HTP FP-26SC Installation And Maintenance Manual

Text of HTP FP-26SC User Guide:

• HTP FP-26SC, 3 The installer should be guided by the instructions furnished with the tank, as well as local codes and utility company requirements. Preference should be given to codes and requirements where they differ from the furnished instructions. Additional publications which should guide the installer include: Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, available from Solar Rating and Certification Corporation, 1679 Clearlake Road, Cocoa, FL 32922-5703, www.solar-rating.org. Code for the Installation o

• HTP FP-26SC, 29 A. CLEANING Regular rain should keep the collectors clean. However, if the collectors are particularly dirty, wash with a soft cloth and warm, soapy water or glass cleaning solution, ONLY if the collector is located in a position which DOES NOT require climbing onto the roof or use of a step ladder. If the collectors are not easily and safely accessible, high pressure water spray is also effective. If cleaning is required and the above outlined methods are not suitable, the company that supplied and installed the solar collector should be contacted. B. INSULATION The plumbing pipes running to and from the collector should be heavily insulated. This insula

• HTP FP-26SC, 16 N. CONNECTION OF MULTIPLE COLLECTORS The maximum number of collectors that can be connected in series is 8. If the entire installation requires more than 8 collectors, use parallel strings of an even number. If even numbers cannot be achieved on parallel strings, flow balancing valves must be installed to ensure each collector has the same flow. In drain back systems, supply and return connections to the collector must use eccentric fittings or a fitting arrangement that allows full draining of header pipes. The collector or array can be mounted level or with up to ¼” pitch towards the return port to facilitate

• HTP FP-26SC, 120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com Flat Plate Solar Collector INSTALLATION MAINTENANCE Models FP-26SC FP-32SC FP-40SC NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature. This manual must be used by a qualified installer/service technician. Read all instructions in this manual before installing. Perform steps in the given orde

• HTP FP-26SC, 19 Position the E1022 strut into the triangle foot and align the hole in the strut with the holes in the triangle foot. Insert the 1 ¾” x 3/8” bolt and secure with a 3/8” nut and washer. When all hardware and fasteners are installed the assembly will look similar to Figure 8 and 9. Check for collector alignment and tighten all fasteners. Use the chart below to determine the length of the rear strut. REAR STRUT LENGTH AT CHOSEN ANGLES COLLECTOR TILT FP-32SC BASE DIM. 98.18” FP-40SC BASE DIM. 122.18” 30 o 53” Strut length

• HTP FP-26SC, 4 PART 3 – INSTALLATION INFORMATION .............................................................................................. 11 A. TRANSPORT, UNPACKING, AND INSPECTION .............................................................................. 11 1. COMPONENT LIST ......................................................................................................................... 11 2. COLLECTOR INSPECTION ............................................................................................................ 11 B. COLLECTOR DIMENSIONS AND WEIGHTS ....

• HTP FP-26SC, 20 E. RACK MOUNTS (HTP Part # FP-RM) Each rack mount package contains enough hardware to secure one collector. The set contains: • (4) Rack mounts • ¼” – 20 stainless steel set screws, pre-installed per flush mount INSTALLATION Fully loosen the set screw. Once loosened, the rack mount will engage into the Quick Lock frame rail. Slide the rack mount to the desired location. Tighten set screw with a 7/16” wrench to a maximum of 10 foot pounds to lock the rack mount into position (Figure 15). PART 5 – ROOF / WALL ATT

• 2 The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, coul

• HTP FP-26SC, 15 I. AVOID SHADE Collectors should be located so that shading does not occur between 9 AM and 3 PM local time. Partial shading due to small objects such as antennas and flues is not of great concern. J. LOCATION To avoid long pipe runs, the collector should be positioned as close as possible to the storage tank. Storage tank location should therefore be considered part of the location requirements of the solar collector. The storage tank should be located as close as possible to the most frequent draw off points in the building. K. EXPANSION TANK Expansion of

• HTP FP-26SC, 8 B. LOCAL STANDARDS AND AUTHORIZED PERSONS Installation must be completed in accordance with local standards and regulations. Installation must also be completed by a qualified tradesperson who holds relevant industry licenses or certificates. The term “authorized person(s)” used throughout this document refers to a suitably qualified professional. Unless otherwise specified in Part 3, no part of the HTP solar collector may be inspected, repaired, or maintained by anybody other than an authorized person. C. TERMINOLOGY Solar terminology differs from region to region. To avoid confusion, please note the following: Supply – The plumbing line runni

• HTP FP-26SC, 28 C. PRESSURE SYSTEM PLUMBING PANEL ATTACHMENT Suggested panel plumbing attachments for pressure systems. This diagram can be used for either vacuum tube or flat plate collectors. The collector can be plumbed from left to right or right to left. Note the air purge is on the hot out pipe. For collectors with 1” male threaded fitting (NPT), use high- temperature thread sealant that can be used with glycol. For collectors with 1” copper pipe, sweat a 1” sweat-to-male pipe thread. PART 8 – MAINTENANCE Under normal conditions, the solar collector i

• HTP FP-26SC, 6 INTRODUCTION ABOUT YOUR FLAT PLATE SOLAR COLLECTOR Your Flat Plate Solar Collector is designed to offer reliable hot water heating in hot, mild, or cold climates. Flat plate solar collectors operate in open loop, closed loop, and drain back solar systems, making these collectors ideal for a variety of installation designs. Job site conditions will require your installation contractor to supply some or all of the following: • Plumbing connections • Piping and insulation • Valves between your backup water system and the sol

• 10 maintained in accordance with the supplier’s instructions if the air temperature is expected to approach the specified freeze tolerance limit.” For open or closed loop systems: In areas with temperatures not falling below -5 o C / 23 o F, a differential solar controller with freeze protection may be used (e.g. requiring pump to circulate if the manifold tempera

• 27 Figure 24 – Reverse return plumbing B. BALANCE FLOW VALVES WITH METERS Below you will find suggested collector piping diagrams using balance flow valves and meters for balanced flow. The following configurations may not work in drain back systems. These drawings can be applied to various system configurations, but may not meet certain requirements.

• HTP FP-26SC, 33 HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document. Customer’s Name: Installation Address: Date of Installation: Installer’s Code/Name: Product Serial Number(s): Comments: Installer’s Phone Number: 1 Signed by Installer:

• HTP FP-26SC, 30 company that supplied and installed the system. Any other system troubleshooting, adjustments, or repairs may be completed ONLY by authorized persons. A. NO HOT WATER If there is no hot water, the problem will generally be related to the gas or electric heating system, not the solar collector. The collector simply pre-heats water, with final boosting completed by the electric element or gas booster system. For a retrofitted solar system, please contact the manufacturer/installer of your

• HTP FP-26SC, 9 For drain back systems, the solar loop often operates at less than 25 psi, far lower than open or closed loop systems. These low operating pressures do not require an expansion tank. A pressure relief valve, installed on the drain back tank and piped in copper to an appropriate drainage location, will provide sufficient expansion protection. This pressure relief valve and drain outlet pipe must never be sealed or blocked. The pressure relief valve is intended to be operated for safety purposes only. NOTE: Sup

• HTP FP-26SC, 7 C. HIGH TEMPERATURES • In sunlight, the copper plumbing ports can reach temperatures in excess of 300 o F. Thick leather gloves must be worn when handling hot components to prevent serious burns. • Keep solar hot water system and components away from children and animals. • In an installed, fully plumbed system, if the pump is stopped in sunny conditions, the copper ports and piping can easily reach temperatures in excess of 300 o F. Caution should be taken when handling such components. • Do not store combustible materials (dry leaves, tree branches, gasoline, etc.) in the vicinity of the solar system. Failure to follow these warn

• HTP FP-26SC, 12 B. COLLECTOR DIMENSIONS AND WEIGHTS Figure 1: Collector dimensions. Copper union in illustration is field-supplied. Allow spacing to assemble fittings and unions. FP-26SC FP-32SC FP-40SC DIMENSION A 3.30” 3.30” 3.30” DIMENSION B 47.2” 47.2” 47.2” DIMENSION C 77.2” 97.2” 121.2” DIMENSION D 50” 50” 50” WEIGHT (LBS) 90 113 153 GROSS FRONTAL AREA (FT 2 ) 25.6 31.8 39.7 TRANSPARENT FRONTAL AREA (FT 2 ) 23.6 29.9 37.4 ABSORBER PLATE AREA (FT 2 ) 23.2 25.7 36.9 FLUID CAPACITY (gallons) .90 1.05 1.22 NOMINAL FLOW RATE (GAL/MIN) 0.8-1.5 gallons per collector 0.8-1.

• HTP FP-26SC, 14 H. COLLECTOR ANGLE, PLANE, AND DIRECTION 1. COLLECTOR DIRECTION The collector should face the equator. In the northern hemisphere, this is due south, and in the southern hemisphere, due north. Facing the collector in the correct direction and angle is important to ensure optimal heat output. A deviation of up to 15 o from due south is acceptable, and will have minimal effect on heat output. Figure 2: Suggested placement of solar collectors NOTE: In Figure 2, B, C, and

• 11 NOTE: If the water heater is left in an operating condition and not used for two weeks or more, a quantity of highly flammable hydrogen may accumulate in the top of the water cylinder. To dissipate hydrogen safely, it is recommended that a hot water tap be turned on for several minutes at a sink, basin, or bath, but not a dishwasher, clothes

• HTP FP-26SC, 5 3. REAR MOUNTS .............................................................................................................................. 18 D. FLUSH MOUNTS (HTP Part # FP-FM) .............................................................................................. 19 INSTALLATION ................................................................................................................................... 19 E. RACK MOUNTS (HTP Part # FP-RM) ................................................................................................ 20 INSTALLATION ....................................................................................................

• HTP FP-26SC, 24 2. PRESSURE OPEN LOOP Run the pump at the highest speed setting, forcing air out of the collector and back into the tank. If an auto-air vent is installed on the outlet of the collector, air will automatically eliminate from the solar line. If using a manual air vent, open it until all air is eliminated. 3. CLOSED LOOP The solar loop may be filled with distilled water (drain back system) or glycol/water mix, unpressurized (drain back system), or vented and pressurized. The exact process will depend on the design of the loop and components used. NOTE: A drain back system does not need to be purged. D. PLUMBING CHECK Water vapor may appear on

• HTP FP-26SC, 23 PART 6 – PLUMBING CONNECTIONS A. TEMPERATURE SENSOR INSERTION The temperature sensor well must be located near the hot out port. If the collector is designed without a sensor well, use a stainless steel clamp to clamp the sensor onto the hot out port directly to the copper pipe exiting the collector. Mount the sensor as close to the collector as possible. Ensure that the sensor and cable used on the collector are high temperature rated (up to 200 o C / 395 o F). The sensor cable should not come in direct contact with the piping. Ensure that any pipe insulation is watertight. Use

• HTP FP-26SC, 17 3. RACK MOUNT (HTP Part # FP-RM) Rack mounts are used to attach collectors to a metal frame (such as Uni-Strut). These mounts can also be used to attach collectors directly to the roof. However, this is unadvisable, as rack mounts install close to the roof surface and allow collectors to collect leaves, snow, and other debris. B. GENERAL MOUNTING INFORMATION Mounts should be attached to collectors as close to symmetrically as possible. Mounting clamps should be attached to the collector between 4” and 10” from corners if installed vertically, and 4” and 16” if instal

• HTP FP-26SC, 31 PART 10 – INSTALLATION CHECKLIST The following list is a guide only. Specific items will depend on the nature of the installation. 1 COLLECTOR FACES AS CLOSE AS POSSIBLE TO DUE NORTH/SOUTH. Y N 2 COLLECTOR IS NOT SIGNIFICANTLY SHADED THROUGHOUT THE DAY. Y N 3 COLLECTOR IS NOT LIKELY TO BE STRUCK BY FALLING OBJECTS SUCH AS BRANCHES OR FALLING FRUIT. Y N 4 COLLECTOR IS INSTALLED AT AN ANGLE OF BETWEEN 20 o – 80 o , PREFERABLY AT LATITUDE ANGLE. Y N 5 IN AREAS PRONE TO LARGE HAIL (>3/4”), COLLECTOR IS INSTALLED AT AN ANGLE OF 40 o OR GREATER. Y N

• HTP FP-26SC, 25 G. PUMP SELECTION When selecting a pump, there are two basic solar designs to consider: pressure glycol and closed loop drain back. In pressure glycol systems, two factors determine pipe size. These are: • Flow rate in gpm (gallons per minute) • Head loss In drain back systems, an additional factor must be considered along with the previous two: • Lift Each collector has a nominal flow rate of between .8 and 1.5 gpm. When determining head loss, consider the following: • Head loss pumping through the collector(s) •

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