Home

PDF format - Butler Sun Solutions, Inc.

1. MORMAL OPERATING RANGE WINTER 40 F AMD SUMAMIDA 1907F 2 Check Overflow Reservoir Level Every 2 Years or When Low Fluid Light stays on all day Refill Overflow Reservoir using 50 propylene glycol and 50 Water mixture Fill without going on the roof by connecting a high pressure hand or electric pump to the Fill Drain Valve or Fill by going to the roof removing the cap and float assembly and pouring in the antifreeze mixture Maintenance Card to be Placed On Customer s Water Tank Figure 5 3 Collar Sign on Solar Wand To Alert Plumbers 47 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL If the system temperatures do not return to normal then telephone or e mail Butler Sun Solutions or your dealer installer after trouble shooting the system using Table 5 1 Table 5 1 Troubleshooting the System SYMPTOM Delta T Controllers Sun is Out amp Pump is off COMPONENT CHECK POSSIBLE CAUSE ACTIONS Controller Power light does _ Electrical outlet is not live Check outlet to be sure it has not come on power Fix or plug into a live outlet Controller is not turning pump Check to be sure that the Place Thermistors in the red LED on and energizing Thermistors are placed in correct locations Pump Plug a lamp into the proper locations of the controller outlet and be sure it collector and hot water does not
2. 180 F 210 F 61 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Heat Ex Delt T Peak Morning Heat up Rate Fluid Flow Rate BTU Output at Peak Material 18 F 10 C 108 F 60 C in 10 minutes 350W m 0 5 Gallons per Min 4 Pounds per Min 4 320 BTU per Hour Copper Fluid Temperature Pressure Air Elimination System Temperature Limit Pressure Limit Vacuum Limit Air Expulsion Heat Up Liquid Backfill Cool Down Reservoir Maintenance Valves for Isolation amp Filling Fill Drain Isolation Valve Wand Inlet Pump Isolation Valve Backflow Prevention Valve Solar Water Storage Tank Retrofit to Existing Tank New Installation Second Solar Preheat Tank Anti Scald Valve Steam to Air Radiator 124 C 256 F 16 psig 2 psig Trapped Air Bubbles Through Overflow Reservoir Liquid Drawn into Closed loop from the Bottom of Overflow Reservoir Fluid Level Gauge Turns On Add Fluid Light on Top of Water Tank 14 Tube valve 4 Tube valve 14 Turn Ball Valve 14 Turn Ball Valve Between Fill and Drain Valves Pressure Open Between Fill and Drain Valves 40 to 60 Gallons 75 100 Gallons 60 80 Gallons Set at 120 F 49 C Solar Collector Modules Manufactured by ACR for Butler Sun Solutions Modules Required Module Shipping Module Area Module Dimensions Module Weight Absorber Plate Flow Path Glazing Insulati
3. Table 2 7 Physical Properties Of 50 Propylene Glycol 50 Water Mixture By Volume Lower Limit or Freezing Point 32 C 26 F with 16 lb Pressure Cap Upper Limit or Boiling Point 124 C 256 F Viscosity over temperature 1 4 to 7 0 Centipoise range of 27 C 80 F to 60 C 140 F System Volume 1 gallon to 2 gallons Antifreeze Safety Always keep antifreeze in a sealed marked proper container with a childproof lid Emergency First Aid According to the Agency for Toxic Substances and Disease Registry ATSDR CAS 57 55 6 Propylene Glycol Antifreeze and Deicing solutions are not considered toxic by the FDA Ingestion of small quantities from leaks or spills should not be cause for alarm for people or animals Skin exposure should just be rinsed off with water Ingestion of large quantities such as from storage containers consult your doctor Burns caused by hot fluid see a physician Proper Disposal Depending on the local codes the propylene glycol should be disposed of in a dry well or a sanitary Sewer not a storm sewer We recommend returning it to an auto parts store or chemical waste disposal site for recycling To clean up spills you can use paper towels or kitty litter to soak up the propylene glycol water mixture and place it in the trash 36 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 9 Pressure Gauge
4. 16 F 8 9 C AND Tank top temperature is below maximum limit 185 F 85 C OVER IF Tank top temperature above OFF TEMPERATURE maximum limit 185 F 85 C STANDBY IF Collector temperature less than tank OFF top temperature 2 6 1 1 Temperature Sensors The temperature sensors most commonly used are thermistor types The thermistor sensor is a resistor whose resistance decreases with increasing temperature as shown in Table 2 5 The most common thermistor sensor is called a 10K Ohm which has about 10K Ohm resistance at room temperature of 75 F The resistance and temperature are highly non linear with temperature accuracy of plus or minus 5 to 10 The fragile thermistor is potted into a short length of copper tube flattened on one end with a 1 8 hole to facilitate attachment to the system These thermistor sensors have proven to be durable rugged accurate and reliable for long periods of time Corrosion of the wires and connectors electrically connecting the thermistor to the controller has been far more troublesome The controller does not know where the resistance is in the thermistor circuit the controller sees the thermistor and all of its connector resistance The thermistor mounted on the solar collector outlet line is most prone to thermistor or connector failure since it 1s exposed to rain thermal cycling snow dew and the wires to UV radiation They should not need to be replaced over the life of the syste
5. 16 pounds above atmospheric pressure See Figure 2 4 for details 1 1 11 Toxicity The recommended heat exchanger fluid propylene glycol and water is non flammable and non toxic Propylene glycol is an American Water Works Association AWAA Class II fluid This means that it has a Gosselin toxicity rating below 1 Class II material are considered non potable and may be objectionable but not dangerous to health A typical system contains from one to two gallons of fluid It should be changed at 5 year intervals over the life of the system Proper disposal is required Propylene glycol water mixtures are recycled by service stations and auto stores Consult your local retailer of antifreeze for proper disposal in your area Leakage or small spills can be absorbed with paper towels or kitty litter and disposed of in the trash 1 1 12 Contamination 14 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL The Wand heat exchanger meets the American Water Works Association Cross Contamination Control s highest level of protection The Wand is an anti siphoning device The space between the two heat exchanger wall potable water and heat transfer fluid is at atmospheric pressure The potable water is usually above 50 psig and hence will leak out of the tank The heat transfer loop is pressurized by the fluid head above the tank usually 10 psig plus 16 psig t
6. ON THE HOT WATER OUTLETS THIS REQUIRES THAT THE NECKED DOWN REGION BE FILED OFF BEFORE THE WAND CAN BE INSTALLED SEE FIGURE 2 2 All that is needed to install the Wand is Teflon Plumber s Tape and a 12 Pipe wrench t has come to our attention Install Wand in Hot Water Tank TO Outlet that some hot water tank eif Wand Will Not Fit Through 34 __outlets have a restriction NPT Thread below them as shown in the cross hatch below If present it must be filed off Then Carefully File the Bottom Edges of the NS Outlet Threads As Shown Small Half or Full Round File Outlet Port Threads Present on only on a few hot water tank outlets rani Gaara a m 5 ERHET A a E a e al a ol ad A Figure 2 2 Solar Wand Installation Note 18 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL NOTICE IT HAS COME TO OUR ATTENTION THAT SOME HOT WATER TANKS MADE BY THE BRADFORD WHITE COMPANY HAVE THE SACRIFICIAL ANODE ATTACHED BELOW THE HOT WATER OUTLET IF YOU HAVE ONE OF THESE TANKS FOLLOW THE INSTRUCTIONS IN FIGURE 2 3 SOLAR WAND INSTALLATION PROCEDURE FOR BRADFORD WHITE HOT WATER TANKS Hot Water Outlet Anti Scald Valve Pipe Cap sA Nipple Anode STEPS i 4 Removed Drain Valve 19 amp te Cold Water Insert a T Fitting re Inlet Pipe Reroute Cold Water Inlet From nel Anode Rod Top Of Tank
7. PM la Polypropylene ee Pe Graphite Ceramic 316 Stainless Steel Radiator Cap Seal yy EPDM a Radiator Cap Vent Copper o o o Radiator Cap Structure Zinc Clad Steel Brass a EPDM T Overflow Tubing Fluid Recovery Reservoir The pumps shown in Figures 2 10 and 2 11 are electrically impedance protected to prevent motor burn out They are corrosion resistant and can be easily disassembled for 32 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL field repair Years of testing have shown these pumps to be reliable and trouble free for over several decades in residential space heating applications with conditions similar to the ones found in the Solar Butler 1 0 system 2 6 Controllers 2 6 1 Delta Temperature Controls The 115VAC system uses a standard Delta T controller to sense the system temperatures and to turn the pump on and off The controller uses the temperature inputs from the temperature sensors 6 a at the solar collector outlet and sensor 6 b at the hot water tank top to control the circulation pump The pump only has two states on and off The controller state table is shown in Table 2 4 Table 2 4 Solar Butler 1 0 Controller State Table for115 VAC System SYSTEM SENSOR PUMP STATE TEMPERATURES STATE ACTIVE SOLAR IF The collector temperature is above ON _ temperature is above OPERATION tank top temperature by
8. The heat transfer fluid is a propylene glycol water mixture which is commonly used for automobile antifreeze coolant Propylene glycol water will not poison pets or people Propylene glycol water is non flammable and non toxic Propylene glycol is an American Water Works Association AWWA Class II fluid This means that it has a Gosselin toxicity rating below 1 Class II materials are considered non potable and may be objectionable but not dangerous to human health The system contains only a small amount of fluid usually less than one gallon A spill or leakage of the entire fluid inventory should not be a problem You can mop it up and then dispose of it properly Depending on the local codes propylene glycol should be disposed of in a dry well or a sanitary sewer not a storm sewer We recommend returning it to an auto parts store or chemical waste disposal site for recycling As an alternative clean up you can use paper towels or kitty litter to soak up the propylene glycol water and put it into the trash 52 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 6 0 Specific Warning Labels The labels are shown in Table 6 0 These labels should be filled out and attached to the system at appropriate locations Table 6 0 Specific Warning Labels for Solar Butler 1 0 System 1 Near Control Butler Sun Solutions Box and Hot P O Box 1666 Solana Beach CA
9. The over temperature radiator has about 0 16 m 1 8 square feet of surface area capable of protecting the solar system from excessive boil over and fluid loss caused by stagnation Stagnation describes the condition where solar energy is being absorbed in the solar collector and there is no fluid flow to remove the heat In this case the fluid in the solar collector will boil at 16 psig creating 124 C 256 F steam The steam makes its way out of the top of the solar collector and toward the radiator cap However it must pass through the liquid to air heat exchanger first The differential temperature between the outside air and the steam causes heat to be removed from the steam and be delivered to the outside air This heat loss to the surrounding air condenses most of the steam back to water which finds its way back to the solar collector The small amount of steam that blows past the radiator cap and enters the overflow reservoir is condensed as it bubbles through the fluid in the reservoir and is held there as liquid for reintroduction into the system upon cooling 1 1 8 Wand Antifreeze to Potable Water Heat Exchanger The Standard 1 2 m 48 inch Long Wand has about 0 18 m 2 square feet of heat transfer area inside the hot water tank The Standard 0 96 m 38 inch Short Wand has about 0 14 m 1 6 square feet of heat transfer area inside the hot water tank The Wand has a small diameter center tube which delivers the hot coll
10. This is the valve used to drain your hot water tank when needed Please see your water tank instructions for how often you should do this to lengthen tank life You should use the drain valve to empty the water out of the tank prior to Wand installation CAUTION ALWAYS ATTACH A HOSE TO THE DRAIN VALVE BEFORE OPENING DO NOT OPEN THIS VALVE WHEN HOT PRESSURIZED WATER IS PRESENT HOT WATER CAN SPRAY OUT AND SCALD YOU TURN OFF THE POWER TO THE TANK AND LET THE TANK COOL DEPRESSURIZE THE TANK BY SHUTTING OFF THE COLD WATER SUPPLY AND OPENING A HOT WATER FAUCET IN THE HOUSE BEFORE OPENING THE DRAIN VALVE 3 7 Gas Burner or Electric Heating System The gas or electric heating elements and systems are not disturbed by the heat exchanger wand installation The wand should not contact them during installation and operation Care must be used to be sure the Wand goes straight down and does not contact the electric elements or center pipe of gas hot water heaters The control set point of the gas or electric heater should be set at 120 F 48 9 C after the solar Wand heat exchanger is installed This allows for excellent solar hot water production while allowing the hot water after several cloudy days to be warm enough for household use 43 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 4 0 System Operation 4 1 Operation The system begins operation in the
11. a waterproof seal 2 4 Solar Collectors The Solar Collector s used with this system must be rated and certified by the Solar Rating and Certification Corp SRCC OG 100 for the complete system to be OG 300 Certified Only systems designated in Table 1 will be certified SRCC OG 300 when the identified SRCC OG 100 collector is installed The SRCC web site www solar rating org will also have an updated list of the SRCC OG 300 certified Butler Sun Solution Systems The SRCC OG 300 Certification is required to receive Federal and or State tax rebates or credits for installing a solar hot water system The solar collector is of a standard design and will be provided with the system kit or can be purchased separately The collector must be sized to provide the correct amount of heat to the hot water tank Too large a collector area will overheat the hot water tank causing the circulation pump to be shut off by the tank high limit switch on the top of the hot water tank or the Delta T controller so collected solar energy will be dumped in the liquid to air radiator Too small a collector won t heat the tank enough A common design rule is that the collector area in square feet should be approximately the tank capacity in gallons divided by 1 for Northern latitudes and 2 for Southern latitudes Local elevation climate and the orientation of the solar collector s away from due South or latitude elevation will also factor into the solar collector si
12. fill and drain valve 11 in Figure 2 0 is used to fill the system from the bottom to get all of the air out or to drain the fluid out of the system It is used together with the Flush Valve 12 in Figure 2 0 and Pump Isolation Valves 13 in Figure 2 0 they are used to pump or gravity feed the glycol water heat transfer fluid into the system This valve is used to drain the system to replace the heat transfer fluid every 5 years 2 12 Flush and Fill the System Including Flush Valve The Flush Valve 12 in Figure 2 0 and Fill Drain valve 11 in Figure 2 0 are used to perform three functions The first function is to flush the system with fresh water to clean out small particles spider webs or other debris that may have found its way into the fluid loop during storage or installation of the system The second function 1s to fill the system for the first time by either gravity or pumping The third function is routine replacing of the heat transfer fluid after 5 years of service This can be done quickly and easily without going on the roof if an external fill pump is available If no fill pump is available then gravity can be used by filling fresh antifreeze from the roof as used antifreeze is drained out of the Flush 12 in Figure 2 0 and Fill Drain 11 in Figure 2 0 valves The Fill Drain Valve 11 also serves as a place to attach a pressure gauge to verify that the heat transfer fluid is circulating properly 37 of 65 SERVICE MANUAL Solar
13. hot water system and the Solar Butler 1 0 is the heat exchanger wand 1 Patent No US 6 837 303 B2 issued Jan 4 2005 se Wand Isolation Valve EETA Anti Scald Valve 6 te Heat Exchanger Wand a gt X Se D n n 1h ll i pea ke T 3 ra 12 Flush Valve X lt OA 13 Pump Isolation Valve Pressure a f Delta T Controller 115 VAC W Or PV Terminal Block Controller Temperature Sensors PV High Limit Cut Off Figure 2 0 System Schematic Diagram 16 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 1 Solar Wand in tank heat exchanger Double walled heat exchanger constructed of copper and brass which screws in the existing hot water tank s hot water outlet AWWA Class DWP Double Wall with leak Protection Provides two distinct walls which separate the transfer medium from the potable water and a path to atmosphere Failure of either wall is indicated by visual leakage on the top of the hot water tank coming from the annular wand vent space Leakage of the transfer medium or potable water and indicates a failure of the heat exchanger The DWP type provides a higher degree of protection than the SW Single Wall with no leak detection or DW Double wall with no leak detection The solar Wand a double walled heat exchanger 1s designed so a single failure of any fluid barrier will not ca
14. morning when the solar collector temperature exceeds that in the hot water storage tank by about 16 F 8 9 C or for PV powered systems when the insolation is above 300 Watts per square meter Operation is defined as circulating the heat transfer fluid between the solar collector and the hot water tank System shut down at night circulation ceases when the temperature in the solar collector is only 4 F 2 2 C above the tank temperature or for PV powered systems when the insolation 1s below 300 Watts per square meter The difference in start up and shut down temperatures is necessary to keep the system from cycling on and off rapidly at start up Clouds or overcast conditions can cause the system to shut down and when the sun reappears the system will begin circulating again Operation is most easily described by following an element of heat transfer fluid through the system The system is described in Figures 1 1 1 2 1 3 amp 2 0 Use Figure 2 0 on page 19 to understand the fluid flow by the numbers The fluid starts at the pump 5 When the controller or PV power turns on the pump it means that the solar collector 1s hotter than the hot water tank by more than 16 F 8 9 C The fluid passes by the Fill Drain Valve 11 which is open to the pressure gauge and the fluid has its pressure read by Pressure Gauge 9 then the fluid passes through the open Pump Isolation Valve 13 then past the closed Flush Valve 12 The fluid then moves i
15. much solar hot water as the Solar Augment because both solar and electricity or gas are heating the water in the single 10 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL existing hot water tank Because the auxiliary heater is always active the water in the tank never goes below the set point of the auxiliary heater except temporarily during times of heavy water usage Thus the solar system can only contribute heat above the set point of the auxiliary heater Solar Augment adds an additional solar storage tank between the incoming cold water and the existing hot water tank or tankless water heater The Solar Augment configuration is shown in Figures 1 3 and 1 4 The Solar Augment configuration provides more solar heated water to the residence because the solar input heats the low temperature water in the solar preheat tank and only electricity or gas are used to heat the existing tank or tankless water heater The cost of the added tank must be balanced against the added solar hot water produced Solar Augment is used when there is room for a new solar storage tank and the existing tank 1s small 30 40 gallons or a tankless water heater is used Self Pressurizing Unit Auto Radiator Cap Radiator AMAA Overflow Flat Plate Solar Collectors PV Panel a Roof Glycol Solution in Loop Umbilical a ot Flush Valve Pump Isolati
16. of the system Place the high pressure pump inlet tube in the bottom of the antifreeze fluid container With the Flush Valve 12 and Fill Drain Valves 11 open turn on the pump and the antifreeze will push the water out of the system When the fluid in the tube from the Fill Drain Valve 11 to the bucket turns green meaning antifreeze has filled the system then relocate the tube from the bucket and place it in the bottom of antifreeze fluid container so it will stay below the liquid level Keep circulating the antifreeze until all bubbles are out of the system Then CLOSE the Fill Drain Valve 11 this will cause the antifreeze to fill the overflow reservoir After about minute the overflow reservoir level light should be off indicating it is full 39 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL CLOSE the Flush Valve 12 and turn the pump off Remove the pump and tubing then reattach the pressure gauge to the Fill Drain Valve 11 2 12 3 Heat transfer fluid replacement every 5 years The pH of the antifreeze mixture needs to be tested every 5 years New propylene glycol mixtures of 50 50 with water will have a pH 8 6 when new This is basic and will not corrode the copper tubing and solar collectors The automotive antifreeze recommended is Peak Sierra which includes a mixture of corrosion inhibiting buffers The pH should be measured using a prop
17. off and then heats up again see Figure Zt Non Vented means that air is not admitted to the heat transfer system Fluid thermal expansion pushes fluid and air out of the system after the radiator cap has been opened to admitting air when the system is filled As the fluid loop cools off the thermal contraction the antifreeze water mixture causes only the antifreeze water mixture to be drawn back in from the overflow This action over a few heat up and cool down cycles removes all air from the fluid loop and keeps it out This is important because the presence of air in the fluid loop accelerates corrosion and promotes acid formation You can tell if a radiator cap is vented or non vented by holding it above your head and looking at the small round disk in the center of the bottom sealing end of the cap If it is falling down it is vented If a small spring force is holding it in place it is non vented Figure 2 7 includes a cross section view of a typical non vented radiator cap CAUTION USE ONLY NON VENTED RADIATOR CAPS ON THIS SYSTEM 23 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL ass C S cc S ee D ll G _ a i Top seal RADIATOR CAP Relic spring FILLER NECK i i Overfi pw vw oe inlet Vacuum relief seal mae spring Pressurized N system Sf N co 7 Pr
18. outlet to achieve a uniform outlet temperature between a minimum of 27 C 80 F and a maximum of 49 C 120 F settable using the rotating handwheel Thus the maximum water temperature delivered to the house is limited to 49 C 120 F Many new homes already include Anti Scald valves as they become more affordable and reliable This is a safety upgrade which increases the value of the solar system by making more effective use of the solar heated water and protecting the hot water users from scalding The Anti Scald valve must be installed to receive the benefits of SRCC OG 300 Certification For disassembly and cleaning see Figure 2 13 Y screw LABEL HANDWHEEL HANDWHEEL STOP UPPER NUT LOWER NUT O RING SEAL TOP ASSEMBLY F LOWER ASSEMBLY DIFFUSER SPRING ANTI BACKFLOW VALVE OPTION VALVE BODY HONEYWELL AQUA MIX ANTI SCALD VALVE AM 101C DISASSEMBLY FOR DESCALING SOAK HOUSING AND LOWER ASSEMBLY IN VINEGAR SOLUTION Figure 2 13 Anti Scald Mixing Valve 41 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 3 0 Water Tank Nomenclature 3 1 Hot Water outlet This is the hot water outlet connection to the house hot water supply This is where the heat exchanger Wand must be installed Newer hot water tanks identify the hot water outlet with a red ring or the letter H embossed in the sheet metal near it and cold water inlet with a
19. the 115AC system the temperature sensor on the solar collector must be connected to the pump control unit 6 This is a low voltage signal usually 14VDC For the 12VDC powered system the power from the PV panel usually 30 to 40 Watts must be sent from the PV panel to the pump This requires at least one pair of wires which can handle the power without loss Both PV and 115 VAC systems need two wires for the overflow float level indicator system By using the two parallel extension cords the system can be changed from 12VDC to LISVAC or visa versa without pulling any new wires just connecting the end differently The PV powered system can use a single 3 wire AWG 18 extension cord as discussed in Figure 2 8 The PV negative connects to the black wire The PV positive and one float level switch wire connect to the white wire and then connect the other float level switch lead to the green wire At the water tank the PV positive white 1s connected through the water tank high limit snap switch to the pump positive The PV negative wire black is connected to the pump negative The float level switch green wire 1s connected to an LED light positive and the LED negative goes through a resistor to the PV negative black Now the PV powered level light will be on when the fluid is low and the sun is out 26 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL PV Pan
20. 007 Figure 2 11 El SID Solar Circulation Pump Several low flow pumps powered by photovoltaic panels have been used successfully with the Solar Butler 1 0 system Table 2 2 shows a comparison of the pumps that have been successfully used in long life systems Table 2 2 Properties of DC Seal less Pumps Power Needed D 4 LCA 1SVDC 15W 3450 10 5 Ft Head 4 60 psi external D 5 LCA 31 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL neml Ivan Labs El SID 2X2 18VDC 10W 1720 2 5 Ft Head 1 09 psi El SID Max 18 VDC 20W 1800 5 0 Ft Head 2 18 psi These pumps are compatible with all automobile antifreeze glycol based solutions however we only recommend that propylene glycol be used in the system WARNING ETHYLENE GLYCOL amp ALCOHOL BASED ANTIFREEZE SOLUTIONS ARE NOT RECOMMENDED FOR USE IN THE SOLAR BUTLER 1 0 SYSTEM THEIR USE WILL VOID YOUR WARRANTY The construction materials of the pump and system are given in Table 2 3 Table 2 3 Materials In Contact With Heat Exchange Fluid Component Copper amp Polymers amp Ceramics Ferrous Compatible Alloys Alloys Tube Fittings Bras Tubing ooo Copper J o o S Tubing Solder connection Lead Free OF ff Heat Exchanger Wand Copper amp Brass To Tl Collector Copper S eed Copper Tin Radiator Copper J o S Pump Housing Bronze S S O Pump O Ring po
21. 1 Solar Collector Outlet Sensor The solar collector temperature sensor is placed at the top of the solar collector on the hot fluid outlet pipe 2 6 1 1 2 Tank Top Temperature Sensor TheCut Off Switch for top tank temperature must be slid under the insulation to touch the top of the metal tank It must be in contact with the outside of the water tank itself on or near the top of the tank This is usually accomplished close to an outlet port where there is a gap in the sheet metal tank covering NOTE THE TOP SENSOR MUST BE IN CONTACT WITH THE METAL SURFACE OF THE HOT WATER TANK TO ASSURE THAT THE CONTROLLER WILL SAFELY LIMIT TANK TEMPERATURE The sensors are connected to the controller with two wires with a minimum wire gauge of 24 Sensor failures can cause the system to pump when the sun is not out or not to pump when the sun is out Refer to Table 5 1 Trouble shooting the System to diagnose a bad sensor If you suspect a bad sensor check its resistance at room temperature They 34 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL are calibrated to read 10 000 Ohms at room temperature 25 C 77 F and have 10 accuracy see Table 2 5 2 6 2 Insolation Powered Pump Control The control for the 12VDC system is different it consists only of a Photovoltaic panel on the roof and a PV powered pump connected in series with a temperature limit
22. 185 F 65 6 C to 85 C CAN RESULT IN VERY HOT WATER WHICH CAN SCALD ALWAYS TEST THE WATER BEFORE YOU USE The pump turn on differential temperature Delta T controllers can be set from 8 F to 24 F 4 C to 13 C We recommend setting it at 16 F 8 8 C PV powered system turn on when the insolation is about 300 Watts per Square meter and no adjustable settings are needed The hot water tank temperature setting for the electricity or gas is user controlled The water tank temperature will fall to the gas or electric backup set point after several days of cloudy weather This should be WARM which should be near 120 F 49 C If the temperature is set below WARM the faucet and shower water may be too cool If the back up temperature is set too high the solar heating of the water will be reduced since solar will not heat above 185 F 85 C the maximum high limit set point The homeowner can and should adjust the back up gas or electric set point temperature to be comfortable at the back up temperature such as 120 F 48 8 C 45 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 5 0 Maintenance Plan and Instructions 5 1 Checking the System for Operation If the temperature gauge on a sunny day reads between 10AM and 2PM reads between 54 C 130 F and 100 C 212 F then the system is working OK ON A SUNNY DAY CHECK THE TEMPERATURE GAUGE BE
23. 92075 1520 Water Tank 858 259 8895 butlersunsolutions roadrunner com www butlersunsolutions com Solar Butler 1 Date Manufactured Month Year System Serial Number For parts contact manufacturer For service contact the Installer 2 Near Control Box and Hot Water Tank 3 On Pump WARNING HOT 4 Near Control Operating Parameters Box and Hot Differential Temperature 16 F 8 9 C Water Tank Maximum Tank Top Temperature 185 F 71 C Maximum Solar System Pressure 16 psig Freeze Protection 26 F 32 C 5S Fill Drain Fill Drain Valve Valve Freeze Tolerance Propylene glycol water 50 50 32 C 26 F Propylene glycol water 60 40 48 C 54 F Heat Exchanger type DWP AWWA Fluid Class II Low Toxicity See manual for proper handling amp disposal instructions Warning Fluid may be discharged at high temperature 127 C 256 F and pressure 16 psig Warning No other fluid shall be used that would change the original classification of this system Unauthorized alterations to this system could result in a hazardous health condition 6 Pump Isolation Pump Isolation Valves Valves Valves Normally Open i me Solar Heated Water Can Scald You aa Test The Water Before Anyone Bathes or Drinks 53 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 7 0 Hazards of All Types As a do it yourselfer you must be comfortable assuming and
24. ABOR If Butler Sun Solutions provides and installs the complete solar system we will provide the one 1 year repair labor warranty If Butler Sun Solutions provides and someone else installs the complete solar system Butler Sun Solutions recommends that the installer provide a one 1 year repair labor warranty The end user must receive this warranty from the installer Butler Sun Solutions will not provide this labor warranty to the end user for systems that Butler Sun Solutions does not install 9 2 WHAT BUTLER SUN SOLUTIONS WILL DO If a defect in parts materials and components or other malfunction or failure to perform becomes evident during the warranty period Butler Sun Solutions will repair or at its option replace the nonconforming component or part within a reasonable time and without charge for the part or transportation In such event the duration of the warranty is extended while the part or component is not functioning 9 3 WARRANTY PERFORMANCE Where and How to File Claims Warranty claims are to be made to Butler Sun Solutions during normal business hours by the registered owner of the solar system Registration must be done at the point of sale Your contract for Butler Sun Solutions installed systems or invoice for systems purchased from Butler Sun Solutions automatically registers the owner If you purchased 58 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTI
25. Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 12 1 Flushing the System Flush the solar system wand collectors and tubing Flushing is needed on initial filling of the solar system to flush out any contamination residue or debris spider webs or dirt which may have gotten into the system during storage shipment or installation HINT FLUSHING OUT THE COLLECTOR TUBING FITTINGS AND VALVES AS INDIVIDUAL COMPONENTS BEFORE INSTALLATION WILL MAKE FLUSHING THE ENTIRE INSTALLED SYSTEM EASIER With the radiator cap in place pressurized water about 40 psi from a GARDEN HOSE TURNED FULL ON or external pump is injected into the system using the Flush Valve 12 in Figure 2 0 With the Pump Isolation Valve 13 in Figure 2 0 closed the fluid must go up through the tubing to the collector through the collector down through the tubing to the heat exchanger wand then out of the Fill Drain Valve 11 in Figure 2 0 Water flushing should continue until the return fluid is bubble free and clear of debris 2 12 2 Filling the solar system with antifreeze 2 12 2 1 Filling the System Using Gravity A single person can fill the system using gravity via the Stopper Siphon method described here but it cannot be done at low temperatures below 20 F 7 C where the water used for flushing the system might freeze although one creative individual used hot water from the tank for flushing then th
26. Caulking in Tube with gun Roof Sealing Compound Tar Roof Patching Mesh Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Hardware Store Manufacturers or Hardware Store Metal Flashings if needed Assorted Nails Assorted Screws and Lag Screws Collector Supporting and Elevating Hardware if Needed 2 inch ABS Drain Pipe Elbows and Angles as needed Zip Ties for Umbilical 1 8 Drill Bit for ABS Drain Holes BSS Hardware Store Hardware Store Hardware Store 57 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 9 0 Warranty Coverage 9 1 SCOPE OF COVERAGE FIVE 5 YEAR WARRANTY ON PARTS AND MATERIALS Butler Sun Solutions warrants all parts materials and components installed according to the installation manual to be free of defects in materials or workmanship This warranty shall be in effect for a period not to exceed 5 years from the date of system installation This warranty shall cover the cost of parts or materials for repair or replacement of defective parts materials or components TEN 10 YEAR WARRANTY ON THE SOLAR COLLECTOR If Butler Sun Solutions provides the solar collector and balance of system we will provide the solar collectors manufacturers warranty against leakage due to corrosion WARRANTY ON REPAIR L
27. Elec BSS PV1 80Ec 300 2005 005G 40 1 80 Elec BSS PV1 40Ga 300 2005 006A 24 6 40 Gas BSS PV1 40Gb 300 2005 006B 20 1 40 Gas BSS PV1 50Ga_ 300 2005 006C 32 9 50 Gas BSS PV1 80Ga_ 300 2005 006E 40 9 80 Gas BSS PV1 40Gc 300 2005 0061 40 1 40 Gas BSS PV1 50Gc 300 2005 006H 40 1 50 Gas BSS PV1 80Gc 300 2005 006G 40 1 80 Gas BSS S1 80E2a 300 2005 007A 40 1 80 50 Sun Elec BSS S1 80E2b 300 2005 007B 40 9 80 50 Sun Elec BSS PV1 300 2005 008A 40 1 80 50 Sun Elec 80E2a BSS PV1 300 2005 008B 40 9 80 50 Sun Elec 80E2b BSS S1 80G2a 300 2005 009A 40 1 80 50 Sun Gas BSS S1 80G2b 300 2005 009B 40 9 80 50 Sun Gas BSS PV1 300 2005 010A 40 1 80 50 Sun Gas 80G2a 7 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL BSS PV1 300 2005 010B 40 9 80 50 Sun Gas 80G2b 1 1 1 System Name Designation Solar Butler 1 0 The system is designated as a Self Pressurized Closed Loop Type Using a Solar Wand Heat Exchanger and Self Pressurizing Unit 1 1 2 System Type Low flow rate 2 Liters per minute 0 55 Gallons per minute flat plate solar collector with a self pressurized antifreeze filled fluid loop and a double walled heat exchanger immersed in the existing hot water tank as shown in Figure 1 1 1 1 3 System Description Glazed low fluid flow flat plate solar collector with passive liquid to air radiator for positive solar collector stagnation protection and dou
28. Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL SERVICE MAN UAL THE SOLAR BUTLER 1 0 SOLAR ASSISTED HOT WATER SYSTEM Solar Wand Heat Exchanger Sun Blocks Modular Collectors Self Pressurizing Unit for Glycol Loop Stagnation Over Temp Protection Automatic Trapped Air Purging SRCC OG 300 Certified ANTI SCALD Protection Commercial J rt 2003 Wand Isolation Valve Q Anti Scald Valve Oy cl fing E p x Flush Wahe Jy j rain alve 13 Pump Isolation n Valve i 1 2 Pressure Gauge 7 nsw 4 Delta T Cor traller PY Termi a Block Cab Controlier Temperature Sensors Ceb Pv High Limit Cut Off BUTLER SUN SOLUTIONS P O Box 1666 OR 811 Academy Dr Solana Beach CA 92075 Phone Fax 858 259 8895 www butlersunsolutions com 1 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL REVISION LOG The latest version of this manual is available for download from our web site www butlersunsolutions com Revision History Initial Release 1 0 January 1 2003 First Revision 1 1 June 30 2003 Second Revision 1 2 October 15 2003 Third Revision 1 3 March 16 2004 Fourth Revision 1 4 January 1 2006 Fifth Revision 1 5 September 7 2007 Self Pressurizing Unit Level Minder LED Solar Pump Service Diagrams and Anti Scald Valve Service Diagrams 2 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Ho
29. IGURES Pictorial View of Solar Butler 1 0 System cccccccessseseeeeeeeeeeeeeeeeees 9 Solar Assisted Hot Water System Single Tank Installation 000000 10 Solar Augmented Hot Water System Two Tank Installation 000000 11 Solar Augmented Hot Water System with tankless water heater backing up the solar storage tank nenennnnnessssssssseeeeeerreessssssssssssssssesen 12 Systemi Schemate Diadora ss iceidaachescrtennsdendadistleravsete yada ncrscsionnsiandadileszennt 16 solar Wand CutAway VICW csc iene eae erie aioe 17 Solar Wand Installation Notes sscoe cs saeco roren a icateabeademeascaatode 18 Wand Installations in Bradford White Hot Water Tanks c eee 19 Operating States of Self Pressurizing UNit ec ccccccccccesssseseeeeeeeeeeeees 20 Closed System Air Bladder Fluid Expansion Tank cccceeceeeeeeeees 22 Glycol Temperature amp Pressure of Self Pressurized and Bladder Pressurized Close Loop Systems spinaren 23 Parallel Pressure amp Vacuum Relief Valves Inside the Radiator Cap 24 Typical Wiring Diagram for PV Powered System cccceeeeeeeeeeeees 27 Heat Exchange Surface Areas vs Loop Temperature amp Collector EPIC TC NOY uer ea aceat naa alan ee T esl TE E 29 Laing Seal Less Solar Circulation PUMPS cccccccssseeeeeeeeeeeeeeeeeeeees 30 El SID Solar Circulation PUMP eseese naea EA E 31 Siphoning Antifreeze into the System to Replace t
30. LOSE the Pump Isolation Valves 13 This will now force fluid to go to the collector to return to the Fill Drain Valve 11 5 Pump fresh fluid into the system until you see it coming out the Fill Drain Valve 11 then pump a little more and stop CLOSE the fill drain valve and pump for 30 seconds to fill the overflow reservoir CLOSE both the Flush Valve 12 and the Fill Drain Valve 11 Remove the tubing from the Flush Valve and Fill Drain Valves Install the Pressure Gauge 9 on the Fill Drain Valve 11 and REOPEN the Fill Drain Valve so the pressure gauge will read the system pressure NOTE THE Pressure gauge will rise 1 2 psi when the system is circulating properly 10 OPEN the Pump Isolation Valve 13 Se ee a 2 11 Now the system 1s refilled with fresh Antifreeze and ready to run 12 Plug the pump into a live outlet or reconnect to the PV panel and verify that a circulation has been established by reading the pressure gauge NOTE The Pressure gauge will rise 1 2 psi when the system is circulating properly Do the ping test by quickly closing the Pump isolation valve 13 and watching the pressure spike up by about 5 psi the settle down to 1 to 2 psi 13 Properly dispose of the drained antifreeze propylene glycol water mixture Depending on the local codes the propylene glycol should be disposed of in a dry well or a sanitary sewer not a storm sewer We recommend returning it to an auto parts store or chemical
31. N SOLUTIONS 9 07 2007 SERVICE MANUAL Collector Efficiency Versus Loop Temperature Above Ambient Based on SRCC Data 3 ey BL ane ee 7 ft a ey sgt Giazed ies Black Paint 060 4 a m a 0 50 4 TA f boon ee Black Chrome a a Double Gaz ia Black Chrame Ape Selective Absorber weogross area 6net area Collector Efficiency z Evacuated Tube Liquid in Absorber Selective Absorber jw agross area Tenet area 2 ft 1000 wir 0 1 4 320 40 30 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 Loop Minus Ambient Temperature Degrees F Figure 2 9 Heat Exchange Surface Areas vs Loop Temperature amp Collector Efficiency The effects of heat exchanger surface area on closed loop temperatures for different types of solar collector are shown in Figure 2 9 The small 2 square foot surface area of the Solar Wand drives the loop temperature of the system up compared to a Rheem Rudd 20 square foot surface area heat exchanger with the 7 square foot surface area Quad Rod in the middle Increasing the loop temperature increases the solar collector heat losses The Solar Wand works well with collectors whose heat losses do not increase dramatically with temperature The solar collector has a much greater effect on system performance than the surface area of the heat exchanger for selective absorber surface solar collectors For black painted solar collectors the
32. NAL HOT WATER CONNECTIONS TO THE HOUSE DO NOT DISCARD 1 1 14 Hazards Hot pressurized heat exchanger fluid can scald and or flash to steam which will also scald CAUTION DO NOT LOOSEN ANY CONNECTIONS WHILE THE SYSTEM IS RUNNING amp DO NOT REMOVE THE RADIATOR CAP WHILE THE SYSTEM IS RUNNING Electrical connections for the thermistors are all low voltage and protected by a fuse The controller plugs into the wall and grounds the pump Be sure that three wire grounded outlets are used and don t try to fix the control box Unplug and call for service A ground fault interrupted outlet is required to minimize the potential electrical shock hazard Water from the hot water tank can scald When the solar collector is installed an Anti Scald valve must be installed on the hot water tank outlet to allow the solar system to be SRCC OG 300 Certified The Anti Scald valve must meet new housing code standards 15 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 0 System Operation and Component Functions The complete system is shown in Figure 2 0 The parts that comprise the Solar Butler 1 0 system and need to be installed in your house are shown as dark in the line drawing The parts that are already in your home are shown as light or faded in the line drawing This allows the Solar Butler 1 0 system to be less complex The interface between your existing
33. NOT STATED HEREIN IMPLIED WARRANTIES This warranty gives you specific legal rights and you may also have other rights which vary from state to state including in California implied warranties or merchantability and in certain instances of fitness for particular purpose LIMITS OF LIABILITY The customer agrees that Butler Sun Solutions liability for any warranty issue is expressly limited to the amount paid by the customer for the Butler Sun Solutions solar system and if Butler Sun Solutions pays this amount it has the right to remove the system from the customers premises RIGHTS TO ARBITRATION Any dispute between the buyer and Butler Sun Solutions pertaining to the warranty may at the option of the buyer or seller be resolved by arbitration in California according to the rules of the American Arbitration Association 60 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision Pump BULTER SUN SOLUTIONS SERVICE MANUAL 9 07 2007 10 0 System Specifications Self Pressurized Closed Loop Antifreeze Toxicity AWWA Class II Min Operating Temp Max Operating Temp Pressure Range Motor Seals Motor to PV panel PV panel size EI SID Laing D4 or D5 Backflow Prevention Materials Controls Umbilical from Collectors to Tank Pump On Off Tank Top High Limit Length Maximum Length Fluid Tubes Fluid Tubing Spacers Insulation Electrical Cable UV Protection Solar Wan
34. ONS 9 07 2007 SERVICE MANUAL a system from a distributor or installer you will have to register on line or by e mail To verify that your warranty is still in effect you must furnish evidence of the date of installation completion Butler Sun Solutions may if it deems it necessary and reasonable arrange for a field inspection of the system or request digital photos of the suspect component within a reasonable time from receipt of a claim The field inspector or photo evidence will be used to verify failure establish the probable cause and determine corrective actions required If the inspection photos reveal a warranty related defect Butler Sun Solutions will replace or repair at its option the parts and components which have failed If no warranty related defects are found the system owner must pay for the inspection Butler Sun Solutions or its representatives shall be granted access to the solar system and if necessary a sample of or the complete failed part of the solar system may be shipped to us or taken for analysis 9 4 LIMITATION OF LENGTH The warranty on parts materials and components extends five years from the date of installation on the original retail customer s home or location This warranty extends to the first retail purchaser and to any subsequent purchasers or owners at the same location during the warranty period Any such transfer will not extend the 5 year duration of the warranty If warranty service causes an e
35. TI ON aeaaea ated vans E iy sshiadnlasiadae i esdtenataladiia eal adninciatiatveheds 44 4 2 SEO e E A ston sapdb abodaccionsaitauctnio th actousantebebaneenianis 45 4 3 Controller and Hot Water Tank Settings 2 0 0 ccecccsecccccecceeeeseeeeeeeeeeseaeeeeees 45 5 0 Maintenance Plan and Instructions cccccsssssssssssssssssssssssssssssssssssssssssees 46 5 1 Checking the System for Operation ccccccccccsssseseseecceeeeeeaeeeeseeeceeeeeeeeeeeeees 46 32 Checkmethe System for Leak S ere a a Sieiteda eda menc eee 49 5 3 Replacing the Heat Traster Fhuldiescnoninsenr i cieeneridpiuaesaniwenettiateannawacene 50 5 3 1 Changing the Fluid With an External Pump ccccccsssessseeeeeeeeeeeeeeeees 50 5 3 2 Changing the Fluid Without a Pump using Gravity Onlly eee 51 54 Fluid Quality Toxicity Sate Disposal heer en ee a smlewnnseitececstenainie 51 6 0 Specific Warning Labels sssccecccccssscccecccccssssccecccocsssscceeccccsssescecccosssssseeeceossssee 53 IM Hazards OL AN TYPES csskscececesiciccrseses cesesicccavseseuccsanevesewseseesecsetecsensestusesetcvesewsesexans 54 7 1 Drinking Water Contamination Hazard cccccecccccccccccceesseeeeeeeeeeeeeessesseeeeeees 54 2 Ot W alter SCalcin Lazare xis cegaacensions he atieires he Aceon hres 54 7 3 Ladder Hazan sustesscsctanecnatesd E and eateewalecdiat ene nene setae 54 Ay POMS H z fd ecrin E 54 7 5 Elecmie Shock and Fire azar anc esate tree ee
36. TWEEN 10AM AND 2PM GOOD BAD 100 fp Sunpro a m z NORMAL OPERATING RANGE SYSTEM IS NOT WORKING WINTER 140 F AND SUMMER 190 F REQUIRES MAINTENANCE Figure 5 1 System Operation Analysis With Temperature Gauge The system requires very little maintenance The controller has operating lights which tell the controller s status when the line power is on and that the pump is turned on The third light on the lower right is for freeze circulation of non freeze protected systems which is not used on this system Every six months look at the controller during a sunny day to see if the pump light is on Two lights will be on the power on and pump on lights When the pump on light is on for Delta T controllers read the temperature gauge 10 in Figure 2 0 mounted near the pump For PV powered El Sid pump shown in Figure 2 10 on page 33 check the 4 LED s on the pump s body which should all be flashing to show the pump is running For the Laing pumps shown in Figure 2 9 on page 33 touch the plastic body to feel the vibration which tells that the pump is running If it is not hot enough the homeowner should check to see if the low fluid level light is illuminated for the coolant overflow recovery reservoir Add the proper propylene glycol water mixture to bring the level in the overflow tank up to half full If the temperature returns to reading within the limits within a few days all is well 46 o
37. The pressure gauge 9 in Figure 2 0 reads the fluid pressure in the heat transfer loop When the system is off 1t will read the pressure head of water in the heat transfer loop One atmosphere 14 7 psi will support a water column of about 32 feet So the pressure gauge will read 4 5 psi for every 10 feet of elevation between the gauge and the radiator cap 2 b The location of the pressure gauge in the system is shown in Figures 1 1 and 2 0 For a single story installation the gauge will read about 5 psi at night When the system is operating in the daytime the pressure will be the sum of the 5 psi head pressure and 16 psi pressure from the radiator cap 2 b so the gauge will read 21 psi around noon when the system is operating Turning the pump on and off will change the gauge pressure by a small amount usually 1 to 2 psi 2 10 Temperature Gauge The temperature gauge 10 in Figure 2 0 is either a bimetallic or paraffin filled automotive non immersion type gauge which reads the temperature of the tube bringing solar collector heated fluid to the wand heat exchanger It is located near the top of the wand heat exchanger close to the top of the hot water tank so it can be easily read Normally the temperature gauge when read between 10AM and 2PM on a sunny day reads between 60 C 140 F and 100 C 212 F This means the system is working Cooler temperatures may indicate a lack of circulation in the system 2 11 Fill Drain Valve The
38. To Ea Drain Valve 19 T Fitting E CH Remove Cold Water Inlet Dip N D Tube 3 amp Discard TS 7 File Out The Cold Water Inlet Dip Tube Retainer As Shown In Figure 2 2 20 6 OC 13 Screw Solar Wand Into Cold Water a Outlet Port amp Cap Outlet A i i Attach The Anti Scald Valve Hot Inlet PRR 2 To The Tank Hot Water Outlet Attach The Anti Scald Valve Mixed Outlet To The House Hot Water T Fitting Attach The Anti Scald Valve Cold Inlet Cold Water Source www butlersunsolutions com Figure 2 3 Wand Installations in Bradford White Hot Water Tanks 22 Self Pressurizing Unit The Self Pressurizing Unit consists of a liquid to air radiator a radiator cap with a 16 psi pressure relief and a 2 psi vacuum relief in parallel and a fluid recovery reservoir The Self Pressurizing Unit operating states are shown in Figure 2 4 The Self Pressurizing Unit 1 Accommodates fluid thermal expansion by regulating the closed loop system pressure and allowing fluid to escape to the overflow reservoir 2 Accommodates fluid thermal contraction by regulating the closed loop system vacuum and allowing fluid to re enter the closed loop from the overflow reservoir 19 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 3 Automatically eliminates air and non condensable trapped gases from the closed loop 4 Limits the temperature of the glycol w
39. UN SOLUTIONS 9 07 2007 SERVICE MANUAL Fifth Revision 1 0 Solar Rating and Certification Corporation SRCC Compliance Information The solar energy system described by this manual when properly installed and maintained meets the minimum standards established by the SRCC This certification does not imply endorsement or warranty of this product by SRCC Only systems using OG 100 certified collectors listed in Table 1 will be OG 300 system certifiable 1 1 Butler Sun Solutions SRCC OG 300 Certified Systems In the System Model Number column of Table 1 PV1 indicates a Photovoltaic powered pump is used to circulate the propylene glycol antifreeze fluid in the solar collector loop S1 indicates a 115V AC Delta T controller is used to power the pump to circulate the propylene glycol antifreeze fluid in the solar collector loop Systems have been rated for ACR Sun Earth and Thermomax solar collectors Both single tank and dual tank systems have been rated by SRCC Figure 1 shows a pictorial view of the system Table 1 Certified System Designations System Model SRCC Collector Solar Aux Solar Aux Number Certification Area Tank Tank Tank Tank Number ft2 Vol Vol Heat Heat gal gal BSS PV1 40Ea 300 2005 005A 24 6 40 Elec BSS PV1 40Eb 300 2005 005B 20 1 40 Elec BSS PV1 50Ea 300 2005 005C 32 9 50 Elec BSS PV1 80Ea 300 2005 005E 40 9 80 Elec BSS PV1 40Ec 300 2005 0051 40 1 40 Elec BSS PV1 50Ec 300 2005 005H 40 1 50
40. Wand in tank heat exchanger ccccccccccessssesseeceeceeeeaeeeeseeeceeeeeeeeaeenees 17 2 2 SelT Press Urine WIA ssa teas eee ia aves etadad tai tow ead epee ade 19 2 2 1 Liquid to Air Radiator for Over temperature Protection eeeeeees 21 2 2 2 Bladder Expansion Tank Thermal Expansion Management 008 21 2 2 3 Pressure amp Vacuum Cap for fluid l00Pisrei ian 23 2 2 4 Fluid Overflow Reservoir amp Recovery System ssseeessesssssoserrsssssssseeeres 24 2 3 Insulated Umbilical including Fluid Tubes amp Electric Lines ee 25 2 3 1 Copper Circulation Tubing amp Compression Connectors cccccecceseeeeeees 25 Zed O MDMICAL INSUE Osga E 26 Deo Omon WI sn a E hte 26 DOA SSPHUWPIDG aene pe e E a E E e E E 27 2 4 Solar Collecti senssa TEE ET 28 29 Circulon PUN de atelea anette tedaeaseta eden tameeh nena ieeaneias 29 Os C ONTO CG niaan aa E ac mene ead Say aea trate reac ene cate 33 27 0 1 Dela Tempere Conio S eener i a E tesco 33 201l Temperature Sensor eorn es aents au Shona 33 20A Sol r Collector Qutlet SENS OF siiente sive 34 2 0 1 1 2 Tank Top Temperature Sensor htciicccoieetdssittincesare a 34 2 6 2 Insolation Powered Pump Control ccccccccsssessseeccceceeeeeeeeeseceeeeeeeaeeeeees 35 2i Power sources LISVAC or 12VDCO isa seh sassa cashes rasan untae nde ved eaa 35 2 8 Heat raster EUs eens tien cane dae teeta tore cand ie ecient laantaunica teeta 36 i
41. ample increasing the square feet of solar collector for the storage tank volume in gallons should only be done in extremely cold climates or where collectors are not oriented and tilted South 22 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL TEMPERATURES amp PRESSURES IN GLYCOL SOLAR HEAT TRANSFER LOOPS Normal Operation Loss of candi a Freeze Inhibitor Pressure in psig Temperature in Degrees F Pressurized Systems 75 psig Relief a Self Pressurzed Systems Heat Up 16 psig Relief 2 psig Vacuum Relief Self Pressurzed Systems Cool Down 16 psig Relief 2 psig Vacuum Relief Unpressunzed Figure 2 6 Glycol Temperature amp Pressure of Self Pressurized and Bladder Pressurized Close Loop Systems 2 2 3 Pressure amp Vacuum Cap for fluid loop The system uses a standard automobile radiator fluid filler neck and standard automobile radiator cap designated as 16 Pound Non Vented The cap maintains 16 psig of pressure above atmosphere If the pressure exceeds that value it releases liquid or steam to the fluid overflow reservoir When the system cools off and goes sub atmospheric the vacuum recovery valve built into the cap automatically allows fluid in the coolant recovery reservoir to go back into the fluid loop You never notice this taking place but it happens in your automobile every time it cools
42. ank eae rata doar Solar Augmented Hot Water With Tankless Backup Closed Loop Self Pressurized 16 psi Screw In Wand Heat Exchanger Figure 1 4 Solar Augmented Hot Water System with tankless water heater backing up the solar storage tank 1 1 4 Solar Collector Single glazed glass selective absorber plate aluminum foil faced poly isocyanurate foam insulation and aluminum frame with provision for 1 Flashing into the roof 2 Mounting parallel over the existing roof and 3 Mounting at higher than roof pitch angles 1 1 5 Water Tank The home s existing gas or electric hot water tank is used as the storage tank for the system The proper collector area must be selected to match the existing hot water tank s capacity of 40 60 or 80 gallons 1 1 6 Collector Area 12 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL The solar collector area needed depends on where the system will be located The OG 300 rating provides an estimate of system performance In good solar areas of the Southwest the collector area in square feet should be roughly half the tank capacity in gallons in poor solar locations the optimum ratio approaches one square foot of collector per gallon of storage So for example a 40 gallon tank would require 20 square feet of solar collector in Arizona and 40 square feet in Maine 1 1 7 Liguid to Air Heat Exchanger
43. ansformer of 30Watt capacity is plugged into the outlet and used to power the DC pump 30 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL EL SID Static Impeller Driver Electronic Low Voltage amp PV Powered Pump with March Pump Head 1 Shaft 4 Must Be Horizontal IN BOTTOM 2 Outlet Arrow basen Point Up To Outlet Solar Pump EL SID Impeller Driver March Model 809 2 Four Tell Tale LED s Maximum Liquid Temp 250 F Off Off Off Off No Power EL SID 10 Impeller Driver 1 800 RPM On Off On Off Trying to Start Max Head 3 5 Feet OnwOff OffmOn Almost Starting Construction Bronze Stainless Steel Ryton On On On On Spinning Dimensions 4 7 8 Tall Inlet to Outlet 3 Wide 3 5 Deep With EL SID 10 REPAIR PARTS LIST DESCRIPTION QTY PART NO 8 x 1 1 4 Rd Hd Screw 4 0923 0003 1000 Pump Housing W 1 2 MPT 1 0809 0013 0000 O Ring Silicone Rubber bronz housing 1 0809 0165 1000 Impeller Shaft w Thread 1 0809 0008 1000 Thrust Washer 1 0809 0043 1000 Impeller amp Magnet 2 Dia 1600 RPM 809 1 0809 0005 0100 Impeller Magnet Housing 1 0809 0012 1000 8 x 3 8 Long Rd Hd Screw 4 0135 0040 1000 El SID 10 Static Impeller Driver 1 Ivan Labs Part IVAN LABS Inc 305 Circle West Jupiter FL 33458 USA Voice 561 747 5354 Fax 561 746 9760 ivandelsol bellsouth net or www marchpumps com Butler Sun Solutions Service Manual 2
44. ater mixture in the closed loop to about 250 F by condensing steam from the solar collectors in the liquid steam to air radiator Items 3 and 4 above increase system life by limiting corrosion causing oxygen from the closed loop and keeping the antifreeze temperature below the point where rapid antifreeze acidification occurs Self Pressurizing Unit Radiator Cap Overflow y Heating Up Air Bubbles Out Cool Down Fluid In No Air Figure 2 4 Operating States of Self Pressurizing Unit 20 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 2 1 Liguid to Air Radiator for Over temperature Protection The liquid to air heat exchanger is a pipe with attached fins to allow the air to remove heat from the pipe efficiently like the finned pipes used in hydronic heating in houses If the sun is out and circulation of fluid stops the collector will begin to boil This can happen if the storage tank top temperature exceeds the 185 F set point on a sunny day and the fluid circulation pump shuts off until the tank needs more solar heat Fluid circulation stoppage with the sun out could also be caused by other events such as a pump or controller failure or a power outage or plugged pipe The system is designed to protect itself from damage if fluid circulation stops It does this by limiting the temperature and pressure in the collector When the collector s
45. aterials which should resist corrosion for at least 35 years or more with low maintenance copper tubing stainless steel pump and brass fittings Because of the double wall wand heat exchanger antifreeze cannot leak into the potable water supply The solar heat storage is accomplished with two different water tank storage configurations Solar Assisted Hot Water Solar Assist and Solar Augmented Hot Water Solar Augment Solar Assist uses your existing hot water tank to store the solar heated water The Solar Assist configuration is shown in Figure 1 2 Solar Assist is used where there is not room for a second tank or the existing tank is large 60 80 gallons Self Pressurizing Unit Auto Radiator Cap Radiator a ee _ AAA 4446 EOE CEEEE Overflow Flat Plate Solar Collectors PV Panel E Glycol Solution in Loop ci Flush Valve ji Pump Isolation Valve Or Pressure Shut Temperature Gauge Off om COLD HOUSE HOT Fill Drain Valve Wa Gauge a Pump Anti Scald ee et l A Mixing Hi Limit Terminal Cutoff Blockor switch Wa Delta T Controller VALVE KEY Glycol Loop p im Open 4 Closed Drain Conventional Water Heater solar Assisted Hot Water Closed Loop Self Pressurized 16 psi Screw In Wand Heat Exchanger Figure 1 2 Solar Assisted Hot Water System Single Tank Installation The Solar Assist configuration does not deliver as
46. ble walled In Your Tank heat exchanger The heat transfer system utilizes a pressurized 16 psig low volume antifreeze filled fluid loop similar to automobile cooling systems The heat transfer fluid is ASTM D5216 propylene glycol commonly used in automobile radiators Heat exchange from the collector heated fluid to the existing hot water tank is accomplished using the screw in Solar Wand The Solar Wand is a double walled copper and brass in tank heat exchanger of the American Water Works Association AWWA Class DWP Double Wall with leak Protection The heat transfer fluid is channeled from the solar collector to the Wand heat exchanger via thin walled small diameter 3 8 copper tubing The copper tubing is run side by side with small plastic standoffs to limit tubing to tubing contact Both tubes together are insulated with closed cell rubber foam insulation to form a collector to hot water tank umbilical which includes all electrical and fluid connections Sensor wiring is attached to the outside of the rubber foam insulation to allow collector temperature sensors to be connected to the controller or photovoltaic panels to the pump The circulation pump is a seal less low flow low power low noise centrifugal pump The systems can be controlled in two ways The first controller type uses a conventional Delta Temperature controller The system controller uses temperature sensors on the collector and at the to
47. blue ring or the letter C embossed in the sheet metal near it If these identifiers are missing do the following to find out which one is hot Turn on a hot water faucet in the house and then carefully determine which one is hotter with a thermometer or other safe means The hot water outlet will be hot CAUTION DO NOT TOUCH THE HOT WATER OUTLET The cold water inlet will be cold Mark them hot and cold with an indelible marker or other suitable label NOTE HOT WATER OUTLET IS THE CONNECTION INTO WHICH THE WAND HEAT EXCHANGER FITS DO NOT TRY TO INSTALL THE WAND IN THE COLD WATER INLET CONNECTION IT WILL NOT FIT NOTE IT HAS COME TO OUR ATTENTION THAT SOME HOT WATER TANKS HAVE NECKED DOWN REGIONS BELOW THE THREADS ON THE HOT WATER OUTLETS THIS REQUIRES THAT THE NECKED DOWN REGION BE FILED OFF BEFORE THE WAND CAN BE INSTALLED SEE FIGURE 2 2 NOTE BRADFORD WHITE TANKS HAVE A SACRIFICIAL ANODE UNDER THE HOT WATER OUTLET NIPPLE AND ATTACHED TOIT INSTRUCTIONS FOR INSTALLING THE SOLAR WAND ARE IN FIGURE 2 3 3 2 Cold Water Supply This is where the cold water from the street or other house supply enters your hot water tank It should have been identified and labeled as outlined in section 3 1 above The cold water supply should have a shut off valve at or near the hot water tank It there is no shut off valve E one must be installed to be OG 300 compliant see Figure 2 0 3 3 Cold Water Distribution Tube This is a plastic or meta
48. conduction which then heats the water inside the hot water tank The fluid is cooled by about 15 F 8 3 C Upon exiting the Heat Exchanger Wand 1 the fluid heads back to the circulation pump Once safely back in the circulation pump the fluid is ready to go around again and again etc The average fluid temperatures in the heat transfer loop are typically 180 to 200 F 82 to 93 C near solar noon and lower earlier and later in the day 44 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 4 2 Stagnation Another mode of operation takes place when you do not use the hot water in your tank such as when you go on vacation The hot water tank is protected from getting too hot by the control system The thermistor measuring the tank temperature tells the controller the tank does not need any more heat and then the controller shuts off the circulation pump This is a limit adjusted into the controller when the system is installed For PV powered systems there is a thermal cut off switch on the hot water tank that will shut off the pump if the tank gets too hot Refer to Figure 2 4 which shows the Self Pressurizing Units operation With circulation stopped the fluid in the collector gets hot enough to boil at 124 C 256 F at 16 psig pressure The built in liquid to air radiator 2 a between the solar collector and the Pressure Vacuum Cap 2 b condenses the s
49. d Heat Exchanger Type Wall Material Protection Failure Indicator Placement Lengths Removable Heat Exchanger Area Connection to Solar Loop Normal Fluid Loop Temp 1 Gallon of Antifreeze 50 Propylene Glycol 50 Water by Volume Gosselin Rating below One Objectionable but not dangerous to health 32 C 26 F 124 C 256 F 2 to 16 psig Brushless DC Seal less leak proof Linear Current Amplifier External Built In 15 Watt DC Peak Rated 1 x 12 x 48 20 Watt DC Peak Rated 1 x 18 x 36 Laing Pump Built In or Separate Check Valve Brass amp Stainless Steel Sun on PV Panel or Delta T Controller 140 F 180 F Snap Switch or Thermistor 25 Feet Standard 150 Feet maximum recommended Two 3 8 Copper Refrigeration Tubes 032 Wall Spaced 1 8 apart Every 6 to 10 along the length 1 2 Wall Closed Cell Rubber Foam Rubitex Armacel 3 Conductor AWG 18 Outdoor Cable 2 ABS Spit Pipe and Elbows Double Walled Protected AWW A DWP Q32 inch Thick Copper Walls No leak of Propylene Glycol into Drinking Water Tell Tale Appearance of Water or Glycol near top of Wand Outside of the Water Tank Threads Into 3 4 FNPT or 1 FNPT Hot Outlet of Water Tank Wands 46 and 36 Tank Inside Bottom to Top of Outlet Threads 46 1 2 36 1 2 Can be Transferred to New Hot Water Tank 2 Sq Ft and 1 6 Sq Ft 3 8 Copper Tube Compression Fittings Both Inlet amp Outlet
50. duce the possibility of electrical shock Plug in ground fault interrupters which protect the controller do not require an electrician and provide electric shock protection 55 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 8 0 Service and Replacement Parts As you can see from the parts list below most of the spare parts are available from local supply stores and are stocked on their shelves for immediate delivery The manufacturer or their outlets must provide only a few parts These would need to be ordered and shipped which takes time These systems are easy for Do It Yourselfers or contractors to maintain and fix The systems are designed to need very little service but if they do the parts are readily available Table 8 1 is the System Parts List located on the next page The Manufacturer dealer distributor supplied Replacement Parts are as follows Solar Wand Solar Pump Solar Liquid to air radiator with filler neck attached Solar Collector PV Panel Solar Delta T controller Solar Delta T controller sensors Hardware Store Supplied Replacement parts e g Home Depot Lowes Ace etc Flexible hot water outlet line from hot water tank to house 3 8 inch copper tubing Rubitex R or Armaflex R pipe insulation 3 8 inch compression fittings Black ABS drain pipe Teflon Tape Control Wire Collector glazing Collector insulation e Solder and copper splic
51. e time If any leakage is detected tighten the compression fittings and check the fluid level refilling if necessary CAUTION NEVER OPEN THE RADIATOR CAP WITH THE SYSTEM HOT OR WHEN THE SUN IS OUT SCALDING STEAM CAN ESCAPE AND BURN YOUR SKIN 49 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL HINT PUT A BLANKET OVER THE COLLECTOR AND LET IT COOL OFF BEFORE OPENING THE RADIATOR CAP TO ADD FLUID DIRECTLY INTO THE SYSTEM 5 3 Replacing the Heat Transfer Fluid We recommend a fluid change once every 5 years over the life of the system There are two ways to do this The first uses an external fluid pump the second uses gravity Following these steps will make it go smoothly All of the numbers are referenced to Figure 2 0 page 17 5 3 1 Changing the Fluid With an External Pump 1 Disconnect Power to the Circulation Pump 5 in Figure 2 0 2 Connect the manual or electric system filling pump output to the Flush Valve 12 with inch diameter plastic tubing Connect the pump inlet to a length of 4 inch diameter plastic tubing and place the other end at the bottom of the container with the propylene glycol water 50 50 antifreeze solution 3 Remove the Pressure Gauge 9 and connect a length of 4 inch diameter plastic tubing to the Fill Drain Valve 11 and place the other end in a suitable container to catch the drained antifreeze solution 4 C
52. ector fluid to the bottom of the Wand near the bottom of the hot water tank This tube is enclosed in second tube the first wall and the hot fluid flows up the annular space between the inlet tube and second tube A third tube second wall is spiral collapsed on the second tube making mechanical contact for heat transfer over about 60 of the wall and leaving an air space The third tube is vented on top of the wand so any fluid between the second and third tubes is vented to atmosphere This assembly is inserted in the hot water tank by being screwed into the hot water outlet port The wand is designed to meet the requirements of the AWWA Class DWP Double Wall with leak Protection Class DWP Provides two distinct walls which separate the transfer medium from the potable water and a path to atmosphere Failure of either wall is indicated by visual leakage of the transfer medium or potable water and indicates a failure of the heat exchanger The DWP type provides a higher degree of protection than the SW Single Wall with no leak detection or DW Double wall with no leak detection The solar Wand is designed so a single failure of any fluid barrier will not cause a cross connection or permit back siphoning of heat transfer fluid into the potable water system 13 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Any barrier which fails allows the disc
53. ed Parts ccccceccccceeeeeeeees 56 5 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision ABS ASTM AWG AWWA DWP GPS Insolation NPT pH psi psig psia PV SOF Stagnation SRCC UV BULTER SUN SOLUTIONS SERVICE MANUAL 9 07 2007 ACRONYMS Acrylonitrile Butadiene Styrene a tough light UV and water resistant plastic pipe UV Ultraviolet light American Society for Testing Materials American Wire Gauge American Water Works Association Double Wall with Leak Protection Global Positioning System which measures compass heading and Latitude Power coming from the sun 1 000 Watts m at solar noon May also be annual daily average which for San Diego is 6 5 kWh m 7 day United States National Pipe Thread Standard Log Scale of H ion activity 1 to 6 is Acidic 7 is neutral and 8 to 14 is Basic Pounds Per Square Inch Pressure Pounds Per Square Inch Gauge or psi above Atmospheric Pressure Pounds Per Square Inch Absolute Photovoltaic Panel Solar Orientation Factor shows solar system performance as a function of Tilt angle and East West orientation The condition where solar energy is being absorbed in the solar collector and there is no fluid flow to remove the heat Solar Rating and Certification Corporation Solar Ultraviolet Radiation which degrades unprotected plastics 6 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System BULTER S
54. el Fluid OK C dei A woke Add Fluid Cei i 1 ee en oo a Float Level Switch Overflow Reservoir Roof Water Tank Check Fluid Level 380 Ohm When Illuminated Resistor Tank Top High Limit Normally Closed Butler Sun Solutions Wiring Diagram for PV Powered Pump with Snap Switch High Limit And Float Level Minder LED System Figure 2 8 Typical Wiring Diagram for PV Powered System 2 3 4 Split Pipe When the umbilical is routed outside where it can be exposed to the weather it must be protected from the elements This is accomplished by using Standard 5 08 cm 2 inch diameter Black ABS drain pipe as a protective covering which prevents the sun s ultraviolet rays from destroying the rubber foam insulation The ABS pipe can be slipped 27 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL over Straight sections before they are bent or split and fit over the wire insulation and tubing The couplings are split by sawing and placed around the bends and glued or mechanically fastened in place NOTE CARE MUST BE TAKEN TO BE SURE THAT WATER WILL NOT BE TRAPPED INSIDE THE ABS PIPE COVERING SINCE IT IS NOT WATERTIGHT DRAIN HOLES MUST BE DRILLED AT ALL LOW SPOTS TO ALLOW THE WATER TO DRAIN The pipe protects the insulation and wire from Ultraviolet radiation and shields it from rain and moisture The pipe is a weather shield not
55. em Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 3 2 Umbilical Insulation The trade term for the insulating rubber foam material is Rubitex or Armacell This type of insulation is resistant to moisture and is a closed cell type which does not allow moisture to penetrate or be absorbed The rubber foam pipe insulation is split along its length with an adhesive to close the insulation around the pipe Once the copper tubes are in place and next to each other the insulation is wrapped around them and the insulation bonded together along its length Electrical tape is used to attach the electrical cable to the outside of the umbilical at 0 46 m 18 inch intervals to make a neat installation 2 3 3 Umbilical Wiring The cable which comes from the roof to the hot water tank serves two different functions Carrying solar collector output temperature sensor data for the 115 VAC systems DC power from the PV panel and float level signal for both systems We recommend that two three wire extension cords be installed in parallel when the system is first putin This pair of cords gives three pairs of AWG 18 wires two wires for a temperature sensor two wires for the overflow float level indicator and two wires for PV power plus and minus One cable three wire electrical schematics are provided but we recommend as two cable set up since the cable is cheap and easy to run at this stage and very costly to install later For
56. er pool or spa test strip and a small amount of fluid from the system If the pH changes to 7 or below the antifreeze must be changed The reason for this is that acidic antifreeze will corrode pin holes in the copper tubing and solar collectors If the antifreeze needs replacing follow the procedures outlined in 2 12 2 1 for gravity change or 2 12 2 2 for external pump change Draining or Pumping should continue until the new fluid container is near empty and the disposal container is near full A typical system with 4 square meters 40 square feet of solar collectors and balance of system contains about 4 Liters 1 gallon of antifreeze Recover the spent fluid into a suitable container for recycling or proper disposal 2 12 4 Pressure Gauge Attachment to System The Fill Drain Valve 11 in Figure 2 0 is on the outlet side of the circulation pump Once the pressure gauge is attached to it the valve can be opened and will allow the pump outlet pressure to be read on the pressure gauge 9 Turning the pump on and off will change the gauge pressure by a small amount usually 1 to 2 psi The easiest way to determine if circulation is occurring 1s to quickly close the Pump Isolation Valve 13 if fluid is circulating the pressure gauge will spike up by about 5 psi then settle back to 1 to 2 psi This ping test uses the momentum in the moving fluid to create the spike in pressure when the fluid flow is quickly blocked hence it is the best test fo
57. es for collector tubing Auto Parts Store Supplied Replacement Parts e g NAPA Kragen Checker etc e Radiator Cap 16 lb Non Vented Type only e Propylene glycol Antifreeze e g Peak or Sierra brands Table 8 1 Parts List for Collector Kit amp User Supplied Parts Parts List for Collector Kit REPLACEMENT LABEL DESCRIPTION PART g oE In Tank Heat Exchanger Wand 1 010 00 Self Pressuring Unit Liquid to Air 2 a b amp c Radiator including filler neck and 1 002 20 BSS Fluid Overflow Recovery System 2 b A Y a OT Gap 1 004 00 BBS Auto Parts Store 16 non vented 56 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Insulated Flexible Umbilical Bee Rubitex R Insulation Hardware Store sane Signal Wire ppt Arete Hardware Store Copper Tubing Hardware Store 3 d 2 ABS Split Pipe and Elbows 1 005 00 A Solar Collector OG 100 Certified 1 001 20 BSS 5 Pump low flow seal less 1 009 00 BSS 6 Delta T Controller 1 003 00 BSS S 6 a b_ Thermistor Sensors 1 011 00 Bss Propylene glycol Antifreeze n 8 Mixed Equal Parts with Water 1 006 00 IBSS Auto Parts Store PV Panel 1 012 00 BSS o oo Butler Sun Solutions ti User Supplied Parts i ee New Flexible Hot Water Outlet Pipe Teflon Tape for Threaded Joints Black Electrical Tape Wire nuts or electrical Solder Plumbers Lead Free Solder
58. es out Pump not moving Fluid Air has been sucked into Check for fluid level in the Pressure gauge does not go up the system from the overflow reservoir If it is by 2 psig when pump is turned overflow reservoir very low check for leaks and repair them before filling Place thermistors in the correct locations Pump Plug a lamp into the proper locations of the controller outlet and be sure it collector and hot water lights tank Check to be sure that the Attach to correct terminals Thermistors are connected to the proper terminals on the control board Check the Thermistors for Replace bad thermistors Resistance Versus Temperature Room Temp resistance 10 000 Ohms Check for Thermistors Tighten connections connections to be sure they are tight Controller is bad Replace bad controller 5 2 Checking the System for Leaks Check connections for fluid leakage or seeping This is easily spotted as a green fluid or a dried green buildup near joints There are only four joints at the water tank and two at the collector If there are joints in the tubing between the collector and the hot water tank the contractor will identify them and you may have to remove insulation to see them Joints in the umbilical should be coupled using a sweated solder joint This could be accomplished by using a tubing expander to make the slip in fit like refrigeration systems use or could be a coupling where both ends slide in and are sweated at on
59. essure amp Vacuum Cap P4 Auto Radiator Cap G Liquid w to Air Radiator _ ___ __ __ __ A Pressure Relief Valve 16 psig 5 Wz Fluid Overflow Reservoir Antifreeze Fluid 2 psig Fluid 8 Level 7 Sensor Figure 2 7 Parallel Pressure amp Vacuum Relief Valves Inside the Radiator Cap 2 2 4 Fluid Overflow Reservoir amp Recovery System This reservoir is there to catch any fluid forced out of the heat transfer loop by thermal expansion or boiling in the loop The reservoir is maintained at half full normally and the fluid from the heat transfer loop enters and exits from the fluid reservoir at the bottom below the waterline Hence once all air has been expelled from the fluid loop the coolant recovery system keeps air from getting back in Just like in your automobile s radiator this lowers the corrosion rate in the fluid loop CAUTION ONLY OPEN THE RADIATOR CAP WHEN THE SYSTEM IS COLD IF YOU MUST OPEN THE RADIATOR CAP WHEN THE SYSTEM IS IN OPERATION WEAR LEATHER GLOVES AND FACE SHILED TO AVOID SCALDING YOUR ARMS HANDS AND FACE The overflow reservoir fluid level is measured by a float switch 17 When the fluid reservoir 1s low the switch turns on the red LED check fluid level light at the hot water 24 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL tank Fluid can be pumped in from the fill drain valve o
60. f 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL SYSTEM OPERATION amp MAINTENANCE 1 Temperature Gauge Reading Below 100 F Noon a Low Fluid Level Fill Overflow Reservoir b Pump Not Running Verify by Feeling Plastic Housing for Vibration c Check for Leak in Overflow Reservoir 2 Water Temperature From Mixing Valve is Too Low a Be Sure that the Hot Water Tank is Hot b Remove Anti Scald Valve Disassemble and Soak in Vinegar Water Solution c Follow Disassembly Diagram 3 When Sun Not Available and Hot Water Tank Is Cold a Electrical Heating Elements Have Been Shut OFF by Solar Heated Water Tripping the Manual Reset Thermal Overload RED Button on the Top Heating Element PRESS RESET then Lower Solar Cut OFF Setting For Gas or Propane If Pilot Is Out Relight If Pilot is ON but Burner Will Not Come On the Fusible Link in Your Gas Control Valve has Melted Replace or Repair with Approved Parts T screw HAN DWHEEL HANDS HEL STOR FPERMT Linh KAT ea SEL TOP ARSE LOWEE ASSEMBLY MM a Bo VAULE BOLIT www butlersunsolutions com Figure 5 2 PERIODIC MAINTENANCE amp INSPECTION 1 Check the Temperature Gauge to Verify Proper System Operation Daily Weekly or Monthly ON A SUNNY DAY CHECK THE TEMPERATURE GALEGE BETWEEN TRAM AND 2PM GOOD SYSTEM I MOT WORKS RECHARES MAINTENANCE
61. h a set of isolation valves so it can be serviced or replaced without draining the fluid from the solar system Laing Spherical Motor Pump for Low Voltage amp PV Power Including Anti Backflow Valve Isolation Ball Valve amp Air Bleed Electronic Magnet amp OUT Impeller Impeller i Driver Rotor O Ring A Anti Ring Flow ae Backflow N 1 Valve SS Air Bleed Locking Isolation Ceramic Ball Rotor Valve Bearing Linear Current Amp LCA Solar Pump LAING ecocirc solar Max Liquid Temp 230 F Impeller Driver 3 600 RPM Max Head 9 feet Construction Bronze Stainless Steel Ryton a Dimensions 4 1 2 Tall Inlet to Outlet fT el Pr i 3 Wide Electronic Ly 5A 4 Deep D 4 or D 5 h A le D 5 12 16 20 24 VDC Built in Linear Current Amp LCA Impeller i A fs D 4 12 18 VDC External LCA Needed for PV Starting Driver al LCA PPT 12 24 3 Solar Converters Inc sci sentex net Laing Thermotech Inc 830 Bay Boulevard Ste 101 Chula Vista CA 91911 USA Voice 619 575 7466 Fax 619 575 2739 customerservice Lainginc com or www lainginc com Butler Sun Solutions Service Manual 2007 Figure 2 10 Laing Seal Less Solar Circulation Pumps Delta T controllers that operate on 115VAC are sometimes preferred over PV panels to operate low voltage DC pumps If a Delta T controller is used to switch a LISVAC pump electrical outlet on and off then a Class I 115VAC to 13 to 18 VDC tr
62. harge of exchanger fluid and or potable water to the atmosphere at a location visible to the operator or owner 1 1 9 Freeze Tolerance Freeze Tolerance Limits The system is designed to operate to 32 C 26 F with the normal 50 50 propylene glycol water mixture Below that temperature slush will form which will not circulate but will not damage the collectors until 48 C 54 F To operate at 48 C 54 F a 60 propylene glycol 40 water mixture would be required Minimum Operating Temperatures e Propylene glycol water 50 50 32 C 26 F e Propylene glycol water 60 40 48 C 54 F 1 1 10 Boiling Tolerance The system is pressurized to 16 pounds above atmospheric pressure 16 psig during operation using a standard automobile radiator cap The antifreeze mixtures have the following boiling points e Propylene glycol water 50 50 124 C 256 F 16 psig e Propylene glycol water 60 40 127 C 261 F 16 psig Boiling activates the liquid to air radiator which limits collector boiling temperature by transferring solar heated steam from the solar collector to the radiator where it is convected to the surrounding air A small amount of liquid will be expelled from the system then boiling and the condensing of steam forms a heat pipe between the solar collector and the liquid to air radiator This heat pipe action limits the temperature in the collector to the fluid boiling point listed above since the pressure is fixed at
63. he Flush Water 39 Anti SCald Maxine Val Ve such cations tose dus viseiaaceadsinantveaciierBaadiancareigenederiant avis 4 System Operation Analysis With Temperature Gauge ccccceeeeees 46 Maintenance Card to be Placed On Customer s Water Tank 47 Collar Sign on Solar Wand To Alert Plumbers cc ceeeceeeeeeeeeeeees 47 Hot Tub Showing Umbilical Coming Down Wall and Into Hot POD eerie gies Weeder atoessadeaieyeans ages igecaaeeaan etree se emer ceen eee 64 Single Wall Solar Hot Tub Heat Exchanger ccccccccssssesseeeeeeeeeeees 64 HOt PUD System SCNE MAL Cpu tinea sue muiansneuewendues thus ee eer eetewits 65 LIST OF TABLES Certified System Designations sanie a a E a 7 3 8 Diameter Refrigeration Tubing Specifications ccceeeeeeeeeeeeeeees 29 Properties of DC Seal less PUMPS accented tena here is 31 Materials In Contact With Heat Exchange Fluid ec cccceeneeeeeees 32 Solar Butler 1 0 Controller State Table forl15 VAC System 0 33 Thermistor Temperature vs Resistance cccccscccccceecceesseeseeceeeeeeeaeeeees 34 Solar Butler 1 0 PV System Controller State Table eeeeeeeeees 35 Physical Properties Of 50 Propylene Glycol 50 Water Mixture By Vole eera nie eee seen a E senescent 36 Troubleshooting the SYSTEM siri eseri EA DRENE 48 Specific Warning Labels for Solar Butler 1 0 System ee 53 Parts List for Collector Kit amp User Suppli
64. he cap pressure Hence heat transfer fluid pressure at the tank gauge would be about 26 psig so fluid would leak out to atmosphere and provide maximum anti siphon protection If the passages to atmosphere were all blocked by accident and both heat exchanger walls were breached potable water usually greater than 50 psig would flow into the collector loop and out the pressure cap The leak on the roof would soon be spotted and the system repaired without contamination of potable water CAUTION FOR ROOFS HIGHER THAN 66 FEET THE COLLECTOR LOOP PRESSURE AT THE WATER TANK COULD EXCEED 50 PSI THE DOUBLE WALL ISOLATION PASSAGES TO ATMOSPHERE MUST BE CHECKED ANNUALLY TO ASSURE NO BLOCKAGE 1 1 13 Leakage Leakage of the heat exchange fluid is not a major problem because there is usually less than two gallons total Leaks can be cleaned up with absorbent towels or kitty litter and disposed of in the trash Leakage of potable water would only occur at the solar Wand There it would come out the small opening in the top of the Wand It would then run down the side of the water tank into the drip pan or onto the floor It would be visually detected This would signal a damaged Wand heat exchanger which would need to be replaced To restore hot water use until a new Wand is installed the damaged Wand should be removed and the hot water pipe reconnected to the hot water tank just as it was before the original Wand was installed HINT SAVE THE ORIGI
65. higher loop temperatures dramatically decrease system performance The Solar Wand should only be used with selective absorber surface solar collectors All SRCC OG 100 certified collectors meet the above criteria and also must have passed a cold water shock test where cold water is sprayed on a collector stagnated by solar heating without fluid flow SRCC certified collectors must also pass a 30 day stagnation test without fluid loop degradation or other collector damage 2 5 Circulation Pump The circulation pump provided is of the seal less centrifugal type The magnetic rotor is driven by chasing an electronically created rotating magnetic field which is transmitted through a thin stainless steel wall The electronics are on the outside of the wall and the pump rotor impeller is on the inside with the heat transfer fluid so the electronic pumps 29 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL have no external bearings to lubricate or wear out Information on seal less pumps is provided in Figures 2 10 and 2 11 There is no rotating shaft seal in this type of pump to wear out Motor driven seal less pumps use an armature and bearings to create a rotating magnetic field with permanent magnets on the outside of the thin stainless steel wall The DC solar pumps are designed for 150 psi pressure and 230 F operating temperature The pump is supplied wit
66. is method to fill before the collectors could cool off too much You will need to have access to the roof to get to the Self Pressurizing Unit filler neck and reservoir a container of antifreeze mix which is greater than the system volume usually one to two gallons and the rubber stopper with siphon tubing to replace the radiator cap This arrangement is shown in Figure 2 12 Mix up a gallon of 60 40 propylene glycol water mixture by volume The higher concentration is needed so water not flushed from the system will not dilute the mixture below 50 50 If your climate requires higher concentration start with an even higher initial concentration mixture Remove the radiator cap and place the stopper in the filler neck as shown in Figure 2 12 Place the other end of the Stopper Siphon tube into the bottom of a to 2 gallon container of antifreeze Now as water is drained from the system antifreeze mixture will replace it At the water tank close the Pump Isolation Valve 13 in Figure 2 0 and open the Wand Isolation Valve 14 in Figure 2 0 Connect a 1 4 plastic tube to the Flush Valve 12 in Figure 2 0 and put the other end into a clean pail or other container OPEN the Flush Valve 12 to drain out fluid until it changes from clear water to the color of the antifreeze being added at the filler neck and then CLOSE the Flush Valve 12 OPEN the Fill Drain valve 11 in Figure 2 0 to drain out fluid until it changes from clear water t
67. l pipe which directs the incoming cold water to the bottom of the hot water tank Since hot water rises the cold water must be sent to the bottom of the tank so the tank remains stratified Stratification means that hot water because of its lower density rises to the top of the tank and cold water because of its higher density settles to the bottom of the tank Hot water for home use is taken from the top of the tank 42 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 3 4 Hot Water Tank Overpressure Over temperature Relief Valve This is a special protection valve mandated by plumbing code to keep your hot water tank from exploding if it boils due to the heating element being stuck in the on position CAUTION DO NOT TAMPER WITH THIS VALVE OR REMOVE IT FOR HEAT EXCHANGER WAND INSTALLATION 3 5 Cold Water Shut Off Valve In most houses this is located at the service entrance to the house and shuts off water to the entire house Some houses have a shut off valve between the house service entrance and the hot water tank Locate this valve and mark it You will need to shut off water to the tank for a short time during installation of the Wand heat exchanger SRCC OG 300 requires that a valve be installed in the cold water line before the hot water tank if no service entrance valve exists and water can only be shut off at the street tap 3 6 Drain Valve
68. light tank Check to be sure that the Attach to correct terminals Thermistors are connected to the proper terminals on the control board Check the Thermistors for Replace bad thermistors Resistance Versus Temperature Room Temp resistance 10 000 Ohms Check for Thermistors Tighten connections connections to be sure they are tight Controller is bad Replace bad controller Pump not on Controller red Pump is not operational Repair or replace pump LED is on and Controller outlet is Live PV panel to pump connection Bad electrical connections Solder All Connections or Polarity Reversed Verify Polarity with a DC Voltmeter Pump electronics driver Check pump LED S and for Replace pump electronics vibration Pump Impeller Check impeller is free and Clean impeller of debris If not rubbing against the rubbing the walls the bearing walls or debris is bad replace the impeller reads below 60 C 140 F Pump not moving Fluid Air trapped in the Pump Put a blanket or cover over the Pressure gauge does not go up solar collector After collector by 2 psig when pump is turned cools off drain one pint of on fluid out using drain valve and fill from radiator cap Check for circulation using the 48 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Pressure Gauge Plug and unplug pump several times to move air bubbl
69. m but checking the resistance from the controller will tell you if the sensor is giving the controller the correct reading We recommend that all leads to and from the temperature sensing element be soldered to the leads to the controller No wire nuts or crimped 33 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL connections should be used which can hold moisture and allow the electrical contract between the wires to corrode adding resistance to the sensor electrical circuit which will be read by the controller as a decrease in the measured temperature If the wire corrodes completely through and breaks the circuit the controller thinks the solar collector is always below 50 F and will keep the pump off If the tank sensor wire corrodes through then the controller thinks the hot water tank is below 50 F and will keep the pump on all of the time day and night Some of the newer controllers are using more accurate temperature sensors such as platinum resistance thermometers wire wound resistance elements semiconductors and thermocouples These sensors are more expensive but much more accurate with accuracy of plus or minus 1 2 Table 2 5 Thermistor Temperature vs Resistance Degrees Fahrenheit Ohms 50 491 400 25 196 450 0 85 378 29 39 919 50 19 900 75 10 500 100 5 827 125 3 382 150 2 044 175 1 281 200 829 225 553 250 378 2 6 1 1
70. m the bottom of the dala Ouisice 3 8 Copper Tubing Ce Inside o ji overflow reservoir into the closed loop The liquid to air EF o lt Flush radiator limits the antifreeze temperature to 250 F 5 piece te Ne Pump Valve minimizing corrosive acid formation Q Isolation Q z Valve Fill Drain kabia Flush PUMP Fill Drain ee Isolation go Pressure Gauge Valve yal Valve ii a Daa Pressure i El Sid PV 10 Temp Gauge Thermal Collectors Hot Out Wand Isolation Valve In Wand lsolati eh Flush amp Fill Kit Pour amp Cap Double Wall HX 16 psi Cap TTT ATTN vo Standard Water Heater Tank Self Pressurizing Unit Drain I Includes Pressure Temp Expansion Contraction Air elimination Insulation Figure 1 1 Pictorial View of Solar Butler 1 0 System 9 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL sun is out This system requires no outside source of power but costs a little more up front The solar collection and delivery parts of the hot water system are simple using about the same amount of copper as your automobile radiator roughly 35 pounds This allows the system to be low in cost Potable water sees only copper tin based lead free solder and silver solder on the solar wand The antifreeze heat transfer fluid is contained in m
71. mitigating the risks identified below If you feel unqualified to assume these risks we recommend that you hire a licensed contractor who is experienced with roof mounted solar installations 7 1 Drinking Water Contamination Hazard The system is designed to prevent cross contamination of the heat exchanger fluid with potable water If water or heat exchanger fluid begins leaking from the top of the heat exchanger wand that means corrosion has breached a heat exchanger wall Even though one wall is still intact the heat exchanger should be removed immediately and replaced with a new one as soon as possible 7 2 Hot Water Scalding Hazard Hot water can scald you Hot water can also be under pressure and squirt out Wear leather gloves to protect your hands and Safety glasses or a face shield to protect your face when opening the Hot Water Tank Drain Valve and removing tank inlet or outlet fittings CAUTION ALWAYS TURN OFF THE POWER AND OR GAS TO THE HOT WATER TANK ALLOW THE WATER TO COOL OFF AND RELIEVE PRESSURE TO THE TANK BEFORE LOOSENING ANY PIPE CONNECTIONS ALWAYS ATTACH A HOSE TO THE DRAIN VALVE BEFORE OPENING 7 3 Ladder Hazard Working on ladders is dangerous Be sure that the ladder is properly placed and seated on the ground Do not lean back while moving collectors from the ground to roof Do not over reach when running the fluid lines and umbilical Itis safest to have someone hold the ladder 7 4 Falling Hazard Working o
72. n roofs is extremely dangerous and sure footing is required Be sure to wear rubber soled shoes which cover your entire foot and are laced snugly Do not wear sandals or flip flops on roofs Falling to the ground can be deadly Be sure to stay a safe distance from the roof edge Do not use collectors as a support even 1f they are attached to the roof The collectors were not designed to be handrails Plan the installation to place the collector on the roof safely and away from the roof edges 7 5 Electric Shock and Fire Hazards Do not drill into the roof or walls until you have looked or verified using a stud wire amp pipe finder that no pipes or electric lines are in your drill path If you have any doubts about what is inside the wall or roof drill a small pilot hole and look or probe to be sure that it is safe to drill Drilling into electric lines water pipes or gas pipes can be both dangerous and costly to repair 54 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 7 6 Electrocution Hazard Beware of electric shock hazards Do not stand in water and touch electrical components Test the 3 pronged polarized electrical outlet you intend to plug the controller into Using an electrical outlet polarity and fault detector check to be sure that the hot neutral and ground are properly wired A ground fault circuit interrupter outlet 1s recommended to re
73. nd slowly drain fluid from the system If you have the stopper siphon assemble or a second person on the roof they will keep the system full as you drain out the old fluid Once you have drained out the darker old fluid and new fluid appears shut the Flush Valve 12 OPEN the Pump Isolation Valve 13 Go back to the roof replace the original 16 pound cap fill the Reservoir and you are done Properly dispose of the drained propylene glycol water mixture Depending on the local codes the propylene glycol should be disposed of in a dry well or a sanitary sewer not a storm sewer We recommend returning it to an auto parts store or chemical waste disposal site for recycling As an alternative clean up you can use paper towels or kitty litter to soak up the Propylene glycol water and put it into the trash Fluid Quality Toxicity Safe Disposal We recommend a fluid change once every 5 years over the life of the system Under normal working conditions the system has a life expectancy of 35 years CAUTION PEAK SIERRA THE RECOMMENDED ANTIFREEZE COMES WITH INHIBITORS BUILT IN WHICH ARE PET SAFE AND NON TOXIC DO 51 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL NOT BUY ADDITIVES OR COOLING SYSTEM CORROSION INHIBITOR FLUIDS SOLD AT AUTO STORES AND PUT THEM IN YOUR SYSTEM IT VOIDS YOUR WARRANTY AND CAN MAKE THE HEAT EXCHANGE FLUID TOXIC
74. nside the small diameter copper tubing toward the collector This fluid will return to the pump in about one minute The small diameter tubing enters the insulated Umbilical 3 The fluid travels in this insulated tunnel until it reaches the bottom inlet of the Solar Collector 4 The fluid then moves through the collector tubes exposing it to the sun s heat The fluid typically warms up by 15 F 8 3 C going through the collector The protective transparent glass or plastic cover lets the light in and stops air convection from removing the heat The insulation behind the collector tubing keeps the heat from going out of the back of the collector The fluid exits the collector and passes a turn off into the Liquid to Air Radiator 2 a the Pressure amp Vacuum Cap 2 b and Fluid Overflow Reservoir 2 c The fluid has its temperature read for Delta T controller systems by the collector outlet Temperature Sensor 6 a on the outside of the tube and heads back into the insulated Umbilical 3 The fluid then travels in the umbilical to the hot water tank where it has its temperature read and displayed by Temperature Gauge 10 then the fluid passes through the Wand Isolation Valve 14 and then fluid enters the Heat Exchanger Wand 1 The fluid travels down the center of the wand to the bottom and then it turns around and returns in the annular space where it heats the first wall The first wall heats the fluted fins of the second wall by contact
75. o the color of the antifreeze being added at the filler neck and then CLOSE the Fill Drain Valve 11 Reopen the Pump Isolation Valve 13 Reattach the pressure gauge from the Fill Drain Valve 11 and open the valve so the pressure gauge will show the pressure Go back to roof remove the stopper fill the filler neck fill the reservoir at least half full then replace and tighten the radiator cap 38 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Pressure relief Top seal setting spring f aw inlet Vacyu relief Spring Pressurized system Pressure sea Pressurized system Pressure Cap on Filler Neck Filler Neck with Filling Stopper n Over Over Pressure Overflow Recovery Temperature Vacuum Recovery Reservoir Fluid Level Radiator Radiator Cap Float Switch Figure 2 12 Siphoning Antifreeze into the System to Replace the Flush Water 2 12 2 2 Fillmg The System Using An External High Pressure Pump Make sure that the overflow reservoir is empty of water and that the radiator cap is closed tight At the water tank close the Pump Isolation Valve 13 and open the Wand Isolation Valve 14 Connect a 4 plastic tube from the high pressure pump outlet to the Flush Valve 12 Connect a 4 plastic tube from the Fill Drain Valve 11 to bucket to hold the water that will be pushed out
76. on Housing Four 40 Sq Ft to Eight 80 Sq Ft 4 per Package FedEx or UPS Ground 10 Sq Ft 20 x72 x3 20 Lbs Thermafin copper with Black Chrome Selective Absorber Serpentine from Headers Double Wall UV Inhibited Polycarbonate Polyisocyanurate Foil faced Aluminum Sheet Metal Dimension for Four Collector Module Arrays Single Column Single Row Two High by Two Wide 80 Tall x 72 Wide 20 Tall x 291 Wide 40 Tall x 145 Wide Alternative Solar Collector Suppliers Sun Earth Flat Plates Thermomax Evac Tubes Empire EC EP 32 Selective Absorber AR Glass Empire EC EP 40 Selective Absorber AR Glass SolaMax Flow in Fin 62 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Mazdon Heat Pipe Sunda Evac Tubes Heat Pipe Apercus Evac Tubes Heat Pipe Filling Procedure Flushing City Water Pressure Filling Gravity Siphon In Antifreeze From Filler Neck on Roof Pump Manual Electric Pump Loop and Fill Overflow System Performance in San Diego CA Energy Produced per Year 14 227 MBTU 2 862 kWh 155 Gallons of Propane System Performance 950 BTU Ft day 2 8kWh m day Latitude Tilt Insolation 1 947 BTU Ft day 5 7kWh m7 day System Annual Efficiency 35 48 for 50 amp 80 gallon tanks respectively Solar Hot Water Daily About 40 Gallons Day Hot Water Needs About 65 Gallons Day for a Family of 4 Solar Fracti
77. on About 60 Provided by Solar Maintenance Operation Check Temperature Gauge Any Sunny Day Fluid Level Check Add Fluid Light 4 Months to Dry Fluid Fill Roof Fill Overflow Reservoir from Float Cap Water Tank Pump Fluid into System to Fill Overflow 63 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 11 0 APPENDIX 1 SOLAR HOT TUB The solar heated hot tubs have become more popular and will be included in full as a part of Revision 6 We have included some materials is this appendix that will help those who are considering hot tub systems A typical hot tub installation is shown in Figure A 1 j a Figure A 1 Hot Tub Showing Umbilical Coming Down Wall and Into Hot Tub The hot tub single wall heat exchanger is shown in Figure A 2 with the large plastic inlet and outlets and the copper fluid loop inlet and outlet Note the warning to keep the pH neutral failure to do so will dramatically shorten the life of the replaceable copper heat exchanger PERIERE PEPE G M HANUFACTURING H KEEP PH AT 7 0 TO PREVENT RAPID CORROSION OF THE COPPER ELEMENT INSIDE eT i a i 7 Sy N l 2 7 Figure A 2 Single Wall Solar Hot Tub Heat Exchanger The Schematic of the hot tub system is shown in Figure A 3 The solar collectors and other working parts of the fluid loop are the same as for the solar hot water system The ne
78. on Valve Shut Temperature Gauge Off mi COLD HOUSE HOT Anti Scald Mixing Valve Pressure Gauge Q Terminal Hi Limit Block or Cut Off Delta T Controller VALVE KEY Glycol Loop gt 4 Solar Tank Isolation Open Drain Solar Storage Conventional Drain HA Closed Tank Water Heater Solar Augmented Hot Water Closed Loop Self Pressurized 16 psi Screw In Wand Heat Exchanger Figure 1 3 Solar Augmented Hot Water System Two Tank Installation 11 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Self Pressurizing Unit Auto Radiator Cap er yy adiator Overflow Flat Plate Solar Collectors PV Panel E Roof Glycol Solution in Loop y 4 Ss Bane de ol Umbilical Tankless Water A e Heater Solar Backup Ready Flush Valve Temperature Gas or Elect Pump Isolation Valve Gauge iy 7 ee Valve m j Boiler Drain Valve Anti Scald gt Fill Drain Valve Wa Pressure og i Gauge HOT HOUSE am COLD Shut Off Terminal Mi Limit Blockor Cutoff Delta T witch Controller VALVE KEY EE Glycol Loop Solar Backup Ready 1 Add less heat to pre heated 2 C water gt 4 Tankless Isolation 2 Add no heat if solar input lt Open Drain Solar Storage water is over 120 F Bosch Aquastar 2585 meets e Closed T
79. ounted to allow for expansion and contraction during heat up and cool down These are the same considerations used by heating and refrigeration technicians to install the pressure and suction copper tubing from the outside compressor condenser unit to the inside evaporator air heat exchanger of a typical home air conditioning system All tubing connectors are standard 3 8 compression fittings A standard tubing cutter and reamer are needed to cut the tubing and open up the end before installing in the connector The compression fittings are tightened using two 6 to 8 inch adjustable wrenches For installations requiring less than 25 feet of copper tubing no soldering of tubing joints is required to connect the heat transfer loop together since refrigeration tubing usually comes in 50 foot lengths For copper tubing runs longer than 25 feet the tubing must be joined end to end Since compression fittings can leak joints in the 3 8 inch tubing that will be in inaccessible places like inside the umbilical insulation should be soldered using sweated joints These joints are common in refrigeration tubing connections and use a swaging tool to expand the end of one tube so the other tube end slides inside and can be soldered for a strong leak tight connection Sweat unions can also be used Table 2 1 3 8 Diameter Refrigeration Tubing Specifications Wall Thickness 0 032 in 25 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water Syst
80. p of the hot water tank to determine when to turn on the circulation pump in the fluid loop to heat the hot water tank If the hot water tank gets too hot the controller turns off the circulation pump The second control configuration uses a photovoltaic panel to drive a 12VDC circulation pump so when the sun is out the pump runs to circulate the heat transfer fluid A cut off switch is used so if the hot water tank gets too hot the pump will be shut off even if the 8 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Ser Tess urizing 1 Unit See Picture Below Auto Cap Tame 16 AAA Uh an odule Gauge Automatic Air elimination Pressure Vacuum StagnationTemperature Control The system is flushed and filled using city water amp pressure Antifreeze fluid is either siphoned in from the radiator filler neck on the roof or pumped in through valves near the water tank As the fluid heats up amp expands the pressure reaches 16 psig Thermal Collector Thermal Collector overcoming the radiator cap spring seal so trapped air amp fluid about 2 oz can escape from the pressurized loop to the bottom of the overflow reservoir where the trapped air bubbles to the surface amp escapes Fluid cool down contraction causes the spring loaded vacuum relief in the radiator cap to open at 2 psi allowing fluid to be drawn fro
81. pansion Tank Thermal Expansion Management In contrast to the Butler Sun Solutions self pressurizing system another type of closed loop antifreeze system in common use today is based upon a bladder lined expansion tank The bladder expansion tank systems do not have automatic air elimination or over temperature protection These expansion tanks are commonly used in hydronic heating systems and have glycol water on one side of the bladder and pressurized air on the other side as shown in Figure 2 5 As the heat transfer fluid expands on heating the bladder is pushed into the air space this raises the pressure slightly because the air space is large compared to the total volume of fluid expansion When the fluid cools off the bladder will contract pushed by the compressed air Since the system is closed any trapped air must be vented by manual valves or special air purging valves If heat transfer fluid flow stops boiling in the solar collectors will raise the pressure in the closed system until the 75 psi pressure relief valve is activated At this point the antifreeze will experience temperatures over 177 C 350 F These temperatures are high enough to cause the normally basic pH 8 6 glycol to break down and form a strong acid pH 5 0 The glycol turns from light green in color to dark brown smells burned and begins to corrode pin holes in the copper tubing containing it If the antifreeze sees these temperatures it must be changed immedia
82. r fluid circulation No pressure rise when the pump is turned on and no 5 psi ping test means that circulation is not taking place because there is an air bubble in the circulation pump system blockage or insufficient fluid in the system Be sure that the Pump Isolation and Wand Isolation Valves 13 14 are open the Fill Drain Valve 11 is open so the pressure gauge 1s reading and that the Flush Valve 12 is closed and the Radiator Cap 2 b is in place and tight 2 13 Circulation Pump Isolation Valves The Pump Isolation and Wand Isolation Valves 13 14 in Figure 2 0 are on the inlet and outlet sides of the circulation pump Once they are closed the pump can be removed from the system for service or replacement The pump removal fluid loss will be refilled with fluid from the overflow reservoir over the next few days of operation Check to be sure the reservoir is full and add fluid if necessary Once the pump is reinstalled then the Pump and Wand Isolation Valves 13 14 can be reopened and the system put back in service The Pump Isolation Valve 13 is closed to flush and fill the system upon installation and to replace the heat transfer fluid every 5 years or as needed AO of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 14 Anti Scald Valve The Anti Scald valve 19 in Figure 2 0 blends cold water from the tank inlet with hot water from the
83. r poured into the reservoir from the top 2 3 Insulated Umbilical including Fluid Tubes amp Electric Lines The umbilical 1s composed of the two 3 8 inch diameter copper circulation tubes 3 a in Figure 2 0 which are surrounded by closed cell foam insulation 3 b that is about 1 27 cm 1 2 inch thick Electrical wires from the roof to the water tank are placed on the outside of the insulation 3 c For protection from the elements and ultraviolet light the entire ensemble is placed inside 2 inch diameter ABS pipe when it is outside or on the roof 2 3 1 Copper Circulation Tubing amp Compression Connectors The copper tubing used to connect the solar collector to the Wand is standard soft copper refrigeration tubing with 3 8 inch outside diameter The specifications are shown in Table 2 1 The tubing is cleaned and annealed to dead soft for ease of running through crawl spaces and attics The fluid supply and return lines are run right next to each other Small plastic clips are used every 15 24 cm 6 inches along the length to keep the tubes from touching each other The copper tubing easily bends around a 0 15 m 6 in radius by hand With a tubing bender radiuses of 0 025 m 1 in can be made easily without kinking the tubing Reasonable care must be used to route the tubing to avoid kinking and over flexing which would cause the tubing to crack then leak The tubing heats up and cools off each day so it needs to be loosely m
84. rie eee ee 54 HO SVC CTROC UG OM Haza ernn cea cs nara cece Bet a asa ce ea naralr ech ON Sra ara 55 8 0 Service and Replacement Parts scccsccccssssssssssssccccccsssssssssssccsssssesssssssees 56 90 Warranty C OVO AGE ssir EAEE Ea E a 58 9 1 SCOPE OF COVE RAGE erson aE a EEAO 58 9 2 WHAT BUTLER SUN SOLUTIONS WILL DO ene 58 9 3 WARRANTY PERFORMANCE Where and How to File Claims 58 9 4 LIMITATION OF LENGTH aaeesssssnsssseeerereresrsssssssssssrssssecerreerrssssssssssanssseees 59 2 WTA rB NOT ON BREE ID ea tata vaete see cesettve cate tencu tate ceuteenece scene ese 59 06 OTHER RIGHTS AND REMEDIES cetacean N 59 10 0 System SPCCIICATIONS 55 sasce ices vevsseh soaks aca sectits ces GecstesGeeetdesuebuasbeviveicencescedeetexeiiestass 61 ILO APPENDIX k SOLAR HOP DUB wissssssssasssdccacis sss sarssssccstesisssaisassacatenssssaisasesas 64 4 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 2 0 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 5 1 Figure 5 2 Figure 5 3 Figure A 1 Figure A 2 Figure A 3 Table 1 Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 2 6 Table 2 7 Table 5 1 Table 6 0 Table 8 1 BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL LIST OF F
85. rs Pe 210 bdo Ea re ane Re eee Nee tees gee amr nr Te eve ae Ist A yee wee 37 210 Temperature Gaule e E T E 37 20 SEAM rai Valya eise A A 37 2 12 Flush and Fill the System Including Flush Valve 37 Z T SMS tine thie Syste siena a a hanen nla nities 38 3 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 12 2 Filling the solar system with antifreeze cc ccccccccccccceceseeeeeeeeeeeeeeaeeeeeees 38 21221 Filling the System Using Gravity sssseseessssssssoeerssssssseserrrsssssseee 38 2 12 2 2 Filling The System Using An External High Pressure Pump 39 2 12 3 Heat transfer fluid replacement every 5 years cccceccccsssseeeseceeceeeeneeeeeees 40 2 12 4 Pressure Gauge Attachment to System s ssseeessssssssoeerrssssssseeerrssssssseeeeres 40 2 13 Circulation Pump Isolation Valy eSsznemenyee a einer eee eee 40 ZA Ani Scald Val yenereananria a e 4 3 0 Water Tank Nomenclature sesiones aanas 42 3 1 Hot Waer ome heseen aa a etoile ees 42 32 old Wr SUPP ae A a 42 3 3 Cold W ater Dist bution TUD a uacteeerieaeiehs 42 3 4 Hot Water Tank Overpressure Over temperature Relief Valve 00 43 3 5 Cold Water SNURO ViVe caiiran naciieinasaanaigsousautesaandadtinboreestnis 43 a DN AU E ea E E E iene 43 3 Gas Burner or Electric Heating System erien Ta 43 AY System Operatoren ienne esae eneee E A Aara EEEE EE 44 4 1 OPE
86. s a photovoltaic panel with a power rating of at least 20 Watts and not more than 32 Watts The 20 Watt panel will begin pumping later in the morning and stop earlier in the evening than the 32 Watt panel The pump will begin pumping after the sun is about 20 degrees above the East horizon pump the heat transfer fluid all day a little faster at noon and stop pumping when the sun is about 20 degrees above the West horizon This matches the solar input and allows for the solar hot water system to work without being connected to an outside power source The PV panel option is more popular since it is simple and reliable and does not require any external power from the house If there are trees or buildings which will shadow the PV array during normal sun hours then 115VAC powered Delta T control would be recommended 35 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL 2 8 Heat Transfer Fluid The heat transfer fluid is a propylene glycol water mixture which is commonly used for automobile antifreeze coolant A propylene glycol water mixture will not poison pets or people and is non flammable and non toxic Propylene glycol is an American Water Works Association AWWA Class II fluid This means that it has a Gosselin toxicity rating below 1 Class II material are considered non potable and may be objectionable but not dangerous to the health of pets and people
87. switch on the hot water tank as shown in Figure 2 11 The high temperature limit switch is placed at the same location as 6 b but it is a thermally activated snap switch or thermally activated transistor switch which is adjustable and usually set so it opens at 185 F 85 C and closes at about 165 F 74 C The thermal switch is wired in series with the PV panel and circulation pump motor Hence if the switch is open the circulation pump will not run Simple linear CMOS semiconductor controllers are also being tested which will use the power from the Photovoltaic panel to power a simple controller which uses a thermistor temperature sensor on the top of the tank to activate a transistor switch to turn the pump on and off Table 2 6 Solar Butler 1 0 PV System Controller State Table SYSTEM SENSORS PUMP STATE STATE ACTIVE SOLAR IF The sun on the PV OPERATION panel is intense enough to run the pump OVER IF Tank top temperature TEMPERATURE above maximum limit 185 F 71 C 2 7 Power sources 115VAC or 12VDC There are two recommended power sources The first is a standard power outlet 115VAC with GFI Ground Fault Interrupter properly wired and tested This should be a 3 wire grounded outlet An outlet tester should be used to verify that the outlet is working properly A Class II transformer can be used on the controller outlet to convert the 11SVAC output into 18 VDC for powering low voltage pumps The second power source i
88. t Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL TABLE OF CONTENTS 1 0 Solar Rating and Certification Corporation SRCC Compliance MPP ORM AION sste cotwcenaieccdeevevsustvaavs dees cstwetvaiaesdacuswaustnesecsdadscstiacresues 7 1 1 Butler Sun Solutions SRCC OG 300 Certified Systems ssesseeoeeenesessseeeeeees 7 LL SystnNaime Desi nato a a a a 8 LLZ System Typi erinan a a a a 8 ELS Syster DC SCM PON agai tacit ste aaceeed gucid iad a yuan dati sauaer sever anon dias sta yasnclubudaeaueeeeee 8 IgA 2SOlar CONCCIOP cir ouecsas sec a anit aacans Cau hein 12 ELS WW ater Panik eiaa ssacuaceaetustuataandaeaeomiennaauananee tues 12 Pele WCOMCCIOE AGC a eas ucerict tetieze ness sanheiacecensah dat icantures sabe eaeauder ahs aacteoeieaawees 12 LIZ Liigud to Air Peat Exchanger asrnane auinaacreiadian eh cieleeaadeas vuiuet 13 1 1 8 Wand Antifreeze to Potable Water Heat Exchanger 13 LLS Treez Toler neeo tested desiauceed ee E a saaeses 14 EERO Bonm Torin osc cr aatutece aural aenne tae ted noid enamine tet T 14 DMEM TOR oysters asa ecg atic cicee Me E eae ocean aw eee ace a taceaays 14 LZ CO Mean MAO 552 sia ca ceen inated ai aliwianstatad sat lieniasin dese dwanaraiadeia eel auninnia dieses 14 E E e AUS AAS E E E A E E usinse auton saudi bbe E E A E 15 E A E a AZ AR US E E S AS A aan ad S EEE ES E E Aon 15 2 0 System Operation and Component Functions ccccccccsssssssssscccccsssssssssssees 16 2 1 Solar
89. tarts to boil a small amount of fluid is pushed out of the collector past the Pressure amp Vacuum Radiator Cap 2 b at 16 psig into the coolant recovery reservoir As the fluid in the collector continues to boil the steam bubbles must pass through the liquid to air heat exchanger to get to the Pressure amp Vacuum Radiator Cap 2 b Outside air cools the fluid in the liquid to air heat exchanger so the steam bubbles condense and do not escape from the system or force more fluid out The liquid to air heat exchanger is sized to dissipate most of the heat energy the sun can put into the collector The boiling action and steam condensation in the liquid to air heat exchanger keeps the collector temperature near 124 C 256 F This is well below the 260 C 500 F glycol water degradation temperature where strong acids form which can corrode through the copper plumbing This heat pipe based collector protection system works the same way a car radiator protects the car s engine from overheating When circulation is restored the system runs normally and when the system cools down at night the fluid with no air is drawn back into the system via the vacuum recovery valve on the Pressure amp Vacuum Radiator Cap 2 b Preventing excessive temperature in the antifreeze allows for a preventive maintenance five year replacement interval With pH checking every 5 years systems have run over 20 years without an antifreeze change 2 2 2 Bladder Ex
90. team and keeps the collector from boiling over through the radiator cap The steam absorbs heat in the collector and gives it up by condensing in the radiator like a steam heat pipe The radiator fins give up the heat to the surrounding air This process forces some fluid and steam through the radiator cap into the overflow reservoir 2 c The steam that makes it to the overflow reservoir is condensed in the fluid slightly diluting it At night the steam in the closed loop condenses and draws fluid back in from the coolant overflow recovery reservoir 2 c to refill the collector This action is normal does not cause any damage to the solar system and will stop when circulation is resumed So when you come home from vacation and start using hot water again the solar heats your water automatically When you go on extended vacations you do not need to do anything with your solar collector It 1s designed to take care of itself 4 3 Controller and Hot Water Tank Settings There are two user adjustable settings on the solar system The water tank top temperature limit can be set from 105 F to 200 F 40 6 C to 99 3 C We recommend settings from 150 F to 185 F 65 6 C to 85 C For PV powered systems the high limit cut off switch is a fixed or variable set point snap action switch which opens at 150 F to 190 F 65 5 C to 87 7 C and closes automatically 40 F 22 2 C below the opening set point CAUTION TANK TOP TEMPERATURES OF 150 F to
91. tely Most system owners are not alerted to the pressure relief 21 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL valve releasing Hence they must be alert for the system circulation stopping due to power outages controller or pump failures When these conditions are detected the system owner must check the pH of the antifreeze and replace it immediately if it has become acidic Schrader Pressurizing Valve Figure 2 5 Closed System Air Bladder Fluid Expansion Tank The pressure temperature diagrams of the Self Pressurizing System and Closed Air Bladder Pressurized System are graphed in Figure 2 6 The Self Pressurizing System curve shown in pink and yellow shows how the liquid to air radiator dissipates the heat from the solar collector when fluid flow stops and automatically keeps the glycol in the safe operating temperature range to keep acids from forming The Closed Air Bladder Pressurized System curve shown in dark blue in Figure 2 6 shows how the solar collector itself dissipates the heat when fluid flow stops and may allow the glycol to go above the safe operating temperature range and allow acids to form Collector overheating can cause early system failure due to copper corrosion so sizing the solar collectors to match the size of the solar hot water storage tank is very critical to the life of Closed Air Bladder Pressurized Systems For ex
92. use a cross connection or permit back siphoning of heat transfer fluid into the potable water system Any barrier that fails allows the discharge of exchanger fluid and or potable water to the atmosphere at a location visible to the operator or owner Figure 2 1 shows a cut away view of a Solar Wand Hot Antifreeze Fluid Fram Collector Cooler Antifreeze ba Fluid Back f to Collector Double Walls et Vent Outside Tank Inner hall Gutier all A SIDE Hot Water Outlet Spiral Fluted Solar Wand Double Wall Heat Exchanger That Fits Into Existing Hot Water Tanks Figure 2 1 Solar Wand Cut Away View 17 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL The solar Wand provides approximately 0 2 m 2 Square feet of copper heat transfer surface in your hot water tank The spiral flutes add heat transfer surface area while still allowing the Wand to be inserted into the hot water tank through the standard 3 4 inch National Pipe Thread NPT female HOT WATER OUTLET port on the top of the hot water tank WARNING DO NOT TRY TO INSTALL THE WAND IN THE COLD WATER INLET OF THE HOT WATER TANK THE COLD WATER INLET FITTING IS SMALLER IN DIAMETER TO HOLD THE DIP TUBE NEEDED TO DELIVER COLD WATER TO THE BOTTOM OF THE TANK NOTICE IT HAS COME TO OUR ATTENTION THAT SOME HOT WATER TANKS HAVE NECKED DOWN REGIONS BELOW THE THREADS
93. w components are a heat exchanger an adjustable thermostat and a spa side circulating pump 1f your spa does not have the circulator run all of the time The thermostat is a bulb type with a temperature adjustment to limit the spa temperature to 104 F 64 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL Self Pressurizing Unit Auto Radiator Cap Radiator Overtiow GED Sahin Flat Plate Solar Collectors PV Panel 7 Roof Umbilical Glycol Solution in Loop Pressure Gauge ss Linear Current Amplifier If Needed 1 04 F Servicing Valves amp Normally Open Digital Thermometer HX Isolation Valve Flush Valve Pump Isolation Valve Fill Drain Valve Glycol Pump Thermostatic Switch Figure A 3 Hot Tub System Schematic 65 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System
94. waste disposal site for recycling As an alternative 50 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 5322 10 11 5 4 SERVICE MANUAL clean up you can use paper towels or kitty litter to soak up the Propylene glycol water and put it into the trash Changing the Fluid Without a Pump using Gravity Only Disconnect Power to the Circulation Pump 5 and cover the solar collectors with a blanket Arrange to have access to the Self Pressurization Unit on the roof Use the stopper and siphon configuration shown in Figure 2 10 HINT If you don t have the stopper assembly remove the 16 pound cap and have a Second person pour in the antifreeze mixture to keep the system full as you drain fluid from the bottom Back at the water tank Attach a length of 4 inch diameter tube to the Fill Drain Valve 11 after removing the Pressure Gauge 9 and place the other end in the bottom of a container that will hold the drained fluid Close the Pump Isolation Valve 13 OPEN the Fill Drain Valve 11 and slowly drain fluid from the system If you have the stopper siphon assembly or a second person on the roof they will keep the system full as you drain out the old fluid Once you have drained out the darker old fluid and new fluid appears shut the Fill Drain Valve 11 Attach a length of 1 4 inch diameter tube to the Flush Valve 12 then OPEN a
95. xtended period of system nonperformance the watranty will be extended by the period of time the system did not perform 9 5 WHAT IS NOT COVERED e Damage due to owner s unauthorized attempts to repair the products inappropriate parts substitution neglect misuse abnormal weather conditions and electric power failures e Conditions arising from a defect in a component which is not part of the system e Products which are not installed and maintained in accordance with the installation operation and maintenance instructions and or applicable ordinances and codes e Consequential damage to your home inconvenience loss of time or loss of the use of your solar system as a result of system malfunction e Normal fading and minor deterioration of exterior surfaces resulting from exposure to the elements except conditions that do or will affect performance e Glass or plastic glazing breakage from any cause 9 6 OTHER RIGHTS AND REMEDIES NO OTHER EXPRESS WARRANTIES The entire obligation of Butler Sun Solutions regarding its solar system is stated within this warranty Butler Sun Solutions does not authorize its representatives or any other person to make any other warranties or assume for it any other liabilities in connection with the sale of its products 59 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SUN SOLUTIONS 9 07 2007 SERVICE MANUAL FURTHER THERE ARE NO WARRANTIES THAT ARE
96. ze needed The solar collector must be Solar Rating and Certification Corp SRCC OG 100 rated and certified It should be single glazed with tempered float glass or low iron high transmission glass Double layered extruded Polycarbonate with Ultraviolet UV solar damage inhibitors has passed OG 300 and has an expected life of at least 15 years The solar collectors should have copper fluid channels capable of withstanding 100 psi pressure and cause the fluid to flow in serpentine or parallel paths for high system performance Parallel flow paths will work but may be lower in efficiency since it is hard to balance flow rates in parallel fluid tubes at low flow rates The collector frame should be corrosion resistant extruded or formed aluminum with an Ethylene Propylene Di amine synthetic rubber EPDM gasket to hold and seal the glazing The frame should support the absorber plate while positioning the low out gassing fire retardant foam insulation in place and holding the bottom sealing plate in place The frame will also be easily attachable to the roof and flashed in or capable of being supported at an angle above the roof pitch The SRCC Certified solar collectors listed on the SRCC web site will be appropriately vented to the atmosphere to prevent internal condensation and thus minimize corrosion to the collector outside of the fluid loop 28 of 65 SERVICE MANUAL Solar Butler 1 0 Solar Assisted Hot Water System Fifth Revision BULTER SU

PDF format - Butler Sun Solutions, Inc.

Contents

Download Pdf Manuals

Related Search

Related Contents