OPEN LOOP DOMESTIC HOT WATER SOLAR SYSTEM

WITH DIFFERENTIAL CONTROL

MODELS SLAR32DC-66, SLAR40DC-80SLAR64DC-120, SLAR80DC-120

INSTALLATION MANUAL Solene™™

927 Fern St. Suite 1500Altamonte Springs, FL 32701

(866) 902-0060

SRCC OG-300 Certified

The solar energy system described by this manual, when properly installed and maintained, meets the minimum standards established by the Florida Solar energy center, in accordance with section 377.705, Florida Statutes. This certification does not imply endorsement or warranty of this product by the Florida Solar Energy Center or the State of Florida.

The solar energy system described by this manual, when properly installed and maintained, meets the minimum standards established by the Florida Solar Energy Center, in accordance with Section 377.705,

Florida Statutes. This certification does not imply or endorse warranty of the product by the Florida Solar Energy Center of the State of Florida. Solar Water Heating System

SLAR-IMDC9-04-09

2

TABLE OF CONTENTS

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11 noitarepO metsyS

11 noitarepO raloS latoT

11 taeH-erP raloS

11 rewoP ytilitU latoT

System Schematic (SLAR32DC-66 & SLAR40DC-80) 12

System Schematic (SLAR64DC-120 & SLAR80DC-120) 13

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61 slebaL Aurora

81 ytnarraW Aurora

3

SAFETY PRECAUTIONS

There is no substitute for safety. Always exercise extreme caution, care and good judgment when working on or around a roof. Here are just a few installation precautions to keep in mind:

When working on the roof, always take care to avoid hazards such as overhead electrical wires or loose shingles. Secure ladders so they will not slip or fall. Wear shoes with proper tread to prevent slipping on the ladder or sloped roof areas.

Always check that power is turned off before attempting any wiring or electrical hook-ups, especially when water is present. It’s always a good idea to shut power off to both the solar storage tank and to the automatic control when there is water leaking at the tank.

Do not hook up or turn on any electricity to the solar storage tank until it is full of water. If the heating element is not covered in water prior to being turned on, it will burn out.

Always consult the proper authorities or check with your local building department for the permit requirements and codes applicable before you start the job. Installation should always be in accordance with the National Fire Code and with all local codes.

INSTALLATION INSTRUCTIONS

SIZING & ORIENTATION

The vast majority of Solar Domestic Hot Water (SDHW) systems are comprised of “Medium Temperature” solar collectors manufactured using tempered glass and some type of metal absorber plate. They differ from “Low Temperature” systems predominantly utilized in swimming pool heating applications. These systems are typically manufactured using plastic resins. “High Temperature” systems are utilized to generate steam for industrial applications.Corona collectors belong to the “Medium Temperature” category.

Normally, only one or two Aurora collectors are needed for a SDHW system. The number of collectors is determined not only by the amount of water that is needed, but also by the latitude of the installation and the collector’s orientation. The following table details Corona’s recommended minimum system sizing guide for a typical installation:

TankCapacity

# of Collectors Needed

Collector Type Control Type System Model Number

66 gallon 1 SLAR-32 (4’ x 8’) Differential Control

SLAR32DC-66

80 gallon 1 SLAR-40 (4’ x 10’) Differential Control

SLAR40DC-80

120 gallon 2 SLAR-32 (4’ x 8’) Differential Control

SLAR64DC-120

120 gallon 2 SLAR-40 (4’ x 10’) Differential Control

SLAR80DC-120

4

Normally, collectors are installed on roofs, as close as possible to the tank, to minimize heat loss through the pipe. The pipes between the tank and the collectors MUST be insulated with at least ½” thick insulation, for the same reason.

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

The recommended angle of the collectors is the angle of the installation location’s LATITUDE. This angle is designed to maximize solar absorption during winter months when the sun is low. A variation of +/- 15 degrees is acceptable. The orientation of the collectors must be due south 55 degrees. Flush mounts on available roof slopes are recommended to allow convenience and cost effectiveness, since these variations from the exact angle and orientation will affect the system’s performance only by about 5%.

COLLECTOR MOUNTING

There are two basic roof-mounting methods:

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

Figure #1, Flush mounted collector

Flush Mount Installations are recommended when the roof’s slope conforms to the orientation requirements as stated previously. This is the easiest and most aesthetically pleasing installation method. After the collector(s) are installed, it should resemble skylight. The flush mount consists of four (4) U-channels (SL-UC) and four (4) Gripper Sets (SL-GS), two set each for the top and bottom.

1. Start from the bottom. The bottom side of the Corona collector is marked by two weep holes placed about 20” apart on the short anodized aluminum edge of the collector. When elevating the collector to the roof, make sure that the “weep holes” are facing down. It is recommended to install the collectors vertically (length up the roof’s slope), but the collectors may be installed horizontally as well.

2. Once the collector’s location is determined, anchor two (2) U channels to the roof using two (2) stainless steel 2” x 5/8” lag bolts for each U-channel. The U-channels should

5

be spaced approximately 30” apart. The collectors will rest on top of the U-channels. (Picture 1)

Picture #1

3. Verify a secure connection to the trusses. If lagging directly into the roof trusses is not possible, secure a 2’ x 4’ wood beam perpendicular to the trusses, inside the attic, and anchor the bolts to this member. Again, verify a secure connection into the new member.

4. Connect the Latch to the Gripper (Picture 2) utilizing the provided nut and bolt. Slide the Latch into the top of the U channel so that the Gripper remains on top of the opening. Place them at the middle of the U-channel’s top and tighten. (Picture 3)

Picture #2 Picture #3

5. Loosen the Gripper providing space to insert the slot at the collector’s edge between the Gripper’s hook and the U-channel’s top. Once both Grippers are grabbing the collector’s edge slot, tighten both Grippers. (Picture 4)

Picture #4 Figure #3

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

6

ANGLE MOUNT INSTALLATION - Not parallel to the roofline, normally used on flat roofs and ground mounts, as illustrated below.

Figure #2, Angle mounted collector

Angle Mount Installations involve positioning the collector(s) at an angle so that the upper part of the collector is higher than the lower in reference to the mounting surface. The “angle mounting” is used on horizontal surfaces or on roofs that slope in directions other than south 55degrees.

1. Use the Angle Mounting kit (SL-MK), see picture 5. Connect the U-channels to the roof just like in the Flush Mounting method. Assemble the mounting clips to both U-channels utilizing the provided bolts (Picture 6).

Picture #5 Picture #6

2. Screw the mounting clips to the BOTTOM part of the collector (the weep hole side) using two (2) stainless steel or aluminum screws each. (Picture 7)

Picture #7

3. Assemble both rods and top mounting clips (picture 8). Connect the clips to the collector’s top by stainless steel or aluminum screws. (Figure 4)

7

Picture #8 Figure #4

4. Connect to the U-channels to the opposite side of the rod, using the provided nuts and bolts. (Picture #10)

Picture #10

5. Lift the collector’s top with the assembled rod kits and anchor the U-channels to the roof, ensuring the proper angle to the collectors. (Picture 11)

Picture #11

Install all components in accordance with local code so that the performance of any structural member or fire rated assembly is not reduced.

8

PIPE INSTALLATION

Careful consideration of the proper piping of the system should be done prior to a final decision being made on the collector mounting. The collectors and piping should slope slightly downward, toward the tank, in order to allow for draining in freezing conditions.

Piping should consist of copper tube (Type M), insulated with at least ½” Armaflex pipe insulation or similar and be wrapped with aluminum tape in all areas exposed to UV radiation. All soldered connections require 95/5 solder.

The cold-water inlet (supply) pipe connection should be made at the lowest corner of the collector. The hot-water outlet (return) pipe connection should be made at the opposite corner of the cold-water inlet. The hot-water return should have the shortest possible run back to the storage tank to avoid heat loss.

The Vacuum Relief Valve (Part #6), Automatic Air Vent (Part #7), Pressure Relief Valve (Part #8), and Freeze Protection Valve (Part #5), should be plumbed into the return line as illustrated in the System Schematic on page 12 of this manual.

It is extremely important to take special care in weather proofing the piping installation through the roof.

1. Drill a hole the same diameter as the copper piping being utilized in the system installation being careful not to place the opening above the collector supply point.The system will not drain properly if the opening is above the above the supply point.

2. Cement a copper roof flashing around the pre-drilled hole. The upper edge of the flashing should slide underneath the adjoining shingle.

3. Push the copper tube up through the roof flashing. Slide the flashing cap over the copper tubing so it rests on the flashing opening. The wiring for the Photovoltaic Module should also be run through this the return line flashing.

4. After all of the piping is completed, solder the flashing cap into place.

5. Utilizing a polybutalyne adhesive, finish weather proofing the roof flashing.

9

PLUMBING

The storage tank should be placed in a location to best minimize heat loss. It should be placed as close to the system return line as possible. Adequate ventilation and access for possible future service work are important considerations. In order to prevent possible water damage in case of tank leakage, a pan with a ¾” drain line should be installed.

As illustrated in the System Schematic on page 12 of this manual there are very specific requirements as to valve, thermostat, and pump placement.

The following component equipment should solder in place according to their specific relative locations as outlined in the System Schematic.

1. Circulation Pump (Part #4) - Taco 006BC4 Circulation Pump 2. Thermometers (Part #11) - Letro SL-2D In-Line Thermometer w/ temperature range

of 50 to 220 F.3. Boiler Drains (Part # 12) - BD-050 (½”), or BD-075 (¾”) Boiler Drains on both

Supply and Return lines. 4. Ball Valves (Part #14) - BV-050 (½”), or BV-075 (¾”) Ball Valves on both

Supply and Return lines. 5. Cold Water Inlet Valve - GV-075 (¾”) Gate Valve. 6. Mixing Valve - Watts 70A-075 (¾”) Mixing Valve.

AUTOMATIC DIFFERENTIAL CONTROL

Power to the circulation pumps is controlled by an automatic differential control that has two temperature sensors. One sensor is located on the outlet of the solar collector and the other sensor is located on the storage tank behind the lower access panel. When the storage tank sensor detects water temperatures cooler than the desired temperature set on the control, and if the collector sensor is 8 F warmer than the storage tank sensor, the automatic control turns on the circulation pump to harvest the energy available from the sun. When the desired temperature is met, or when the solar collector sensor drops to within 4 degrees of the storage tank sensor, the control turns off the circulation pump. (This on/off differential can be set to 24º/4º rather than the 8º/4º.)

The automatic control has a three-position switch - ON, AUTO or OFF. (Sometimes this switch is located on the inside of the cover.) During normal operation, the control is switched to AUTO where the control will turn the circulation pump on and off at the appropriate times. When switched to ON, the control sends power to the circulation pump. When switched to OFF, the control turns the circulation pump off.

THE AUTOMATIC CONTROL HAS A HIGH LIMIT STORAGE SETTING THAT CAN BE ADJUSTED FROM 110°F TO 200ºF AND IS TYPICALLY PRESET TO 140°F.

10

ELECTRICAL AND WIRING REQUIREMENTS

A properly licensed contractor must make the 230-volt electrical connection to the water heater or solar storage tank and the electronic time switch (Optional). If your solar contractor is not allowed by law to make these connections consult a licensed electrician.

NEVER ACTIVATE THE CIRCUIT BREAKER CONTROLLING THE ELECTRICAL HEATING ELEMENT UNTIL THE SOLAR STORAGE TANK IS COMPLETELY FILLED WITH WATER. This will prevent “dry firing” of the heating element. The electrical heating element will be destroyed almost instantaneously if not completely submerged in water when activated. Make sure the water heater circuit breaker is off until the solar storage tank is completely filled.

We recommend the use of a 115-volt differential control with a factory installed six-foot line cord. The installation requires one 115-volt outlet to be installed near the solar storage tank.Plug the control into the outlet. The circulation pump line cord is plugged into the receptacle on the side of the controller. A 230-volt control and circulation pump may be substituted, but troubleshooting the components in the future becomes more difficult. The specified differential thermostat is the Goldline model GL-30-LCO.

THERMOMETERS

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

LABELS

Label installation is mandatory at several locations of the system. Please insure compliance by affixing labels at the designated locations.

SYSTEM START-UP

The Start-up Procedures are detailed in the Solene Open Loop (SLAR-HMDC) Homeowner’s Manual.

11

SYSTEM OPERATION

Solene systems are designed to accommodate three separate modes of operation. Your solar water heating system can (1) provide 100% solar operation during good weather, or (2) serve as a pre-heater to your electric water heater adding solar energy when and as available, or (3) 100 % on utility power during inclement weather.

TOTAL SOLAR OPERATION

Turn off the circuit breaker to your solar storage tank. If a water heater time switch has been installed, set the switch to the “off” position. If you have a mechanical timer remove the trippers from the face of the switch.

TOTAL PREHEAT

Leave the circuit breaker to your solar storage tank on and set the tank thermostat to the lowest acceptable temperature setting. The electric resistance heating elements will come on only when the tank temperature falls below the thermostatic set point. If the solar heated water entering the tank is warmer than the thermostatic set point, the electric heating elements will not come on. If you have a water heater timer, you may preset the timer to turn the heating element on and off at specified times throughout the day if desired.

TOTAL UTILITY POWER

Leave the circuit breaker to your solar storage tank on and close the isolation ball valves in the collector loop. In this mode of operation you must turn off the circulation pump. To turn the pump off, open the controller and change the operational setting from automatic to off. Failure to turn off the pump can quickly damage the pump motor, shaft, bearings or impeller.

14

COMPONENT PARTS LIST AND FUNCTION

While specific products are mentioned below, there are many components that can be substituted with like or equal products. For instance there are several different mixing valves or isolation valves that can be utilized, not just the one specifically listed. Sometimes sweat or threaded connections or varying fitting sizes are dealer preference. All of the components listed below are available from Solene at 950 Sunshine Lane, Altamonte Springs, FL, 32714 (866) 902-0060.

See the schematics on page #12 & #13 for the location of the following list of components.

1. Aurora Solar Collector –Aurora SLAR40 4 x 10, or SLAR32 4 x 8 with all copper chrome plated absorber plate.

2. Solar Storage Tank – Lochinvar FTA066K 66 Gallon, or FTA082K 80 Gallon, or FTA120K 120 Gallon Solar Storage Tank with Single 4500W Backup Element, or or AO Smith Sun-80, or AO Smith Sun-120.

3. Differential Control – Goldline Differential Control with Adjustable High Limit determines when system is on or off.

4. Circulation Pump – Taco 006BC, Grunfos, or March 80AC, circulate water through system.

5. Freeze Valve – Therm-Omega ½’ Freeze Valve protects system from freezing.

6. Vacuum Relief Valve – Watts N-36 Vacuum Relief Valve allows air into the system when draining collector.

7. Air Vent – Sparco FV-147 Air Vent allows air trapped in collector to purge.

8. Pressure Relief Valve – Watts 530C Pressure Relief Valve protects system from excessive pressure.

9. Pipe Insulation – ACT05834 Armaflex Copper Pipe Insulation to prevent heat loss through pipes. Any Pipe Insulation that is exposed to sunlight must be wrapped with foil tape or coated with a water-based acrylic resin coating as specified by the Insulation Manufacturer.

10. Roof Penetration Flashing – All Copper Roof Flashing. Gooseneck type flashing is recommended for feed line to accommodate sensor wire.

11. Thermometer – Letro SL-2D In-Line Thermometer w/ temperature range of 50°F to 220°F.

12. Boiler Drains – BD-050 ½’, or BD 075 ¾’ Boiler Drains on both Feed and Return lines used in conjunction with #13 Ball Valves, allow for manually draining the solar system.

13. Check Valve – Heliodyne SCV 75/50 Check Valve for PV Systems prevents thermo-siphoning from storage tank through solar collectors.

14. Ball Valves – BV-050 ½”, or BV-075 ¾” Ball Valves used as Isolation Valves in conjunction with #11 Boiler Drains to manually drain the solar system.

15. Cold Water Inlet Valve – GV-075 ¾” Gate Valve gives ability to turn off the cold feed to the Solar Storage Tank.

16. Mixing Valve – Watts 70A-075 ¾” Mixing Valve tempers temperature of hot feed line to home.

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

MODE

L SL

AR40

DC-8

0MO

DEL

SLAR

32DC

-66

ROOF PENETRATION

COPPER TUBING & INSULATION

COLLECTOR SENSOR

AUTOMATIC FREEZE VALVE

VACUUM RELIEF VALVE

AUTOMATIC AIR VENTPRESSURE RELIEF VALVE

MANUAL DRAIN

BALL VALVE(ISOLATION VALVE)

ELECTRICAL SUPPLY

PRESSURE &TEMPERATURE RELIEF VALVE

SOLAR RETURN FROM COLLECTOR

SOLAR HOT WATER TANK

TANK DRAIN

DIFFERENTIAL TEMPERATURE CONTROL120v

COLD WATERFROM HOUSE

RESET BUTTON

HEATING ELEMENTTHERMOSTAT CONTROL

SOLAR FEED TO COLLECTOR

SOLAR COLLECTOR

TANK SENSOR

CONTROL SWITCH

HOT WATER TO HOUSEMIXING VALVE

(BYPASS)

MANUAL DRAIN

CHECK VALVE

BALL VALVE(ISOLATION VALVE)

ENIL

NRU

TER

RALO

S

CIRCULATION PUMP

ENI L DEEF RAL OS

SO

LE

NE

DH

W S

YS

TE

M S

CH

EM

AT

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PIPEINSULATION

COLD SERVICE VALVE

1

18

16

14

15

13

5

8

9

12

10

76

4

2

3

18

12

14

17

11THERMOMETER

9-04-09

ROOF PENETRATION

COPPER TUBING & INSULATION

AUTOMATIC FREEZE VALVE

VACUUM RELIEF VALVE

AUTOMATIC AIR VENTPRESSURE RELIEF VALVE

MANUAL DRAIN

BALL VALVE(ISOLATION VALVE)

ELECTRICAL SUPPLY

PRESSURE &TEMPERATURE RELIEF VALVE

SOLAR RETURN FROM COLLECTOR

SOLAR HOT WATER TANK

TANK DRAIN

DIFFERENTIAL TEMPERATURE CONTROL120v

COLD WATERFROM HOUSE

RESET BUTTON

HEATING ELEMENTTHERMOSTAT CONTROL

SOLAR FEED TO COLLECTOR

TANK SENSOR

CONTROL SWITCH

HOT WATER TO HOUSEMIXING VALVE

(BYPASS)

CIRCULATION PUMP

SO

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NE

DH

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YS

TE

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EM

AT

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5

8

9

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76

4

2

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16

12

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17

SOLARCOLLECTORS

COLLECTOR SENSOR

1 1

MANUAL DRAIN

CHECK VALVE

BALL VALVE(ISOLATION VALVE)

ENIL

NRU

TER

RALO

S

ENI L DEEF RAL OS

14

13

12

11THERMOMETER

MODE

L SL

AR80

DC-1

20MO

DEL

SLAR

64DC

-120

MODE

L SL

AR60

DC-8

0

9-04-09

15

COMPONENT LIFE EXPECTANCY

Installed and maintained properly, your Solene Solar Hot Water Heating System should provide many years of trouble free, uninterrupted service. The main component of the system, the Aurora Solar Collector, is designed to last 25 to 30 years. Solar Storage Tanks have a life expectancy anywhere from 10 to 20 years depending greatly upon regional water quality. (Tank life can be extended by replacing the internal sacrificial anode rod from time to time.) Differential Control and Circulation Pump life expectancies run from 5 to 10 years. As electrical components, they are susceptible to lightning strikes or electrical surges. Valve life expectancy varies greatly depending water quality and usage.

FOR MORE INFORMATION

Detailed information regarding System Operation, Routine Maintenance, Freeze Protection, and Start-up and Shutdown procedures can be found in the Solene Open Loop (DC) Domestic Hot Water Solar System Homeowner’s Manual (SLAR-HMDC).

CONTACT INFORMATION

If you have any questions regarding the operation of your system, please contact your Installing Solene Dealer.

Solene™™ 927 Fern St. Suite 1500Altamonte Springs, FL 32701

(866) 902-0060

Solene Dealer Contact Information

16

SOLENE OPEN LOOP OG-300 SYSTEM LABELS (Whole page will be embossed foil)

The following labels provide the system owner with important safety and operating information. Be sure to cut out the labels below and apply them to the proper system components as described below. Refer to the Solene DHW System Schematic in this manual for reference numbers.

Place these labels on Isolation Valves (#13)

Place these labels on Circulation Pump (#4), Manual Drains (#11) and Mixing Valve (#15)

Place this label in visible location on Solar Tank Place these labels on Solar Feed and

Return Line above Solar Tank

Solene System Isolation Valve Normally Open

WARNING HOT

Solene System Isolation Valve Normally Open

WARNING HOT

WARNING HOT WARNING HOT

FREEZE PROTECTION Collector loop filled with water is protected by Freeze

Valve under normal conditions. When air temperatures are expected to be below 32ºF for

extended periods of time, drain solar loop as instructed in manual.

Maximum Operating:

Temperature: 200ºF Pressure: 130psi

WARNING Ungrounded Piping

Stay clear during any thunderstorm activity.

WARNING Ungrounded Piping

Stay clear during any thunderstorm activity.

17

(5 X 7 Freeze Protection Label)

SOLENE FREEZE PROTECTION INSTRUCTIONS (Models SLAR32DC-66, SLAR40DC-80, SLAR64DC-120, SLAR80DC-120)

Your Solene Solar System has a Freeze Valve on the roof that protects your system from freezing. During near freezing conditions this valve will allow water to flow through the collector from the storage tank and trickle onto the roof. This Freeze Valve needs water pressure to operate properly. DO NOT CLOSE THE ISOLATION VALVES unless you are going to completely drain your solar system as described below.

MANUAL DRAIN DOWN FREEZE PROTECTION – Follow these steps:

Disconnect the wires from the PV Panel to the Circulation Pump.

Close both Isolation Valves.

Connect drain hose to the Drain Valve on the return line of the solar system, or use a water vessel to catch the water. Open the Drain Valve on the return line. (CAUTION - WATER MAY BE EXTREMELY HOT - POSSIBLE STEAM) Allow all water to drain out of the solar system.

Move drain hose or water vessel to the Drain Valve on the feed line below the circulation pump and open the Drain Valve on the feed line.

Leave these Drain Valves open while your system is turned off.

Ten (10) Year Warranty Plus Lifetime Limited Warranty

WarrantyThis warranty is issued by SOLENE LLC, 927 Fern Street, Suite1500, Altamonte Springs, Florida 32701, and applies to all new AURORA collectors when purchased for use on residential or commercial water heating applications. SOLENE LLC, warrants to the original purchaser only that the AURORA collector will be free from defect in materials and workmanship in the manufacturing process under normal use and service for a period of ten (10) years from the date of initial installation when purchased from and properly installed by an AUTHORIZED DEALER within that dealer’s authorized territory. During that time, should AURORA collector or component exhibit a manufacturing defect, the defective collector or component will be repaired or replaced, without charge for the equipment by SOLENE LLC, or its authorized dealer or distributor. Labor expenses to repair or replace a defective AURORA collector is reimbursable, to an authorized dealer, up to $100 in years one (1) and two (2), $75 in years three (3) through five (5), and $50 in years six (6) through ten (10).

Your dealer is __________________________, ___________________ Authorized Dealer Phone

Bonus Lifetime Limited Warranty AURORA collectors carry a Lifetime Limited Warranty. Any AURORA Collector found to be defective in material or workmanship subsequent to the initial Ten Year (10) Warranty will be replaced, so long as the purchaser pays fifty percent (50%) of the published collector list price at the time the replacement is required.

Exceptions SOLENE, LLC will not be liable for inspection, freight, removal, or any other charges arising from this warranty unless specifically stated in this warranty statement. Neither SOLENE LLC, its dealers, nor its distributors shall be liable for incidental or consequential damages, damage of any sort or nature resulting from abuse, misuse, neglect, abnormal weather conditions, freezing, scaling due to hard water, acts of God, or damage caused by improper installation. This warranty does not apply to installation components or to solar collectors which have not been installed and maintained in strict compliance with SOLENE’s installation and operation manuals and instructions and/or applicable ordinances or codes or to systems not installed by an authorized dealer within its authorized territory. In no event shall the liability exceed the purchase price of the product. There are no implied warranties of merchantability or implied warranty of fitness, which extends beyond the description of the face hereof.

Proof of Purchase It is the responsibility of the consumer to establish the original purchase date for warranty purposes. We recommend that a bill of sale, canceled check, or some other appropriate payment record be kept for that purpose. If the system is registered within 10 days of installation at www.solene-usa.com, the electronic registration confirmation is the only future proof of purchase necessary. The completion of the Online System Registration Form is a condition precedent to coverage under this warranty.

NoteThis warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

Solene LLC 927 Fern Street, Suite 1500 Altamonte Springs, FL 32701

Rev 08/27/09

PLUMBING DETAILS

ALTERNATE SYSTEM TANK PLUMBING DETAILS.

SCOPE OF WORK: SOLAR SYSTEM COLLECTOR:

MODEL: ALL

SHEET NO:

DATE:

SOLAR WATER HEATER

REVISION NO./DATE:

SHEET NAME:

ALLEN GEZELMAN

16502 HANNA RD.

LUTZ, FLORIDA 33549

PH. 813 650 7246

FX. 866 397 9050ALLEN@GEZELMANPE.COM

DRAWN:

APPLICABLE CODE:

FLORIDA 2007 CODE W/09 SUPP

THIS SHEET IS A SUPPLAMETAL

PUMBING DETAIL SHEET

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EXPLANATORY INSTRUCTION:

THIS DRAWING IS INTENDED TO PROVIDE PLUMBING DETAILS FOR OEM SOLAR HOT WATER SYSTEMS NOT SHOWN ONOEM, PERMIT-READY, SOLAR DOMESTIC HOT WATER PLAN. THAT PLAN SHOWS THE PLUMBING DETAILS FOR OEM'SMOST COMMON SYSTEM “DIRECT” WHICH DETAILS ARE THEREFORE NOT REPEATED ON THIS “ALTERNATE SYSTEM

PLUMBING DETAILS” DRAWING.

04SCALE: N.T.S.

GENERIC MULTIPLE TANK INSTALLATION

TANK ALTERNATE PLUMBING SHEET:

THIS PLAN SHEET SHOWS THE VARIOUS TANK ALTERNATE PLUMBING ARRANGEMENTS FOR SOLAR WORLD SOLARDOMESTIC HOT WATER SYSTEMS - EXCLUDING THE STANDARD DIRECT SYSTEM WHICH IS SHOWN ON THE

COLLECTOR/SYSTEM INSTALLATION SHEETS A.1.0 AND A1.1. AND THEREFORE NOT DUPLICATED ON THIS TANK

ALTERNATE PLUMBING SHEET. CONTRACTORS, INSPECTORS, AHJS, AND OTHERS ARE CAUTIONED THAT LATITUDE ISALLOWED, E.G. A PARTICULAR SYSTEM PLUMBING MAY APPEAR SLIGHTLY DIFFERENT FROM WHAT IS SHOWN HEREAND STILL BE ACCEPTABLE SO LONG AS THE HYDRAULICS WORK THE SAME AS ONE OR THE OTHER OF THEARRANGEMENTS SHOWN N THIS SHEET.

02SCALE: N.T.S.

DRAIN BACK SYSTEM INSTALLATION03

SCALE: N.T.S.

CLOSED LOOP SYSTEM INSTALLTION01

SCALE: N.T.S.

DHW RETROFIT STANDARD TANK INSTALLATION

INSTALLATION INSTRUCTIONS:

1) REMOVE ALL PIPING FROM TOP OF THE EXISTING WATER HEATER

2) INSTALL ARRANGEMENT SHOWN AT THE MIDDLE TANK HOLE #2

A. MATERIALS NEEDED:

● DI-ELECTRIC NIPPLE ● 4" LONG DIP TUBE ● 34" FFC TEE ● 34" T&P W/8" STEM ● 34" MALE

ADAPTER ● 34" PIPE ABOUT 24" LONG.

B. PRE SOLDER MALE ADAPTER TO ONE END OF THE 34" PIPE AND THE TEE TO THE OTHER

END OF THE TUBE, LET COOL. CUT 24" TUBE IN HALF.

C. INSTALL DI-ELECTRIC NIPPLE ONTO THE TANK & INSERT THE 4" DIP TUBE INTO THE NIPPLE.

D. INSTALL TEE ASSEMBLY FROM STEP 1 ONTO NIPPLE.

E. INSTALL T&P INTO THE TEE AND T&P DRAIN PIPE

F. NOTE: FFC = FEMALE THREAD X FEMAL THREAD X COPPER

3) INSTALL ARRANGEMENT SHOWN AT THE LEFT TANK HOLE#1

A. MATERIALS NEEDED:

● DI-ELECTRIC NIPPLE ● A PLAIN NO HOLES DIP TUBE

B. INSTALL THE 34" DI-ELECTRIC NIPPLE.

C. CUT THE DIP TUBE TO PROPER LENGTH, ABOUT 12" FROM TANK BOTTOM, BUT NEVER LESS

THAN ONE FOOT BELOW TOP ELEMENT, INSTALL IN NIPPLE.

D. CONNECT THE PREFABRICATED FROM COLLECTOR ASSEMBLY SUPPLIED IN THE

"DREAM PACKAGE" BOX.

4) INSTALL ARRANGEMENT SHOWN AT THE RIGHT TANK HOLE#3

A. MATERIALS NEEDED:

● DI-ELECTRIC NIPPLE ● 12" MALE ADAPTER ● 34X

12X

34 FFC TEE ●PLAIN NO HOLES DIP TUBE ●

34X3"

PIECE OF COPPER TUBING

B. PRE SOLDER THE 12" MALE ADAPTER TO THE TO SOLAR (PUMP ASSEMBLY), AND PRE

SOLDER THE 34"X3" LG. COPPER PIPE TO TEE, LET COOL.

C. INSTALL PLAIN DIP TUBE AFTER CUTTING TO PROPER LENGTH, ABOUT 6" OFF TANK

BOTTOM.

D. SCREW BOTH PIECES TO THE NIPPLE, AFTER INSTALLING NIPPLE TO TANK TOP. POINT

TEE ASSEMBLY TO BACK OF TANK, PUMP ASSEMBLY TO TANK FRONT. FINISH THE COLD

WATER HOOK UP BY WRAPPING A WET RAG AROUND THE 3" COPPER TUBE WHEN SOLDERING

TO PREVENT OVERHEATING OF THE DIP TUBE.

INSTRUCTIONS

DIAGRAM

NOTE: IF THE HOUSE IS PLUMBED IN CPVC THEN TRANSITION TO COPPER BEFORE THE CITY WATER

SUPPLY SHUT OFF VALVE. MAKE SURE TO USE TEFLON TAPE ON ALL THREADED CONNECTIONS.

IF THE EXISTING TANK HAS A SIDE MOUNTED T&P, FOLLOW THE SAME INSTRUCTIONS AS LISTED IN

THE FIRST SECTION ABOVE. MAKE SURE AN EXPANSION TANK AND PROPER SIZED COLLECTORS ARE

USED TO REDUCE THE PROBABILITY OF OVERHEATING/BURSTING PLASTIC PIPING.

NOTE: PROPER SENSOR LOCATION AND INSTALLATION: REMOVE LOWER ELEMENTCOVER , WEDGE

SENSOR TIGHTLY TO TANK WALL AT ELEMENT OPENING AFTER THOROUGHLY CLEANING AND HEAT

SINKING THE SENSOR AND TANK WALL. INSULATE THOROUGHLY.

DIAGRAM DIAGRAM

INSTRUCTIONS INSTRUCTIONS

INSTALLATION NOTES: DRAIN BACK

DRAIN BACK TANK NEED NOT BE CO-LOCATED AT THE SOLAR TANK. DRAIN BACK TANK CAN BE LOCATED IN THE

ATTIC WITHIN REASONABLE DISTANCE OF SOLAR TANK (30-FEET ONE-WAY SHOULD BE CONSIDERED A

MAXIMUM)

A WIDE VARIETY OF HEAT TRANSFER FLUIDS MAY BE USED. WATER IS THE NORM. HOWEVER, FOOD GRADE

ANTI-FREEZE IS AN ACCEPTABLE ALTERNATE (AMONG OTHERS) .

FILL THE DRAIN BACK TANK UNTIL THE HEAT TRANSFER FLUID SHOWS AT THE TOP END OF THE VIEW TUBE.

THE FREEZE RECIRCULATION MODE IS TURNED “OFF” IN THE ELECTRONIC PUMP CONTROLLER.

BOTH PUMPS RUN AT THE SAME TIME.

CLOSED LOOP CHARGING INSTRUCTIONS

FOOD GRADE ANTI-FREEZE (AVAILABLE FROM COMMERCIAL REFRIGERATION PARTS HOUSES) IS THE ONLY HEAT

TRANSFER FLUID ACCEPTABLE.

A SEPARATE PUMP AND “CHARGING BUCKET” ARE NEEDED.

THE CLOSED LOOP WILL HOLD 2-PLUS GALLONS.

THE CHARGING BUCKET SHOULD HAVE A NIPPLE AT THE BOTTOM WITH A VALVE AND THE CHARGING PUMP.

THE CHARGING PUMP SHOULD CONNECT TO THE UPPER CHARGING VALVE ON THE CLOSED LOOP WITH A

WASHER CONNECTION HOSE.

THE BALL VALVE ON THE CLOSED LOOP SHOULD BE CLOSED.

THE LOWER CHARGING VALVE SHOULD BE PARTIALLY CLOSED AND HAVE A WASHER HOSE CONNECTED TO IT

WITH THE OTHER END OF THE WASHER SUPPLY HOSE DROPPED INTO THE CHARGING BUCKET .

USE THE SOLAR PUMP TO ASSIST IN FILLING THE CLOSED LOOP. OPEN THE VALVE AT THE BOTTOM OF THE

CHARGING BUCKET AND TURN ON BOTH THE CHARGING PUMP AND THE SOLAR PUMP.

PUMP FLUID THRU THE CLOSED LOOP UNTIL AIR STOPS COMING OUT OF THE LOWER CHARGING VALVE. THEN

CLOSE THE LOWER CHARGING VALVE AND TURN OFF BOTH PUMPS.

SWAP HOSES. THE HOSE FROM THE UPPER CHARGING VALVE SHOULD DROP INTO THE CHARGING BUCKET.

THE HOSE FROM THE CHARGING PUMP SHOULD NOW CONNECT TO THE LOWER CHARGING VALVE.

OPEN THE BALL VALVE.

START THE CHARGING PUMP, OPEN THE LOWER CHARGING VALVE AND “CRACK” THE UPPER CHARGING VALVE.

WHEN STEADY FLUID WITH NO AIR IS COMING OUT OF THE UPPER CHARGING VALVE, CLOSE THE CHARGING

VALVES AND TURN OFF THE CHARGING PUMP.

THE FREEZE RECIRCULATION MODE IS TURNED “OFF” IN THE ELECTRONIC PUMP CONTROLLER.

GENERAL NOTES:

BRASS NIPPLES MAY BE USED IN PLACE OF DI-ELECTRIC NIPPLES.

VALVES SHOWN ARE THE MINIMUM. CONTRACTOR IS FREE TO ADD ADDITIONAL VALVES AT PLACES OF HIS CHOOSINGSUCH AS ABOVE PUMP TO ENABLE SWAPPING WITHOUT HAVING TO DRAIN SOLAR.

NOTE:

NUMBER OF TANKS AND SIZE DETERMINED BY SQUARE FOOTAGE OF SOLAR COLLECTOR. SIZING SHOULD USETHE GENERAL RULE OF THUMB, “2-GALLONS OF STORAGE PER SQUARE FOOT OF COLLECTOR”.

FULL LENGTH DIP TUBE ON INLETS.

NO DIP TUBE ON OUTLETS.

FULL LENGTH DIP TUBE ON COLLECTOR FEED. (MAY BE BY TEE OFF COLD INLET)

½-LENGTH DIP TUBE ON COLLECTOR RETURN.

ELECTRIC BACK UP HOOKED UP IN THE LAST TANK IN THE CHAIN WHICH FEEDS HOT WATER TO THE BUILDINGONLY.

DIAGRAM

INSTRUCTIONS

THIS IS THE ONLY ONE OF MY MANY PLANS WHICH I ALLOW TO BE PLACED AS ‘PLAN ON FILE’

WITH BUILDING DEPARTMENTS – I WILL PROVIDE A SEALED AUTHORIZATION LETTER – IF

REQUESTED FOR A SPECIFIC BUILDING DEPARTMENT

STARDARD DETAILS WHICH MAY BE PLACED ON FILE WITH AHJS

ENLARGED VIEWING & HYPERLINKS:

PRINT VERSION OF THIS PLAN PROVIDES MINIMUM INFORMATION NEEDED BY USERS.

ELECTRONIC VERSION (EV) PROVIDES MAGNIFIED VIEWING UP TO 6400%. EV ALSO PROVIDES HYPERLINK

ACCESS TO OEM MANUALS AND ABUNDANT OTHER SUPPLEMENTARY INFORMATION.EV MAY BE ACCESSED AT:

WWW.CADVICE.US/SW/P.1.1.PDF

5/12/2011 6:10 PM

P.1.1.dwg

OEM:

950 SUNSHINE LANE

ALTAMONTE SPRINGS, FL 32714

1-800-79-SOLAR