Free Hot Water FHWFC 4000 Series Operation & User’s Manual

Text of Free Hot Water FHWFC 4000 Series User Guide:

• Free Hot Water FHWFC 4000 Series, _______________________________________________________________________________ _______________________________________________________________________________ Free Hot Water 2146 Bering Dr. San Jose, CA 95131 Tel: 408 218 3660 Fax 408 872 4142 www.FreeHotWater.net Manual Installation Manual FHWFC 4000 Series Version 2009.07

• Free Hot Water FHWFC 4000 Series,  Page 2 Content _________________________________________ Safety information.........................................................................................3 Transport note ..............................................................................................4 Assembly instructions - Collector .................................................................5 Overview of tools ..........................................................................................6 Overview of materials ...................................................................................7 Attachment points...................

• Free Hot Water FHWFC 4000 Series,  Page 5 General Assembly instructions _____________________________________________________________________________ General and transport instructions The mounting system is suitable for tiled roofs only. Installation must only be carried out by qualified personnel. The entire information in these instructions is intended exclusively for such qualified personnel. Only the supplied material should be used for the installation. Prior to starting installation and operation of the solar collector sy- stem, please inform yourself about the applicable local standards and regulations. The use of a carrying strap is r

• Free Hot Water FHWFC 4000 Series,  Page 6 connected to the main potential equalisation bus by a qualified electrician in accordance with ÖVE/ÖNORM E 8001-1 or the country-specific standards. Connections Connect the collectors using the cutting ring screw connections. If flexible pipes are not used as connectors, precautions must be taken to protect the connection pipes against temperature fluctuations caused by heat expansion, e.g. expansion bends and flexible piping (see Connecting the collectors to one another/Operational recommendations). Larger collector arrays must be assembled with expansion bends

•  Page 8 Collector Specs Collector Technical Data Gross Area Sqft 21.85 Weight (Dry) Lbs 64.00 Net Area Sqft 19.50 Content Gallon 0.42 Aperture Sqft 20.24 Max Pressure PSI 147 Fig 1.0

• Free Hot Water FHWFC 4000 Series,  Page 10 Pressure drop and flow rates Mass flow rate To ensure the performance of the collector, a specific flow rate of 30 l/m²h is to be selected up to a collector panel size of approx. 25m². Pipe diameters Dimensions table with a specific flow rate of 30 l/m²h Collector Size (m^2) 5 Collectors 8 Collectors 12 Collectors 25 Collectors Pipe Diameter / Cu (mm) 10-12 15 18 22 Pipe Diameter / SS (mm) 12 22 Pressure loss collector for anti-freeze / water mixture (

• Free Hot Water FHWFC 4000 Series,  Page 11 General Closed Loop System Schematics Flushing and filling For safety reasons you should only fill the collectors when there is no direct irradiation from the sun (covering the collectors can be an option). Especially in regions exposed to frost, for flat plate collectors you should use a mixture of anti freeze with water (40% anti freeze). The solar thermal system should be filled and commissioned within one week of installation, because heat build-up in the collector array can damage the flat gaskets in empty systems. If this is not possible, the flat gaskets should be replaced before commissioning

• Free Hot Water FHWFC 4000 Series,  Page 12 It may not be possible to completely empty collectors one they have been filled. For this reason collectors exposed to frost should only be filled with a water/antifreeze mixture, also for pressure and function tests. Alternatively, the pressure test can also be carried out using compressed air and leak detection spray. Installing the temperature sensor The temperature sensor should be installed in the sensor sleeve nearest to the collector array flow. To ensure optimal con

•  Page 13 Connecting the collectors to one another The diagram below is an example of how the collectors can be connected to one another. However, the actual connection may be different depending on structural conditions. A maximum of 6 collectors may be connected in a series! If a collector panel is made up of more than 6 collectors, the pane

• Free Hot Water FHWFC 4000 Series,  Page 14 Installation Steps for Pitched Roof Mounting 1. Locate and mark the roof rafters into which the solar collector mounting brackets will be mounted (one way to find rafters is to see the “tails” at the edge of the roof). 2. To create a set point for plumbing and level installation, measure the distance from the edge of the roof to the desired mounting points and mark the points where the collector mounting brackets will be installed (fig 1.2). *Note: you need to install a screw into one of the holes in the mounting bracket, not both holes (fig 1.1). * Note: for collector model 7000 upper and lower mounting bracket should

• Free Hot Water FHWFC 4000 Series,  Page 15 4. Holes should be slightly overlapping to form a sideways “8” shape (see illustration 1.3). Mark the penetration before making holes. If you are installing on a composition shingle roof make holes 5” below the bottom of the shingle above the penetration. Fig 1.3 5. Using a hole saw, cut the hole (penetration) for the 2 hoses or pipes from step 3. 6. If using flex hose: before connecting the hose, measure, cut, and lay out the hose, including enough length for 8’ of hose above the roof. Pull the

• Free Hot Water FHWFC 4000 Series,  Page 16 9. Next, using a cutting tool, cut out a piece of the roof material beneath the top layer of the composition shingle (the top layer will NOT be penetrated for the mounting brackets) as marked 1.5” X 2.5” in the shape of the mounting bracket. Cutting out a piece of roofing material will provide for a flush-mounted roofing bracket. Fig 1.5 Fig 1.6 Fig 1.7 10. Pre drill mounting bracket screw holes into rafter or other appropriate mounting substrate (one hole per bracke

•  Page 17 19. Once collector fits and lines up appropriately, apply AT 60 to ½” bolts for collector and fasten collector to profiles using ½” bolts and washers. 20. If installing more than one collector, cut flex hose or copper pipe in length necessary to connect collectors. On all plumbing connections use Anti Leak (part # FHWM-AA- 72050) 21. Connect collector

• Free Hot Water FHWFC 4000 Series,  Page 24 Guarantee and Warranty No liability will be assumed for use other than for the intended purpose or for inadmissible alteration of installation components or consequences thereof; likewise for failure to observe the installation instructions correctly. All information and instructions in this manual refer to the current state of development. Please always use the respective assembly instructions supplied with the collectors. Figures and illustrations used. Due to the possibility of set

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