Solene SLAR64DC-80HE-XG Installation guide

Brand: Solene

Model: SLAR64DC-80HE-XG

Type: Installation guide

Before attempting installation, read these instructions and

acquaint yourself with the component names. Great care

has been taken to make this an easy-to-follow procedure.

A little time spent understanding the system and its parts

will assure a successful, trouble-free installation.

CAUTION: SAFETY COMES FIRST

When working on or around your roof or system, please

take care to avoid hazards such as electrical wires and

loose shingles.

1410 | Rev. 05

SOL-INSTALL | 1608

MODELS:

SLAR40DC-80HE-XE, SLAR40DC-80HE-XG, SLAR40DC-80HE, SLSG40DC-80HE-XE, SLSG40DC-80HE-XG, SLSG40DC-80HE,

SLAR64DC-120HE-XE, SLAR64DC-80HE-XE, SLAR64DC-120HE-XG, SLAR64DC-80HE-XG, SLAR64DC-120HE, SLAR64DC-80HE,

SLAR80DC-120HE-XE, SLAR80DC-80HE-XE, SLAR80DC-120HE-XG, SLAR80DC-80HE-XG, SLAR80DC-120HE, SLAR80DC-80HE,

SLSG80DC-120HE-XE, SLSG80DC-80HE-XE, SLSG80DC-120HE-XG, SLSG80DC-80HE-XG, SLSG80DC-120HE, SLSG80DC-80HE,

SLCO32DC-80HE-XE, SLCO32DC-80HE-XG, SLCO32DC-80HE, SLCO40DC-80HE-XE, SLCO40DC-80HE-XG, SLCO40DC-80HE,

SLCO60DC-80HE, SLCO64DC-120HE-XE, SLCO64DC-80HE-XE, SLCO64DC-120HE-XG, SLCO64DC-80HE-XG, SLCO64DC-120HE,

SLCO64DC-80HE, SLCO80DC-120HE-XE, SLCO80DC-80HE-XE, SLCO80DC-120HE-XG, SLCO80DC-80HE-XG, SLCO80DC-120HE,

SLCO80DC-80HE, SLSG40DC-75HE-G, SLAR40DC-75HE-G, SLAR64DC-75HE-G, SLAR32DC-75HE-G

SOLENE® INSTALLATION MANUAL

CLOSED LOOP DOMESTIC HOT WATER SOLAR SYSTEM

WITH DIFFERENTIAL CONTROL

Congratulations on investing in one of the most advanced

solar water heating systems available. Utilizing the free,

environmentally friendly energy from the sun to heat water

for your home makes so much sense. Solar energy is safe and

reliable and your decision to use solar energy is helping to

preserve our environment and to reduce our rapid depletion of

non-renewable, fossil fuels.

Your new Solene Solar Hot Water System uses state-of-the-

art technology and will provide you with many years of

maintenance free and dependable service. If you have any

questions, please feel free to contact your local dealer or our

home oce.

1 1. Introduction/Table of Contents.

2 2. Getting Started.

3 3. Installation Instructions.

5 4. Collector Mounting.

9 5. Plumbing.

11 6. Pipe Insulation.

11 7. Dierential Controller & Sensors.

12 8. Electrical & Wiring Requirements.

12 9. Thermostats.

12 10. Charging the System.

14 11. Noburst HD HTF.

15 12. System Operation.

16 13. Components Parts List & Function.

1. Introduction/Table of Contents.

INTRODUCTION/TABLE OF CONTENTS. - 1

18 14. System Schematics (SLAR40DC-80HE-XE,

SLAR40DC-80HE-XG, SLAR40DC-80HE, SLSG40DC-80HE-XE,

SLSG40DC-80HE-XG, SLSG40DC-80HE, SLAR64DC-120HE-XE,

SLAR64DC-80HE-XE, SLAR64DC-120HE-XG, SLAR64DC-80HE-XG,

SLAR64DC-120HE, SLAR64DC-80HE, SLAR80DC-120HE-XE,

SLAR80DC-80HE-XE, SLAR80DC-120HE-XG, SLAR80DC-80HE-XG,

SLAR80DC-120HE, SLAR80DC-80HE, SLSG80DC-120HE-XE,

SLSG80DC-80HE-XE, SLSG80DC-120HE-XG, SLSG80DC-80HE-XG,

SLSG80DC-120HE, SLSG80DC-80HE, SLCO32DC-80HE-XE,

SLCO32DC-80HE-XG, SLCO32DC-80HE, SLCO40DC-80HE-XE,

SLCO40DC-80HE-XG, SLCO40DC-80HE, SLCO60DC-80HE,

SLCO64DC-120HE-XE, SLCO64DC-80HE-XE, SLCO64DC-120HE-XG,

SLCO64DC-80HE-XG, SLCO64DC-120HE, SLCO64DC-80HE,

SLCO80DC-120HE-XE, SLCO80DC-80HE-XE, SLCO80DC-120HE-XG,

SLCO80DC-80HE-XG, SLCO80DC-120HE, SLCO80DC-80HE,

SLSG40DC-75HE-G, SLAR40DC-75HE-G, SLAR64DC-75HE-G,

SLAR32DC-75HE-G).

24 15. NOBURST HD.

26 16. System Labels.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

COMPONENT LIFE EXPECTANCY - Installed and maintained properly, your Solene Solar Hot Water Heating System should

provide many years of trouble free, uninterrupted service. The main component of the system, the Aurora Solar Collector, is designed

to last 25 to 30 years. Solar Storage Tanks have a life expectancy anywhere from 10 to 20 years depending greatly upon regional

water quality. (Replacing the internal sacricial anode rod from time to time can extend Tank life.) Dierential Control and Circulation

Pump life expectancies run from 5 to 10 years. As electrical components, they are susceptible to lightning strikes or electrical surges.

Valve life expectancy varies greatly depending water quality and usage.

2. Getting Started.

GETTING STARTED. - 2

Caution - SAFETY COMES FIRST!

There is no substitute for safety. Always exercise extreme caution, care, and good judgment when working on or

around a roof.

BEFORE YOU START YOUR INSTALLATION, HERE ARE A FEW IMPORTANT TIPS:

Check with your local building department to determine permitting and code requirements in your area.

While this manual explains how to install Solene solar collectors properly in typical situations, it cannot possibly

address all the unique or individual circumstances possible. If you have any installation questions, contact your

Solene representative for assistance.

Before starting any work, determine the location of your system and prepare a schematic drawing of the

installation area. Roof areas often times look bigger than they really are, so be sure to measure the available area

before making your schematic.

Familiarize yourself with all of the Solene components and plumbing materials that you will need to complete the

installation.

Don’t take shortcuts. Whenever possible, panels should be installed so they are accessible and away from roof

edges.

Depending upon your specific job, you will need various plumbing items and materials. Be sure to use quality

products that will withstand direct sunlight year after year.

• Please take care to avoid hazards such as overhead electrical wires or loose shingles.

• Be sure to secure ladders so they will not slip or fall.

• Do not allow extension cords to lie in standing water.

• Wear shoes with proper tread to prevent slipping on the ladder or sloped roof areas.

• Disconnect all power to any energized equipment when installing dierential control system.

NOTE: As the installer, you are responsible for exercising good judgment when installing Solene systems to

protect the long term integrity of the collectors as well as the mounting surfaces.

THE CLOSED LOOP SYSTEM - A closed loop system design is common in northern climates, where freezing weather more

frequently occurs. An FDA-approved heat transfer uid solution circulates through the collector, and a heat exchanger transfers the

heat from the solution to the water in the storage tank. A dierential controller controls when uid is pumped through the collector

and back to the heat exchanger by sensing the temperature dierence between the collector and the tank.

Flood grade propylene glycol is mixed with water and used as the heat transfer uid as it freezes at a much lower temperature than

water which eliminates freeze damage.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

3. Installation Instructions.

INSTALLATION INSTRUCTIONS. - 3INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

SIZING & ORIENTATION: The vast majority of Solar Domestic Hot Water (SDHW) systems are comprised of “Medium

Temperature” solar collectors manufactured using tempered glass and some type of metal absorber plate. They differ

from “Low Temperature” systems predominantly utilized in swimming pool heating applications. These systems are

typically manufactured using plastic resins. “High Temperature” systems are utilized to generate steam for industrial

applications. Solene collectors belong to the “Medium Temperature” category.

Normally, only one or two Solene collectors are needed for a SDHW system. The number of collectors is determined not

only by the amount of water that is needed, but also by the latitude of the installation and the collector’s orientation.

The following table details Solene’s recommended minimum system sizing guide for a typical installation:

Tank Capacity

(Gallons)

Number of

Collectors

Collector

Type Control Type Model Number SRCC

Number SEF

80 1SLAR-40 Differential Control SLAR40DC-80HE-XE 2010142A 1.74

80 1SLAR-40 Differential Control SLAR40DC-80HE-XG 2010143A 0.99

80 1SLAR-40 Differential Control SLAR40DC-80HE 2010141A 2.03

80 1SLSG-40 Differential Control SLSG40DC-80HE-XE 30004071 1.71

80 1SLSG-40 Differential Control SLSG40DC-80HE-XG 30004074 0.98

80 1SLSG-40 Differential Control SLSG40DC-80HE 30004068 1.99

120 2SLAR-32 Differential Control SLAR64DC-120HE-XE 2010142D 2.5

80 2SLAR-32 Differential Control SLAR64DC-80HE-XE 2010142B 2.66

120 2SLAR-32 Differential Control SLAR64DC-120HE-XG 2010143D 1.28

80 2SLAR-32 Differential Control SLAR64DC-80HE-XG 2010143B 1.39

120 2SLAR-32 Differential Control SLAR64DC-120HE 2010141D 3.14

80 2SLAR-32 Differential Control SLAR64DC-80HE 2010141B 3.64

119 2SLAR-40 Differential Control SLAR80DC-120HE-XE 2010142E 3.42

80 2SLAR-40 Differential Control SLAR80DC-80HE-XE 2010142C 3.81

120 2SLAR-40 Differential Control SLAR80DC-120HE-XG 2010143E 1.61

80 2SLAR-40 Differential Control SLAR80DC-80HE-XG 2010143C 1.69

120 2SLAR-40 Differential Control SLAR80DC-120HE 2010141E 5.19

80 2SLAR-40 Differential Control SLAR80DC-80HE 2010141C 7.03

119 2SLSG-40 Differential Control SLSG80DC-120HE-XE 30004073 3.22

80 2SLSG-40 Differential Control SLSG80DC-80HE-XE 30004072 3.46

120 2SLSG-40 Differential Control SLSG80DC-120HE-XG 30004076 1.53

80 2SLSG-40 Differential Control SLSG80DC-80HE-XG 30004075 1.69

120 2SLSG-40 Differential Control SLSG80DC-120HE 30004070 4.81

80 2SLSG-40 Differential Control SLSG80DC-80HE 30004069 5.85

80 1SLAR-32 Differential Control SLCO32DC-80HE-XE 2006029A 1.16

80 1SLAR-32 Differential Control SLCO32DC-80HE-XG 2006035A 0.73

3. Installation Instructions. - Cont.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

Normally, collectors are installed on roofs, as close as possible to the tank, to minimize heat loss through the pipe. The pipes between

the tank and the collectors MUST be insulated with at least ¾” thick insulation, for the same reason. Check local codes for well

thickness in your area.

The solar collectors must be located in a structurally sound area of the roof that will be exposed to the sun for the majority of the day,

all year round. A solar pathnder can be used for solar site analysis.

The recommended angle of the collectors is equal to the location’s LATITUDE. This angle is designed to maximize solar absorption

annually. For increased energy production in winter months, the collector angle can be increased up to +15 degrees from latitude.

For increased summer energy production, decrease collector angle up to - 15 degrees from latitude. A variation of +/- 15 degrees is

acceptable. The orientation of the collectors must be due south ± 55 degrees. Flush mounts on available roof slopes are recommended

to allow convenience and cost eectiveness, since these variations from the exact angle and orientation will aect the system’s

performance only by about 5%.

INSTALLATION INSTRUCTIONS. - 4

To comply with SRCC certification the storage tank shall have an additional insulation jacket.

80 1SLAR-32 Differential Control SLCO32DC-80HE 2006023A 1.25

80 1SLAR-40 Differential Control SLCO40DC-80HE-XE 2006029B 1.21

80 1SLAR-40 Differential Control SLCO40DC-80HE-XG 2006025B 0.75

80 1SLAR-40 Differential Control SLCO40DC-80HE 2006023B 1.31

80 2SLCO-30 Differential Control SLCO60DC-80HE 2006023C 1.45

120 2SLAR-32 Differential Control SLCO64DC-120HE-XE 2006029E 2.19

80 2SLAR-32 Differential Control SLCO64DC-80HE-XE 2006029C 2.21

120 2SLAR-32 Differential Control SLCO64DC-120HE-XG 2006025E 1.19

80 2SLAR-32 Differential Control SLCO64DC-80HE-XG 2006025C 1.2

120 2SLAR-32 Differential Control SLCO64DC-120HE 2006023F 2.7

80 2SLAR-32 Differential Control SLCO64DC-80HE 2006023D 2.85

120 2SLAR-40 Differential Control SLCO80DC-120HE-XE 2006029F 2.85

80 2SLAR-40 Differential Control SLCO80DC-80HE-XE 2006029D 2.93

120 2SLAR-40 Differential Control SLCO80DC-120HE-XG 2006025F 1.44

80 2SLAR-40 Differential Control SLCO80DC-80HE-XG 2006025D 1.46

120 2SLAR-40 Differential Control SLCO80DC-120HE 2006023G 4.03

80 2SLAR-40 Differential Control SLCO80DC-80HE 2006023E 4.47

75 1SLSG-40 Differential Control SLSG40DC-75HE-G 30004222 1

75 1SLAR-40 Differential Control SLAR40DC-75HE-G 30004221 1

75 2SLAR-32 Differential Control SLAR64DC-75HE-G 30004220 1.5

75 1SLAR-32 Differential Control SLAR32DC-75HE-G 30004219 0.9

Tank Capacity

(Gallons)

Number of

Collectors

Collector

Type Control Type Model Number SRCC

Number SEF

COLLECTOR MOUNTING. - 5

4. Collector Mounting.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

There are three basic roof-mounting methods:

FLUSH MOUNT INSTALLATION - Parallel to the roof line, as illustrated below.

Fig. 2Fig. 1A

Start from the bottom. When elevating the collector to the roof, make sure that the “weep holes” are facing down. It is

recommended to install the collectors vertically (length up the roof’s slope), but the collectors may be installed horizontally as

well.

Flush Mount Installations are recommended when the roof’s slope conforms to the orientation and slope requirements as stated

previously. This is the easiest and most aesthetically pleasing installation method. After the collector(s) are installed, it should

resemble a skylight. The ush mount (1-5060-031) consists of four (4) mounting brackets, four (4) carriage bolts, four (4) nuts, and

associated hardware. There are two sets each for the top and bottom.

Once the collector’s location is determined, anchor two (2) ush mount brackets to the roof using two (2) stainless steel 3/8”

lag bolts for each bracket. Each bolt should be sealed using an appropriate roof sealant in order to prevent any possible leaks

from penetrating the roof members. The ush mount brackets should be spaced so the lag bolts penetrate the roof trusses. The

collectors will rest on top of the ush mount brackets. (Fig. 2)

Verify a secure connection to the trusses. If lagging directly into the roof trusses is not possible, secure a 2’ x 4’ wood beam

perpendicular to the trusses, inside the attic, and anchor the bolts to this member. Again, verify a secure connection into the new

member.

Connect the ush mount brackets to the collector’s frame by stainless steel self-drilling screws or bolt mounting bracket into

frame slot using (1) 5/16” carriage bolt, nut, and washer.

Repeat steps 1-4 for the top. That’s it. The collector is anchored.

Solene Collector Typ.

Solene Aluminum

Mounting Bracket

Roof Truss

COLLECTOR MOUNTING. - 5INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

FLUSH MOUNT GRIPPER INSTALLATION - Parallel to the roof line, as illustrated below.

Fig. 1B

Start from the bottom. When elevating the collector to the roof, make sure that the “weep holes” are facing down. It is

recommended to install the collectors vertically (length up the roof’s slope), but the collectors may be installed horizontally as

well.

Flush Mount Installations are recommended when the roof’s slope conforms to the orientation and slope requirements as stated

previously. This is the easiest and most aesthetically pleasing installation method. After the collector(s) are installed, it should

resemble a skylight. The ush mount gripper (1-5060-030) consists of four (4) U-channels four (4) grippers, four (4) strut nuts with

springs, and associated hardware. There are two sets each for the top and bottom.

Once the collector’s location is determined, anchor two (2) U-channel to the roof using two (2) stainless steel 3/8” lag bolts

for each U-channel. Each bolt should be sealed using an appropriate roof sealant in order to prevent any possible leaks from

penetrating the roof members. The U-channel should be spaced so the lag bolts penetrate the roof trusses, and the U-channel

should run parallel to the truss. The collectors will rest on top of the U-channel. (Fig. 2)

Solene Aluminum Gripper Mount

3/8” Bolt - Washer - Nut Typ.

Solene Collector Typ.

Roof Truss

4. Collector Mounting. - Cont.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

4. Collector Mounting. - Cont.

COLLECTOR MOUNTING. - 6

Fig. 3

Fig. 5

Fig. 4

Fig. 6

Verify a secure connection to the trusses. If lagging directly into the roof trusses is not possible, secure a 2’ x 4’ wood beam

perpendicular to the trusses, inside the attic, and anchor the bolts to this member. Again, verify a secure connection into the

new member.

Connect the latch to the gripper (Fig 3) utilizing the provided nut and bolt. Slide the latch into the top of the U channel so that

the gripper remains on top of the opening. Place them at the middle of the U-channel’s top and tighten. (Fig 4)

Loosen the gripper providing space to insert the slot at the collector’s edge between the Gripper’s hook and the U-channel’s top.

Once both grippers are grabbing the collector’s edge slot, tighten both grippers. (Fig 5)

6. Repeat steps 2-5 for the top. That’s it. The collector is anchored.

Solene Aluminum

Tilt Mount Bracket

Solene Collector Typ.

Solene Aluminum

Swivel Mounting

Bracket

Roof Truss

Tilt Leg

ANGLE MOUNT INSTALLATION - Not parallel to the rooine, normally used on at roofs, east/west, and ground mounts, as

illustrated below.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

COLLECTOR MOUNTING. - 7

4. Collector Mounting. - Cont.

Angle Mount Installations involve positioning the collector(s) at an angle so that the upper part of the collector is higher than the

lower in reference to the mounting surface. The “angle mounting” is used on horizontal surfaces or on roofs that slope in directions

other than south at 55 degrees.

Use the angle mounting kit (1-5060-039), see gure 8. Connect the U-channels to the roof just like in the Flush Mounting method.

Assemble the mounting clips to both U-channels utilizing the provided bolts (Fig. 7)

Screw the mounting clips to the BOTTOM part of the collector (the weep hole side) using two (2) stainless steel self-drilling

screws, each. (Fig. 10). Mounting clips may also bolt into collector frame slot using (1) 5/16 carriage bolt, nut, and washer.

Fig. 8

Fig. 10

Fig. 11 Fig. 12

Fig. 9

Assemble both tilt legs and top mounting clips Fig. 11. Connect the clips to the collector’s top by stainless steel self-drilling screws.

Mounting clips may also bolt into collector frame slot using (1) 5/16 carriage bolt, nut, and washer.

Connect the U-channels to the opposite side of the tilt leg, using the provided nuts and bolts. (Fig. 13).

Fig. 13

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

COLLECTOR MOUNTING. - 8

4. Collector Mounting. - Cont.

Fig. 14

Lift the collector’s top with the assembled tilt leg kits and anchor the U-channels to the roof, ensuring the proper angle to the

collectors. (Fig. 14). Use compatible sealant and roof ashing as required.

INSTALL ALL COMPONENTS IN ACCORDANCE WITH LOCAL CODE SO THAT THE PERFORMANCE OF ANY STRUCTURAL

MEMBER OR FIRE RATED ASSEMBLY IS NOT REDUCED.

PLUMBING. - 9

5. Plumbing.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

Make sure that all the components are accessible and easy to reach. Provide for clear access to the storage tank, pump, mixing

valve, dierential control and other key components. If a component in the potable waterside of the system may require future

service or maintenance, make the connections with brass unions. Use only brass nipples and unions and copper and brass ttings in

plumbing the solar storage tank and expansion tank. The use of galvanized ttings or nipples, PVC pipe is prohibited.

Hard copper connections to the city cold water supply line and the home hot water feed lines are recommended. The gaskets in

standard water heater ex hose connectors can become brittle and compressed over time and begin leaking on the water heater.

If not detected in a timely manner even a small drip or leak may cause serious damage to the tank’s electrical components or, in

extreme cases, may cause the tank to leak from the outside in.

Tank plumbing is required to provide for the isolation of the solar storage tank from the city cold water supply line by means of an

isolating valve.

The circulation pump shall be pre-wired with a 6” line cord so that it can be plugged directly into the 115-volt receptacle on the

dierential control. Repairs or routine system maintenance can be completed without introducing air into the system or draining

the HTF.

A high quality thermostatic mixing valve is a required component in all OG-300 certied systems and should be plumbed in line with

brass union connections for ease of future repair or replacement. The specied mixing valve shall be the Watts model 70A-075 or

equal. It should have an operating range between 95°F and 140°F. The mixing valve should be set to 120°F.

The temperatures generated by your Solene system will vary throughout the year. In the Northern Hemisphere the water temperature

will be hottest in the spring and summer months while cooler temperatures are to be expected from November through March. On

sunny days system temperatures may range from 110°F to 180°F depending upon the season and hot water demand. The mixing

valve described above blends the hot and cold water supplies to deliver hot water to your xtures at a safe, controlled temperature.

A pressure relief valve is required on the collector loop portion of the system.

WARNING: SCALDING CAN OCCUR WITHIN FIVE SECONDS WHEN WATER TEMPERATURES APPROACH 140°F. THE MIXING VALVE

SHOULD BE ADJUSTED BY THE INSTALLATION CONTRACTOR TO PROVIDE WATER TO DWELLING FIXTURES AT NO MORE THAN 120°F.

PLUMBING. - 10

5. Plumbing. - Cont.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

The ¾” cold water supply line to the solar storage tank must be insulated with minimum 7/8” x ¾” pipe insulation to a minimum

distance of 5 feet behind the storage tank, or to the wall if closer than 5 feet.

The storage tank should not be placed directly on an un-insulated oor or concrete slab. The tank should be placed on a well-

insulated pad with a minimum R-value of 10. An R-20 insulated tank is recommended for all Solene systems. If your tank needs

additional insulation, an “Insulation Jacket” is recommended. (Frost King or equal).

Fig. 17

Fig. 16Fig. 15

Two Tank Conguration - Gas/Electric

PIPE INSULATION | DIFFERENTIAL CONTROL & SENSORS. - 11

6. Pipe Insulation.

7. Dierential Control & Sensors.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

The minimum ¾” collector loop cold supply and hot return lines must be well insulated with a high quality exible closed cell

insulation to minimize heat loss. The wall thickness of the pipe insulation should not be less than ¾”. A 1”- wall thickness is required

in all areas prone to annual hard freeze conditions. When it comes to pipe insulation the rule is simple: thicker is better. The specied

insulation material is Armaex or equal.

To the extent possible, slide the insulation material over the pipe without cutting or taping. All butt joints must be sealed with

contact adhesive. The use of rigid polyethylene pipe insulation is prohibited.

All outdoor insulation should be protected from moisture and ultraviolet deterioration by either paint or foil tape. All copper piping

should be properly supported, approximately every 6’. The support clamps should be installed in a way as to not compress the pipe

insulation.

The Dierential Control has a high limit storage setting that can be adjusted from 110°F to 200°F and is typically preset to 140°F. It

is very important to verify that the high limit is set and engaged per manufacturer’s instructions. This will prevent “overheating” in

cases of high solar irradiation and low water usage. Please refer to the installation instructions of the controller manufacturer for all

items relating to controller connections, settings, sensor location and sensor wiring.

In order to properly mount the heat sensor on the solar storage tank follow these steps:

The roof sensor should be mounted to the outlet of the collector. A stainless steel hose clamp should be used. The entire outlet should

be completely wrapped with insulating tape so that the sensor is insulated from the outside air.

Remove the round cover located at the bottom front of the tank.

Attach sensor to storage tank.

Attach a length of sensor wire to sensor leads and the other end to the controller terminals marked tank or water.

Begin by lling the solar tank with water. Do this by opening the cold-water isolation ball valve to the solar tank. When the tank

is lled, inspect all threaded ttings and solder joints for leaks.

Fill and pressurize the solar collector loop with water. Begin by connecting a washing machine hose to the upper charge valve

and ll the collector loop with water. The isolation ball valve remains closed at this point. While the hose is still connected to

the upper charge valve and the water is running, open the lower purge/drain valve and let the water run out until it is free

of impurities or debris that might have entered the piping as the components were plumbed. Run the water long enough to

eliminate any air bubbles that may be trapped in the system

Close the lower purge/drain valve. The collector loop now has been subjected to city pressure and the pressure gauge should

read somewhere in the range of 50 – 75 psi in most cases. Make a nal inspection of the collector plumbing connections to

ensure that there are no leaks anywhere in the collector loop piping.

8. Electrical & Wiring Requirements.

9. Thermometers. (Optional)

10. Charging the System.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

A properly licensed contractor must make the 230-volt electrical connection to the water heater or solar storage tank and the

electronic time switch (Optional). If your solar contractor is not allowed by law to make these connections consult a licensed

electrician. NEVER ACTIVATE THE CIRCUIT BREAKER CONTROLLING THE ELECTRICAL HEATING ELEMENT UNTIL THE SOLAR STORAGE

TANK IS COMPLETELY FILLED WITH WATER. This will prevent “dry ring” of the heating element. The electrical heating element will be

destroyed almost instantaneously if not completely submerged in water when activated. Make sure the water heater circuit breaker

is o until the solar storage tank is completely lled.

We recommend the use of a 115-volt dierential control with a factory installed six-foot line cord. The installation requires one 115-

volt outlet to be installed near the solar storage tank. Plug the control into the outlet. The circulation pump line cord is plugged into

the receptacle on the side of the controller. A 230-volt control and circulation pump may be substituted, but troubleshooting the

components in the future becomes more dicult.

The specied dierential thermostat is the Goldline model GL-30-LCO or Steca model TR0301-US.

Locate two thermometers; one at the supply line and one on the return line of the solar loop so that the temperature rise across the

collector can be determined.

Once the components are plumbed you are ready to ll the solar storage tank with water and to charge the collector loop with a

mixture of heat transfer uid (HTF) and distilled or de-ionized water. The use of regular tap water as a mixing agent is prohibited.

Proceed as follows:

ELECTRICAL & WIRING REQUIREMENTS | THERMOMETERS | CHARGING THE SYSTEM. - 12

With both charge faucets now open, run the Flojet pressure pump until the pinkish glycol mixture begins owing into the empty

bucket. Quickly switch the hose from the empty/return bucket to the bucket containing the glycol mixture. Continue to circulate

the uid using the pressure pump until the bubbling has stopped and the air has been purged.

After charging the collector loop, shut the lower charge faucet and let the pressure pump drive up the loop pressure to the

appropriate level (Generally in the range of 25 psi). To more accurately calculate the proper pressure measure the height of the

solar collector above the solar storage tank and divide this number by 2.31. Then add 20 psi to this number. As a word of caution,

the pressure in the glycol loop should not exceed 45 psi when the system is operational on a good sunny day.

After you have determined the integrity of the entire piping system turn on the circulating pump. Do this by setting the manual

switch within the controller to the “on” position. Run the pump for a full ve minutes and carefully check to ensure there is

proper uid ow and that all the air has been purged from the solar collector glycol loop. An inexpensive ow meter such as

manufactured by Blue White Industries or Letro is recommended as an optional system component. A ow meter allows you to

monitor and adjust the ow rate through the piping and also to visually inspect the HTF uid quality.

Set the controller to the “o” position and proceed to the next step.

Mix the propylene glycol and distilled water mixture in accordance with Table 4 and Table 5 in a large clean bucket. You will need

a second empty bucket as well. The charging process also will require a low ow diaphragm pump (Flojet or equal) to ll and

pressurize the collector loop.

Connect the discharge side of the pressure pump to the upper charge faucet. Place the pump suction side hose in the glycol

solution. Close the isolation ball valve and connect a second hose to the lower charge faucet. Place the other end of the hose in

the empty bucket. Open the upper charge faucet and allow the pressure from the expansion tank to push the water in the glycol

loop back to prime the pressure pump. When the hose in the bucket containing the glycol mixture stops bubbling you may begin

charging the collector loop with glycol.

CHARGING THE SYSTEM. - 13

10. Charging the System. - Cont.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

SYSTEM PROTECTION - Freeze is the temperature where the rst ice crystal forms in the uid. Flow is the temperature where the

uid will contain ice crystals but still ow. Burst is the temperature where the uid is solid, expanding and bursting the vessel.

*THE AO SMITH SUNX 80 OR SUNX 120 HEAT EXCHANGER HAS A 2.8 OR 4 GALLON FLUID CAPACITY. THIS TABLE ASSUMES A TOTAL

100 foot PIPE RUN USING ¾” TYPE M HARD COPPER TUBING.

CONTACT YOUR SOLAR CONTRACTOR IF THE CHARGED COLLECTOR LOOP PRESSURE EXCEEDS THIS THRESHOLD.

100% -60°F -70°F -100°F

75% -60°F -60°F -100°F

50% -30°F -40°F -75°F

40% -7°F -15°F -60°F

35% 0°F -10°F -60°F

Noburst HD Freeze Point Flow Point Burst Point

CHARGING THE SYSTEM | NOBURST HD HTF. - 14INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

10. Charging the System. - Cont.

Your Solene solar water heating system must be charged and the uid quality maintained by an experienced contractor. If

the system is drained during the winter, or you notice a signicant drop in collector loop pressure, contact your installation

contractor immediately for service. The glycol HTF provides the freeze protection for your system and must be properly

maintained. An experienced contractor should periodically check the HTF uid quality.

TO ENSURE MAXIMUM EFFECTIVENESS FOR CORROSION PROTECTION, THE GLYCOL INHIBITOR PACKAGE IS DESIGNED FOR A

MINIMUM 25-30 PERCENT CONCENTRATION OF GLYCOL IN WATER.

NOBURST CHARACTERISTICS - NOBURST HD is a non-toxic antifreeze and heat transfer uid. The product is to be used in place

of water and other water-like uids in systems where freezing may either cause damage or interfere with the functioning of systems

or equipment and/or toxicity to humans or animals is a concern. NOBURST HD is safe for use when there is a possibility of contact

with potable water.

SYSTEM START UP-PROCEDURES - Throughout the installation procedures outlined above, emphasis has been placed on the

correct procedures for plumbing and wiring the components, checking for plumbing leaks, pressurizing the collector glycol loop,

and eliminating any trapped air that can impact uid quality and pump performance. Having completed these tasks it is time to

start up your Solene solar water heating system. When the glycol loop has been fully charged and the pressure is around 25 psi

(check the pressure gauge), set the dierential controller to the “Automatic” setting. This will activate your circulating pump.

NOBURST CHARACTERISTICS

INHALATION – Move person to fresh air; if eects occur, consult a physician

EYE CONTACT – Flush eyes thoroughly with water for a few minutes. Remove contact lenses after the initial 1-2 minutes and continue

ushing for several additional minutes. If eects occur, consult a physician, preferably an ophthalmologist.

SKIN CONTACT – Wash skin with plenty of water.

SWALLOWING – No emergency medical treatment necessary.

The table on page 13 shows the concentrations of NOBURST HD required to provide freeze and burst protection at various

temperatures. Use the mixture most appropriate for your climate. Do not use a higher glycol to water concentration than necessary,

as this will adversely impact the relative heat transfer eciency of the solution. Generally, for an extended margin of protection, you

should select a temperature that is at least 5°F lower than the expected lowest ambient temperature. These gures are examples

only and should not be regarded as specications.

As use conditions are not within our control, neither Solene nor NOBLE CO. guarantees that freeze damage may not occur at

temperatures other than shown. Water used to dilute the HTF must meet certain minimum standards for purity. Impurities in the

dilution water can increase metal corrosion, reduce the eectiveness of corrosion inhibitors, increase inhibitor depletion rate,

and cause the formation of scale and other deposits on the heat exchanger’s internal heat transfer surfaces. DISTILLED OR DE-

IONIZED WATER IS REQUIRED. THE HTF PH LEVEL MUST BE MAINTAINED BETWEEN 8 AND 10 TO MINIMIZE CORROSION AND GLYCOL

OXIDATION IN THE PIPING SYSTEM.

10.

11. Noburst HD HTF.

NOBURST HD HTF | SYSTEM START OPERATION. - 15

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

11. Noburst HD HTF.

TOTAL SOLAR OPERATION - Set the water heater time switch to the “o” position. If you have a mechanical timer remove the

trippers from the face of the switch.

TOTAL UTILITY POWER - In this mode of operation you must turn o the circulation pump. To turn the pump o, open the controller

and change the operational setting from “automatic” to “o”. Failure to turn o the pump can quickly damage the pump motor,

shaft, bearings or impeller.

TOTAL PREHEAT - Pre-set the heater timer to turn the heating element on and o at specied times throughout the day if desired.

The Goldline controller allows you to set the “on” dierential. Turn the red rotary switch inside the control housing to 12. The controller

also allows you to limit the nished solar storage tank temperature if desired. Turn the red rotary switch inside the controller marked

“Hi Limit” to the 160° setting. Solene does not recommend that the Hi Limit be set any lower than 160°. Adjust the valve settings in

accordance with the following section:

Solene systems are designed to accommodate three separate modes of operation. Your solar water heating system can (1) provide

100% solar operation during good weather, or (2) serve as a pre-heater to your electric water heater adding solar energy when and

as available, or (3) 100 % on utility power during inclement weather.

12. System Operation.

COMPONENT PARTS LIST & FUNCTIONS. - 16

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Solar Collector – Aurora SLAR40 4 x 10, SLAR32 4 x 8, or SLAR24 4 x 6, or SLSG40 4 x 10.

Solar Storage Tank – AO Smith SunX-80 or SunX -120 solar storage tank or equivalent with 4500W Backup Element.

Dierential Control – Goldline Dierential Control with Adjustable High Limit determines when system is on or o or Steca

0301u or equal. (include Goldline model number)

Circulation Pump – Taco 006BC4 , WIlo Star 8 or G rundfos U P15-18B5 .

Expansion Tank – Appropriately-sized Expansion Tank with 150 PSIG working pressure and 40PSI pre-charge.

Pressure Gauge - ¼” Pressure Gauge for Expansion Tank ranging from 0-60 PSI.

Drain/Charge Valve – 1-5115-017 or 1-5115-020 Boiler Drain used to charge, drain and purge air from the heat

transfer uid loop.

Charge Valve - 1-5115-017 or 1-5115-020 Boiler Drain used to charge and purge air from the heat transfer uid loop.

Isolation Ball Valve – 1-5115-023, or 1-5115-027 Ball Valve used in conjunction with #10 and #11 to isolate Circulation Pump

and/or solar loop.

Isolation Ball Valve – 1-5115-023, or 1-5115-027 Ball Valve used in conjunction with #9 to isolate Circulation Pump.

Isolation Ball Valve – 1-5115-023”, or 1-5115-027 Ball Valve used in conjunction with #9 to isolate solar loop.

Check Valve – Watts 600 Check Valve or equal to prevent thermo-siphoning from storage tank through solar collectors.

Pressure Relief Valve – Watts 530C Adjustable Pressure Relief Valve or equal used to relieve excess pressure from heat transfer

uid loop. If uid is expelled call your dealer immediately. Ranges of adjustment are 50 to120 psi.

Line Thermometers – 1-5020-028 Line Thermometer w/ temperature range of 50°F to 220°F.

Hot Water Thermometer – 1-5020-028 Line Thermometer w/ temperature range of 50°F to 220°F.

Mixing Valve – Watts 1-5115-015 Mixing Valve tempers temperature of hot feed line to home.

Pressure & Temperature Relief – Watts 100XL-4 P&T Relief Valve located on the solar storage tank opens at 150psi or 210°F.

Rotate the top portion of the pressure relief valve until the 120 PSI line is ush with the pressure relief valve housing.

Tank and Collector Sensors – Goldline SB Tank and Collector Temperature Sensor or equal, but must be type of sensor

compatible with type of #3 Dierential Control used.

Cold Water Inlet Valve – 1-5115-034 Gate Valve gives ability to turn o the cold feed to the Solar Storage Tank.

13. Component Parts List & Functions.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

While specic products are mentioned below, there are many components that can be substituted with like or equal products.

For instance there are several dierent mixing valves or isolation valves that can be utilized, not just the one specically listed.

Sometimes sweat or threaded connections or varying tting sizes are dealer preference. All of the components listed below are

available from Solene at 950 Sunshine Lane, Altamonte Springs, FL 32714 (866) 902-0060.

See the schematics on pages 18-23 for the location of the following list of components.

COMPONENT PARTS LIST & FUNCTIONS. - 17

20.

21.

22.

Pipe Insulation – ACT05834 Armaex Copper Pipe Insulation to prevent heat loss through pipes. Any Pipe Insulation that is

exposed to sunlight must be wrapped with foil tape or coated with a water-based acrylic resin coating as specied by the

Insulation Manufacturer

Roof Penetration Flashing – All Copper Roof Flashing. Gooseneck type ashing is recommended for feed line to accommodate

sensor wire.

Existing Hot Water Tank (for two tank systems) – Serves as a storage tank for hot water produced by solar system.

13. Component Parts List & Functions. - Cont.

INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

To comply with SRCC certification the storage tank shall have an additional insulation jacket.

COMPONENTS PARTS LIST & FUNCTIONS. - 18INSTALLATION MANUAL SOLENE® HOT WATER SYSTEMS

14. System Schematics.

SLAR40DC-80HE

SLSG40DC-80HE

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