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Solar Boiler
INSTALLATION MANUAL FOR MODELS:
SB32-9PV AND SB64-9PV
WARNING
The approved heat transfer fluid is 40% Propylene Glycol USP and 60% distilled
water. The substituion of any other heat transfer fluid can cause irreparable dam-
age and create a health and safety hazard.
The Solar Boiler™ module conatins 3.75 liters (1 US gallon) of heat transfer fluid
when full.
The installation of the Solar Boiler™ system should be installed by a qualified
technician.
Assemblies and materials shall meet requirements of the applicable codes and
Standards for fire safety.
TM
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Summary of Contents for Solar Boiler SB32-9PV
- Page 1 E C O L O G I C A L The Solar Boiler™ module conatins 3.75 liters (1 US gallon) of heat transfer fluid when full. E C O N O M I C A L The installation of the Solar Boiler™...
- Page 2 SB32-9PV and SB64-9PV Solar Boiler™ System Components Congratulations on the purchase on your new Solar Boiler™ system by Thermo Dynamics Ltd. The Solar Boiler™ is the newest and most advanced concept in residential solar domestic water heating systems. This manual outlines all of the steps necessary for a quick trouble free installation.
- Page 3 In this manner, the solar water heater saves electrical energy. NOTE: The Solar Boiler™ is designed to shut off when a temperature of 70°C (158°F) is at- tained in the solar storage tank. The heat transfer fluid is a 40/60 % by volume mixture of Propylene Glycol USP and distilled water.
- Page 4 Solar Boiler™ System and Installer Details Installer Address Tel: Email: System Details Solar Boiler Model Solar Collector Serial#(s) Solar Boiler Serial# Storage Tank Serial# Orientation E or W of South Collector Slope Collector Mount (Flush or Inclined)
- Page 5 Installation Manual for SB32-9PV and SB64-9PV Solar Collector Location Micro-Flo® solar collectors are de- signed to work with the Solar Boiler™ module and other Micro-Flo® systems. Locate the solar collectors on the roof of your home that is oriented true south or as close as possible.
- Page 6 Solar Boiler™ 1 – Locating Roof Rafters Locate the rafters directly under the solar collectors, and at least 8” from the ends of the solar collectors. In the case of 4’ x 8’ solar collectors and 24” rafter spacing, the clips should be mounted six feet apart (that is, one foot from the edge of the collector).
- Page 7 Installation Manual for SB32-9PV and SB64-9PV 3 – Optional Second Solar Collector If you have a two solar collector system, place the B solar collector above the A solar collector. Make sure that the ports are on the right hand side.
- Page 8 The copper tube roof penetration is made adjacent to the “A” collector for the SB64-9PV system and the “B” collector for a SB32-9PV system. Make a roof penetration at a position 8" - 10" hori- zontally away from the “A”, (“B”) collector bottom ports.
- Page 9 Installation Manual for SB32-9PV and SB64-9PV 7 – Connection Between Collector A and B Place the 3/8" compression nuts on the fitting body finger tight. Insert the copper tubes into the ports as shown, until they bottom out. Using a 5/8" and a 11/16" wrench, tighten the nuts one full turn.
- Page 10 Solar Boiler™ 9 – Wiring the Photovoltaic Module and Collector Sensor Open the junction box located on the photo- volatic module, and note the positive terminal Service Plug Compression Nuts marked "+" and the negative terminal marked "-". Drill 2 small holes and insert the 18/4 LVT wire Pinch in the box.
- Page 11 Installation Manual for SB32-9PV and SB64-9PV 10 a – Temperature Sensor Enclosure (some models) As of May 2010, some models of the S32B-P solar collector are equipped with a tempera- ture sensor enclosure. A picture is shown to the right.
- Page 12 Solar Boiler™ 11 – Setting Up the Solar Boiler™ Module, (Bottom Connections) Place the Solar Boiler™ module and solar storage tank next to your auxiliary water heater. Remove the drain valve from the solar storage tank. Install the bottom tank assembly. Posi- tion the tee such that one end points toward the Solar Boiler™.
- Page 13 Installation Manual for SB32-9PV and SB64-9PV 13 – Isolation Bypass Preparation Close the main cold water supply valve to the existing water heater. Install two copper tees and a ball valve #1 as shown in the diagram. Label this ball valve: BALL VALVE #1.
- Page 14 Solar Boiler™ 15 – Solar Boiler™ Copper Tube Connections The Solar Boiler ™ module is prefilled with heat transfer fluid. Carefully remove the plugs from the brass fittings and retain. Replace with the 3/8” compression nuts provided. Turn the nuts on until finger tight.
- Page 15 The Solar Boiler™ module contains 3.75 liters (1 USG) of HTF. An additional 3.75 liters (1 USG) is provided to top up the system. Once filled, an SB32-9PV or SB64-9PV Solar Boiler™ system contains 4 – 6 liters (1.1 – 1.6 USG) of HFT...
- Page 16 Solar Boiler™ 19 – Solar Boiler™ Start Up (continued) You will hear air bubbling in the Solar Boiler unit. This is normal. Place a container under the vent tube. Using a funnel, SLOWLY pour the supplied heat transfer fluid into the Solar Boiler™ unit until fluid comes out of the vent tube.
- Page 17 Installation Manual for SB32-9PV and SB64-9PV 21 – Delta-T Booster II LED’s The following describes the conditions required to illuminate each particular LED: (Delta T refers to the difference in temperature between the collector temperature and the storage temperature.) - RED: low delta T; Collector sensor open circuit.
- Page 18 1. S Series (Micro-Flo®) solar collector(s) 2. Solar Storage Tank 3. Delta-T Booster (inside the cover of the Solar Boiler) 4. Solar Boiler™ Module 5. 3/4” Hard Copper Tube 6. Photovoltaic Module, 20 Wp 7. Copper Tube Kit, 3/8” with insulation and 18/4 wire 8.
- Page 19 Installation Manual for SB32-9PV and SB64-9PV Operating Restrictions and Maintenance Do not use the Solar Boiler™ system to heat any treated water system, such as pools, directly. Use the proper mixture and quantity of propylene glycol USP and distilled water for freeze protection.
- Page 20 Solar Boiler™ Repairs and Energy Saving Tips If any of the components of the Solar Boiler™ or Micro-Flo® solar collectors are damaged, your local dealer or Thermo Dynamics Ltd. should be advised before any repair is attempted. In the case of broken glass, we recommend the use of an industrial vacuum cleaner to remove all glass fragments from the collector and surrounding area.
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Page 21: Troubleshooting Guide
Installation Manual for SB32-9PV and SB64-9PV Troubleshooting Guide PROBLEM COMPONENT CAUSE ACTION REQUIRED Solar Boiler™ stays Potovoltaic Module snow covered - remove snow or allow to melt “OFF” module is in the shade - check to see if there are any removable... - Page 22 Solar Boiler™ is - adjust cover Noisy resting against the motor or pump Solar Boiler™ module low fluid level in resevoir - turn Solar Boiler™ OFF and wait for it to cool. Open brass cap and check fluid level with wooden dowel.
- Page 23 Fluid may be HOT. • To drain the fluid in the Solar Boiler™ module, you will have to wait until their is enough sunlight for the system to operate. With a container under the outlet of the pump, install the “Service Plug” and turn the Solar Boiler™ ON. Keep the unit on until no liquid comes out of the pump.
- Page 24 Solar Boiler™ and the connections at the solar collector on the roof. Also inspect under the Solar Boiler™ case for signs of HTF on the floor. The HTF, Propylene glycol USP, is very slippery and dries very slowly and will remain on surfaces for an extended period of time.
- Page 25 Installation Manual for SB32-9PV and SB64-9PV Material Safety Data Sheet for Propylene Glcyol USP The HTF (heat transfer fluid) used in this Solar Boiler™ system is a mixture of Pro- pylene Glycol, USP and distilled water (40/60)% by volume. The following is a brief outline of the Material Safety Data Sheet for Propylene Gly- col, USP.
- Page 26 Solar Boiler™ Material Safety Data Sheet for Propylene Glcyol USP continued INHALATION: A single prolonged (hours) inhalation exposure is not likely to cause adverse effects. Mist may irritate nose and throat. Chronic Effects of Exposure: Repeated excessive ingestion may cause central nervous system effects.
- Page 27 • Close the valve at the bottom of thesolar storage tank near the 1/2” brass tee that connects the tank to the Solar Boiler™, shown in the diagram in the diagram. • Connect a hose to the drain bib at the bottom of the solar storage tank, and place the free end in a drain.
- Page 28 Solar Boiler™ Temperature vs Resistance Chart for 10 kohm thermistors Measure the resistance of your collector or storage sensor and compare to the chart below. Ensure that the corresponding temperature is correct. Replace inaccurate sensors if necessary. Temperature vs. Resistance Chart Thermistor @ 25°C...
- Page 32 S E N S I B L E E C O L O G I C A L SB64-9PV Solar Boiler System only E C O N O M I C A L A F F O R D A B L E...
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