EnerWorks Solar Water Heating Appliance
Installation Manual / Energy Kinetics Inc. - Page
28
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© 2011 EnerWorks Inc.
2. Cut off excess line-set and insulation. Use a proper tube cutting tool and use a light feed to
minimize burr, work-hardening and tube compression. To obtain maximum sealing surface,
remove burr with de-burring or reaming tool. Remove only burr, do not remove material from
original wall thickness.
3. Place flare nuts over line-set tube ends. Flare ends of line-set with compression or generating
type flaring tool. Follow tool manufacturer’s instructions regarding positioning and correct
number of turns on feed handle.
4. Inspect flare. Flare-cone should be checked for smooth surface on ID. Measure with calipers
or micrometer over largest OD for proper size (0.471-0.487” for 3/8” OD tube).
5. Seat flare-cone onto Energy Station manifold connection. Thread flare-nut onto manifold and
tighten (
Fig.4.9.1.1
). Do not over-tighten as soft copper flare may be ripped or damaged.
Fig.4.9.1.1 – Line-set connections to Energy Station. Note: For clarity, line-set is not insulated. Proper
installation must have insulated line-set to prevent heat loss and to limit burn risk.
4.9.2 Supplemental expansion tank
A supplemental expansion tank may be required due to additional fluid volume in long line-sets
or in Appliances with large vertical elevation between collectors and Energy Station. Two, three
and four-collector systems require supplemental expansion tanks. Kit
KAA098
includes 2 gal US
(7.6L) expansion tank, connection assembly and mounting hardware.
Supplemental expansion tank should be in heat transfer fluid line supply hot fluid
from collectors (from upper manifold). To prevent air from getting trapped in
expansion tank, it must hang below line with Schrader air valve at bottom, pointing
down. Do not remove smaller expansion tank from EnerWorks Energy Station.
With supplied self-drilling screws, expansion tank can be mounted to solar-storage
tank or to hot-water tank. Expansion tank may also be attached to wall with
appropriate screws (not included). Ensure access to expansion tank and to
Schrader valve is maintained for charging and maintenance procedures.