 • 0 = Normal (no health threat) • No special precautions required

Fire Hazard Red 1 • 1 = Ignites when pre-heated • Vapour is combustible over 200oF

Reactivity Yellow 0 • 0 = Normally Stable • Stable under recommended storage conditions Special Hazard White -

• Not applicable

0

1

0


50

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51

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Printed with manufacturer’s permission.


52

\\\\ 11.0 COMMISSIONING AND OPERATION

The commissioning procedure must be completed prior to removing the white plastic covering from the solar collectors. Failure to follow these instructions may cause

overheating of the solar heat transfer fluid resulting in property damage or personal injury.

Filling the System Installation Checklist 1. Filling the System - Fill the system

with glycol-deionized water mixture, as instructed before commissioning.

2. Complete Solar Loop Installation - Install solar tank, pump station, flat plate collectors, expansion tank, and solar circuit plumbing as described in

this manual. Ensure the expansion tank pressure is set to the required system operating pressure (Table 4-2).

3. Complete Wiring - Install the temperature sensors and complete the wiring according to the system layout, see Figures 9-1 to 9-5 and field wiring (Section 8.0). Leave the power turned off at this point. Notice: for the purpose of filling and purging the front cover of the pump station must remain off.

4. Complete Installation of DHW Plumbing - Purge and fill the solar tank as described in the solar tank manual. Prepare Heat Transfer Fluid - Mix the pure glycol provided in the kit with de-ionized water (field provided) to obtain the desired concentration (Section 10.0). The total volume required to fill a typical system is between 5 and 7 usgal; recommend mixing a minimum of 10 gallons prior to beginning the filling process.

5. Connect Filling Hose - Connect the pressure hose from the outlet of a fill pump to fill valve (2), see Figure 11-2; open the fill valve. The inlet (suction side) of the filling pump must be inserted into the container of mixed heat transfer fluid. NOTICE : The filling pump must incorporate a filter to prevent unwanted particles from entering the system. See Figure 11-1.

Trade Tip - Glycol

Mix DowFrost glycol concentrate with de-ionized water to the level of freeze protection required for the local climate zone. Refer to DowFrost Product Information Sheet included with the system or Section 10.0. De-ionized water is typically available at local wholesalers,

drug stores, or pharmacies. Do not use distilled water or tap water as aggressive pH levels in these fluids can breakdown glycol, damage solar piping or degrade collector seals.

pH Levels - The maximum time period that the heat-transfer fluid can

remain in the system without attention is 1 year. Glycol pH levels should be checked/maintained annually. Refer to the Maintenance Schedule in section 11.0.

Plumbing - Solar tank installation and DHW plumbing must be

complete and the tank filled with water prior to adding fluid to the solar thermal system. Failure to follow these instructions may cause overheating of the solar heat transfer fluid resulting in property damage or personal injury.

�� Check List

Figure 11-1 Filling the System A B

Trade Tip

5

1 - Pressure Gauge 2 - Fill Valve 3 - Adjustment Valve 4 - Flush Valve 5 - Bleed Screw

Figure 11-2 Filling & Commissioning


53

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Flushing Collectors - Attempts to pressure test or flush the solar collectors with water is not recommended as it is difficult to completely remove the water from the system.

Failure to follow these instructions may cause deterioration of glycol or freezing resulting in damage to collectors.

6. Connect Flush Hose - Connect a flush hose to the flush valve (4), see Fig. 11-2, to the container of mixed heat transfer fluid; open the flush valve.

7. Close Adjusting Valve - To prevent short circuiting during the filling process, close the adjusting valve (3) by turning the screw slot horizontal, see Fig. 11-3.

8. Bypass Check Valves - Remove the thermometers and turn the ball valves 45º clockwise using a 14mm wrench, see Fig. 11-3. This action bypasses the check valves, aiding in the filling and purging process.

9. Fill/Flush Solar System - Ensure the isolation valve located beneath the auto air vent at the collector outlet is in the open position. Fill the solar system by operating the filling pump; continue flushing for an additional 15 minutes to help de-aerate the system; periodically open the bleed screw (5) on the de-aerator. Notice: it is necessary to briefly open the adjustment valve (3), by turning the screw slot vertical, two or three times during the flushing process.

10. Pressurize - Close the flush valve (4) and allow the pressure to increase at the pressure gauge (1) to approximately 70 psi, then close the fill valve (2) and turn the fill pump off. Open the adjusting valve (3) by turning the screw slot vertical. Check for leaks.

Commissioning the System Installation Checklist 1. De-aerate System - Open the bleed screw (5) on the de-aerator to remove air; close the

screw when the fluid exits without bubbles or when the pressure drops below 25 psi. Re-pressurize to 70 psi and check for leaks; if the pressure drops significantly there is a leak in the system.

2. Set Operating Pressure - Set the operating pressure in accordance with Table 4-2. 3. Circulate at High Speed - Turn the power to the pump station on and manually operate the

solar pump; set adjustment channel MAN1 to ON, see Table 9-3. Set the dial on the solar pump to the highest speed (three) and ensure the adjustment valve (3) is fully open with the screw slot in the vertical position. Allow the system to circulate for at least 15 minutes; periodically open the bleed screw (5) to allow any air to escape. Notice: re-pressurize if the pressure drops below the required operating pressure.

4. Set Maximum Flow Rate - Close the check valves by turning 45º counterclockwise, see Figure 11-2. With the solar pump in manual override (see previous step) reduce the flow to the desired rate (0.7 pgm for two collectors, 1.2 gpm for three collectors). First reduce the dial setting on the solar pump, followed by adjustment of the adjustment valve (3). Record the flow rate indicated on the flow meter then return the solar pump to automatic mode, set MAN1 to Auto, see Table 9-3.

5. Complete - Check the system for leaks, close the isolation valve located beneath the auto air vent at the collector outlet, remove the white plastic covering from the collectors, remove the filling and flushing hoses and install the captive caps.

6. Control Setup - Set operating parameters according to the system layout, see Section 9.0. 7. Open Check Valves - For normal system operation, the check valves must in the open position (Fig.11-3). 8. Installation Log - Document all installation parameters, system settings, and cold fill pressures in Table 11-1.

Original set-up parameters will be verified against existing performance during preventative and routine maintenance checks and for troubleshooting purposes. The Sol-R-Therm installation is not considered complete until the Installation Log is filled out and installation settings are captured and recorded.

9. Technical Support - Installers requiring assistance can speak directly to a NTI technical service representative by calling our North American toll free number at 1-800-688-2575.

Draining the System Installation Checklist 1. Handling Instructions - Decomposed glycol can be acidic depending on its condition at the

time of removal. Review the Handling Instructions for Heat Transfer Fluid in Section 10.0 before draining the system.

2. Turn System Off - Turn power off to the system. Cover collectors and allow hot glycol to cool to a safe temperature before attempting to drain the heat transfer fluid from the system.

3. Bypass Check Valves - To empty the system completely, turn the ball valve 45° clockwise to bypass the check valve. See Fig. 11-3.

�� Check List

�� Check List


54

\\\\ 4. Air Vent - Open the air vent at the highest point of the system above the collector. 5. Fill/Drain - Open the fill and drain valve at the lowest point of the system, close to the store connection, if

possible, or at the drain valve and the pump. 6. Drain heat transfer fluid into a large bucket. If glycol needs to be completely replaced, mark container USED

GLYCOL. Refer to Handling Instructions for recommended disposal methods. DO NOT dump down the drain. 7. Refill - Follow the steps detailed in Filling the System to recharge the system. 8. Commissioning - Re-commission the system as per commissioning procedure, uncover collectors, and turn on

system. Update maintenance log with glycol mix ratios, freeze protection levels, system volume and pressure. 9. Normal Operation - The check valve has to be in the open position for normal operation. See Fig. 11-3.

Figure 11-3 Check Valve Positions

Table 11-1 Sol-R-Therm Installation Log

Item Description Initial System Set-up Installing Contractor

Installation Date

Plumbing � Solar Closed Loop Piping

� Domestic Plumbing

Other

Type of System Layout

� Basic Preheat � Preheat with Auxiliary Storage � Preheat with Surplus Heat Distribution � Supplemental with Electric Backup � Supplemental with Boiler Backup

Mix Ratio: _____ % glycol + _____ % de-ionized water Glycol Freeze Protection Level

Protection required for Latitude: _____oC / _____ oF

Approximate System Volume

Pump Speed Setting Operation Speed: 1 � 2 � 3 �

Expansion Tank Cold Fill Pressure: ____ psi

Field adjusted controller settings Temp Differential

Installers Notes:

Turn 45º clockwise with a 14mm wrench to bypass the integrated check valves to aid in the filling or draining process.

Open Closed Fil l / Drain


55

\\\\ Normal Operation The pump station circulates heat transfer fluid from the outlet of the solar collectors to the inlet of the lower coil in the solar tank, where heat is transferred to the domestic hot water stored in the tank. A temperature differential is used to turn the solar pump on and off based on the configuration and settings programmed in the controller. Safety features are used to cool the tank or shut down the pump when collector or tank temperatures get too hot. Table 9-1 serves as a Quick Reference Table describing basic system operation. Figure 11-4 provides an overview of normal operational temperatures, pressures, and flow rates at the various access points in the system.

Vacation Operation Holiday Tank Cooling Mode is normally only used when the occupants are going to be away for extended periods of time when there is no load to drain the hot water from the solar tank. By using this function, it permits the solar tank to cool beyond the normal temperature. It functions the same as Normal Tank Cooling (OSTC), with the exception it replaces the normal Solar Tank Set Point (SMX) with Holiday Tank Set Point (THOL). Refer to Section 9.0, Holiday Tank Cooling Mode for more details regarding extended vacation settings.

Figure 11-4 Normal Operational Parameters

Solar Relief Valve Pressure Rating 58psi (400 kPa)

2 Collectors (SRT-Pk1) Flow Rate 0.4-0.85gpm (1.4 - 3.2 L/min)

3 Collectors (SRT-PK2) Flow Rate 0.6-1.3gpm (2.1- 4.8 L/min)

Expansion Tank Cold Fill Pressure See Table 4-2

System Flow Flow Meter 0.4 - 1.3 gpm (1.4-4.8 L/ min)

Indirect Coil Flow Rate See Table 1-2, Trin & Stor Manual

Air Vent Pressure 15psi (100 kPa)

System Pressure Max Working Pressure 58psi (400 kPa)


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12.0 MAINTENANCE AND TROUBLESHOOTING Maintenance Preventative Maintenance - Preventative maintenance is always the best policy so there are a few routine checks NTI recommends that can easily be performed by the system owner. We encourage you to get to know your SDHW system by doing a semi-annual visual inspection in spring and fall on major system components so you are familiar with what is normal operation and can recognize what isn’t. Refer to Table 12-2 for the Preventative Maintenance Checklist. Regular Maintenance - Regular maintenance on your system is a pre-requisite for potential warranty claims. Verification of adequate freeze protection of the solar circuit and reserve alkalinity of the heat transfer fluid in the collectors are critical to system safety and performance. Contact a solar contractor and ensure they can perform the specialized and regular maintenance tasks in Table 12-1. Refer to Table 12-2 Maintenance Procedures, Table 12-3 Troubleshooting Guide, and Table 12-4 Maintenance Log Template for additional information.

Heat Transfer Fluid - Refer to Section 10.0 for instruction on glycol handling, storage, disposal, and first aid.

Power down the system and cover collectors before commencing maintenance work on any solar components. Failure to follow instructions may result in equipment damage or injury.

Troubleshooting Not every problem is an indication of abnormal behaviour by the system as explained in the following examples. When troubleshooting, check the normal operating conditions specified in Table 1-3 and compare them to existing values, if measured values are outside the normal range proceed to Table 12-3 Troubleshooting Guide.

Pressure Fluctuations - Directly after start up, the system may experienced pressure fluctuations due to residual air in the solar circuit. Pressure generally stabilizes after the remaining air has been evacuated from the system.

Steamed-up Collectors - This is usually a result of moisture accumulated during storage and transport. Once collectors are in operation, the mosisture will start to evaporate through the collector’s built-in exhaust vents at the top and bottom end of the colloctors. Fogging typically disappears completely after a few weeks.

Table 12-1 Maintenance Schedule W M Y Month # Year # Visual Check Preventative Maintenance - - - 3 9 5 10 15

Collectors Check for glass damage, fluid leaks; clean if dirty with soapy water. � �

Controller Check that power light on, outputs displayed correctly on screen. � Flow Temperature difference between inlet/outlet temp gauges; flow meter. �

Fluid Leaks Check for leaks at connection points and solder joints. �

Solar Pump Check for excessive noise, vibration, or overheating when operating. � �

Relief Valve Check if pump station relief valve is weeping or discharging fluid. � �

System Pressure Check if pressure below normal (see Fig. 11-2 to locate gauge). �

Insulation Solar piping not exposed, insulation not damaged. �

Specialized Regular Maintenance

Controller Performa a function check on controller; connections not corroded. � Expansion Tank Inspect expansion tank for signs of malfunction. � R

Insulation Check if line sets damaged by debris/birds/vermin, patch or repair. � R Freeze Protection Confirm freezing point of the glycol in the system. � R

PH Levels Check PH quality of heat transfer fluid. � R

Piping Supports are not sagging, building penetrations are properly sealed. � R Relief Valve Manually function the safety relief valve on the pump station. � R

Valves Check all valves, verify normal operation. � R

Structural Support Check if bolts tight/damage to components after heavy snow/winds. � R = Estimated time table for part and fluid replacement or minor repairs. Refer to Trin & Stor manual for solar tank maintenance schedule.


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\\\\ Table 12-2 Maintenance Procedures Maintenance Task and Repairs Maintenance Procedure

Glycol - Freeze Protection Test � Test for the proper concentration using the following tool: - refract meter (ensure it is one specifically for propylene glycol)

Glycol - Adjusting the Freezing Point of Existing Glycol in the System

� Greater freeze protection - determine the amount of HTF to drain and replace with DOWFROST and increase glycol concentration. Formula: A=V(D-P)/(100-P)

� Less freeze protection - determine the amount of HTF to drain and replace with de-ionized water and increase glycol concentration. Formula: A=V(P-D)/P

�

� Best time to check PH is after summer, but before first freeze. � Draw a small fluid sample from the pump station purge valve. � Test fluid PH level using one of the following tools:

- digital PH tester - tight range litmus paper (i.e. pHydrion)

� Recommended course of action based on measured PH level: PH 8.0 - 10.0 Good PH 7.0 - 8.0 condition glycol with inhibitor booster

Glycol - Testing PH Levels

PH <7.0 or >11.0 completely replace glycol

Glycol - Conditioning � Make adjustments to the system’s glycol PH levels by using a 50% solution of sodium hydroxide or potassium hydroxide.

Glycol - Drain/Flush/Replace (see Section 11.0 for Draining, Filling and Commissioning procedures)

� Cover collectors and shut off pump. � Drain existing glycol from system. � Refer to freeze protection procedure to verify freeze/burst levels. � Mix new DowFrost with de-ionized water to freeze protection level. � Fill system with new glycol mix, circulate through the system. � Remove air from system. � Record new freeze protection and pH levels on Maintenance Log.

Insulation & Wiring – Weatherizing

It is possible for exterior insulation or wiring to become damaged by storms, debris, birds or vermin. � Replace missing/severely damaged insulation (UT/Solaflex), seal joints. � Repair torn insulation so piping is not exposed, seal with Armacell solar tape.

Table 12-3 Troubleshooting Guide Potential Problems Symptoms and Causes Suggested Course of Action Glycol - drop in PH Level

A drop in PH level often means: � frequent collector stagnation

Contact NTI technical support.

Glycol - change in appearance or odor

Indication that fluid needs replacing: � presence of oily layer � black or dark-grey colour � burnt odor � heavy sludge in fluid

Drain/Flush/Replace - Table 12-2

Fill and Commission - Section 11.0

System Pressure - below normal (closed loop glycol circuit)

Check for signs of leaks in glycol loop: � liquid showing up on the floor � soggy insulation adjacent to leak � blue-green film on copper fittings � fluid discharged from relief valve � check if relief valve has discharged

Check pipe connections for leak, fix it, top of glycol, re-pressurize the system (see Section 11.0).

If relief valve has discharged, collectors may have stagnated or expansion tank pre-charge pressure may be too low.

Pump Failure

Pump does not respond. Veri

Check fuse in controller. Verify R1 is getting power.

Faulty Sensor/Controller

Shorted; Open - Collector Sensor FKP6 (black) - Tank Sensor FRP6 (white)

Verify sensor is functioning properly. Check resistance with multi-meter.


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Table 12-4 Sol-R-Therm Maintenance Log Service Contractor Completed # Maintenance Task Performed Name Contact Info dd/mm/yy

General Notes: 1 Power down the system and cover collectors prior to commencing any maintenance work on solar system components. 2 Use the template in Table 12-4 to document inspections and service work performed on the Sol-R-Therm system.


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\\\\ NOTES

NY Thermal Inc. 65 Drury Cove Road Saint John, NB E2H 2Z8 Canada Technical Assistance: 1-800-688-2575

Website: www.nythermal.com Fax: 1-506-432-1135

Documents

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