Solar Boiler SB32-9PV Manual de usuario

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Solar Boiler

INSTALLATION MANUAL FOR MODELS:

SB32-9PV AND SB64-9PV

WARNING

The approved heat transfer uid is 40% Propylene Glycol USP and 60% distilled

water. The substituion of any other heat transfer uid 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 uid

when full.

The installation of the Solar Boiler™ system should be installed by a qualied

technician.

Assemblies and materials shall meet requirements of the applicable codes and

Standards for re safety.

Solar Boiler™

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.

Read the entire manual carefully before any installation attempt is made.

Be sure to follow all local codes when installing the Solar boiler system.

Quantity System Model Description

1 SB64-9PV only S32A-P 4’ x 8’ S Series Serpenitne Collector, “A”, 4 ports

1 SB32-9PV

SB64-9PV

S32B-P 4’ x 8’ S Series Serpentine Collector, “B”, 2 ports

1 SB32-9PV

SB64-9PV

SBM13DC Solar Boiler Module

- Solar Pump (complete with Delta-T Booster II and temp sensors)

- Heat Exchanger

- Expansion Tank

- Glycol Resevoir (Complete with 4 liters of glycol)

- Glycol inlet/outlet ports

- Water inlet/outlet ports

1 SB32-9PV

SB64-9PV

PV20 Photovoltaic Module, 20 Watt

1 SB32-9PV only K1050 Serpentine Collector Mounting Kit (for 1 S Series - mounts ush to roof)

1 SB64 9PV only K1055 Serpentine Collector Mounting Kit (for 2 S Series - mounts ush to roof)

1 SB32-9PV

SB64-9PV

K1060 Photovoltaic mounting kit (mounts to Serpentine Collector)

1 SB32-9PV

SB64-9PV

K2030-50 Copper Tube Kit (3/8” Copper tube, 2 x 50 ft, Insulation, 100 ft, 18/4 LVT

wire, 60 ft

1 SB32-9PV

SB64-9PV

GLYUSM Propylene Glcyol USP, (mixed 40% glycol 60% water), 4 liters

1 SB32-9PV

SB64-9PV

Tank Connection Fittings, (Brass)

SB32-9PV and SB64-9PV Solar Boiler™ System Components

K1050

K2030-50K1055

K1060

A 270 liter, (60 IG) Storage tank is required for the installation and is not included.

In Canada, the tank must be CSA approved and all plumbing ttings must comply

with CSA B.125

S32A S32B

Solar Collectors

S Series (Micro-Flo®)

Solar Boiler™ module

Installation Manual for SB32-9PV and SB64-9PV

• Solar collectors absorb sunlight and convert it to heat.

• When there is sufcient sunlight, the photovoltaic module pro-

duces electricity and turns the pump.

• The pump circulates heat transfer uid, (HTF), through the

solar collectors.

• Heat is transferred to the HTF in

the solar collector.

• The HTF is returned to the heat

exchanger in the Solar Boiler™

module.

• The heat is transferred to the wa-

ter which circulates naturally to the

top of the solar storage tank.

• Solar heated water is stored in the

solar storage tank until water is

drawn from the auxiliary tank (in

this case an electric water heater).

• As hot water is drawn from the

electric water heater it is replaced

with solar heated water.

• The electric heaters increase the

temperature of the solar heated

water, if necessary.

• The electrical energy required

to heat water is signicantly less

when water is preheated by the

solar water heater.

• In this manner, the solar water heater saves electrical energy.

S32 A

Solar Collector

[Optional]

S32B

Solar Collector PV module

Wire - supplies 12 VDC

from PV module to

Solar Boiler™

Cold Water IN

Hot Water OUT

Solar Storage Tank Auxiliary Water Heater

Solar Boiler™

module

Solar Pump™

Ball valve #1

Ball valve #3

Ball valve #2

Normal Operation

Ball valve #1 - Close

Ball valve #2 - Open

Ball valve #3 - Open

[Inside the Solar

Boiler™]

solar heated water IN

cold water IN

solar heated water IN

HTF [heat transfer fluid]

Domestic Water

How the Solar Boiler™ Works

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 uid is a 40/60 % by volume mixture of Propylene Glycol USP and

distilled water. The Solar Boiler™ module contains 3.75 liters (1 US gallon) of heat

transfer uid. An additional 3.75 liters (1 US gallon) is supplied with the system for

lling the system during start up.

The maximum safe working pressure of the heat transfer uid is 60 psi, (410 kPa).

The Solar Boiler™ system is inherently grounded through copper piping connected

to the main water supply. Ensure that household ground is adequately electrically

grounded.

Solar Boiler™

System and Installer Details

Installer

Address

Tel:

Fax

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)

Installation Manual for SB32-9PV and SB64-9PV

S o ut h

Inclined mount

Flush mount

South

H/L

0.25

0.33

0.42

0.50

0.67

1.0

Angle

14°

18°

23°

27°

34°

45°

Rise/Run

3/12

4/12

5/12

6/12

8/12

12/12

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. There are no

major losses up to 45° east or west of

true south. If your orientation is not in

this range, consider a ground mounting

system. The solar collectors are to be

installed such that they are not shaded

for at least 5-6 hours during the middle

of the day.

The recommended slope is equal to the

local latitude plus or minus 10°. For

example, Halifax, Nova Scotia is at a

latitude of 45°. Therefore the recom-

mended collector slope for a home lo-

cated in or near Halifax is between 35°

and 55°. For effective snow removal

in the winter a slope of at least 45° is

recommended.

To calculate the slope of your roof,

measure the dimensions “H” and “L”

as shown in the gure. Calculate the

quantity H/L and compare it to the table

to determine if an inclined mount is

required.

Inclined Mount

The inclined mounting kit allows the

collectors to pivot in the front and uses

aluminum channel to support the solar

collector at the rear. Instructions are

provided with the rack mount kit.

Solar Collector Location

Solar Boiler™

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).

To nd the center of the rafters, lift the

shingle and use small nails to nd the

two edges of the rafter.

Drill a 1/4” pilot hole in the rafter for

each of the front mounting clips.

Fill the holes with silicon sealant and

secure the two front clips to the roof

using lag bolts. Seal the perimeter of

each mounting clip base with silicon.

Take the “A” solar collector and slide

two 3/8” bolts in the bolt track.

Loosely fasten these bolts to the bot-

tom hole of the front mounting clips

using a lock washer and nut.

Center the solar collector so that the

spacing from the end of the solar col-

lector to the mounting clip is equal on

both ends. The solar collector ports

must be on the right hand corner of

the solar collector when, viewed from

below.

1 – Locating Roof Rafters

2 – Flush Mounting Micro-Flo® Solar Collectors

3/8” Bolt,

nut, lock

washer

3/8” lag

screw

Mounting Clip

Installation Manual for SB32-9PV and SB64-9PV

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.

Using the aluminum channel, fasten col-

lector B to A as shown in the gure.

Fasten the upper mounting clips (not

shown) to the top of the collector(s),

and use lag bolts to secure them to the

rafters in the same manner as for solar

collector A.

Tighten all nuts that secure the

collector(s) to the mounting clips.

Silicon seal all roof attachments.

lock

washer

bolt track

3/8" bolt

aluminum

channel, (6")

3/8" nut

OUT

3 – Optional Second Solar Collector

4 – Copper Tube Kit Installation

LifeLine® tubin g

The copper tube kit is used to connect

the Solar Boiler™ module to the solar

collectors.

All of the copper tubing should be

sleeved with the insulation provided.

The insulation is Elastomeric Expanded

Closed Cell with a 0.5” thickness. Mark

one copper tube at both ends with tape

to identify the supply and return lines.

Run the copper tube and PV Sensor

wire (LVT 18/4) to the solar collectors

via an unused space or closet. If the

bundle is run outside along the house, sleeve it in a plastic

conduit such as down spout. Note: All copper tube installed

in the horizontal position must slope down 1/4" for every hori-

zontal foot. Secure the Copper tube at intervals of 6 feet with

clamps. Use caution when bending the tube to avoid kinking.

Solar Boiler™

5 – Copper Tube at Solar Collectors

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. A 3/8” hole for each tube and the wire is

sufcient.

Pass about 2 feet of Copper tube through the roof

penetration from below. Clamp the copper tube to

the truss. Do not crimp the copper tube.

Seal the roof penetration with silicon sealant.

If the copper tube has been installed on the outside

of the house, a roof penetration is not necessary.

Simply bend the tubing bundle around the soft

and up to the solar collectors

Connect the 3/8" copper tube to the "IN" (blue) port using a 5/8" and 11/16”

wrench. Be sure to hold the bulkhead union from moving during this process.

Connect the other 3/8" copper tube to the "OUT" (red) port.

6 – Copper Tube Connection to Collector

Bulkhead Union

3/8” Compression

Nut

IMPORTANT: The 11/16” wrench is required to pre-

vent the bulkhead union from rotating while turning

the nut with the 5/8” wrench.

As of January 2010, S Series collectors are

equipped with Bulkhead Union locking plates. This

eliminates the need for an 11/16” wrench. Bulkhead Union Locking Plate

Installation Manual for SB32-9PV and SB64-9PV

Place the 3/8" compression nuts

on the tting body nger 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.

IMPORTANT: The 11/16" wrench is required to prevent the

tting body from rotating while turning the nut with the 5/8"

wrench.

As of January 2010, S Series collectors are equipped with

Bulkhead Union locking plates. This eliminates the need

for an 11/16” wrench.

OUT

Attach the two large aluminum brackets

to the photovoltaic module using the

3/8" bolts, nuts, and lock washers sup-

plied. Make sure that the junction box on

the back of the PV panel is at the top.

Make sure both aluminum angle brackets

are securely fastened to the photovoltaic

module.

Grounding: The photovoltaic module is

inherently grounded through the mount-

ing hardware attached to the solar collec-

tors.

3/8" nut and

lock washer

3/8"

bolt

Photovoltaic module

junction box

8 – Preparing the Photovoltaic Module

7 – Connection Between Collector A and B

Bulkhead Union Locking Plate

Solar Boiler™

Open the junction box located on the photo-

volatic module, and note the positive terminal

marked "+" and the negative terminal marked

"-".

Drill 2 small holes and insert the 18/4 LVT wire

in the box. Connect the “RED” to “+” terminal

and the “BLACK” to “-” terminal.

If your “B” solar collector is equipped with a

sensor enclosure as pictured in step 10a, pro-

ceed to step 10a.

Feed the white and green wires out of the

junction box and connect them to the collector

sensor using pinch connectors supplied.

Locate the photovoltaic module as

shown in the diagram, along the port

side of the “B” collector. Using the

3/8" bolts, washer, and nuts, attach

the photovoltaic module to the "B"

collector bolt track as shown in the

diagram. Ensure that all the nuts

are tightened securely in order to

provide proper grounding of the PV

module.

Insert the temperature sensor into

the “B” collector. It should go in

about 6 to 8 inches. Seal with

silicon.

Using the connectors provided,

crimp the sensor wires to the green

and white wires.

Photovoltaic module

"B"

Collector

bolt

track

3/8" bolt, washer,

nut

9 – Wiring the Photovoltaic Module and Collector Sensor

10 – Locating the Photovoltaic Module

Temperature Sensor

Compression Nuts

Service Plug

Collector Temperature Sensor

Pinch

Connectors

Dart Clips

PV/Sensor wire

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