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O. MOUNTING FRAME

HTP solar collectors are supplied with an adjustable, extruded aluminum frame, which allows installers to
change the angle of the collector to maximize efficiency. Feet are supplied to fasten the panel securely to
the roof. It is important that frame attachment points and externally supplied fasteners are of suitable
structural strength and corrosion resistance. Be sure to tighten all hardware securely.

P. CUSTOMIZING THE FRAME

The standard frame can be adjusted to various angles and used creatively to suit a range of different
installation formats.

Q. GALVANIC REACTION BETWEEN STAINLESS AND ZINC GALVANIZED STEEL

Zinc galvanized components should NOT be installed in direct contact with stainless steel, as galvanic
reaction between the two metals can cause premature oxidation of the zinc coating and steel underneath.

1. If roof surface is galvanized steel, refer to Corrugated Roof installation guidelines.

2. Avoid using galvanized steel bolts. Use stainless steel components instead.

However, if galvanized components ARE used, avoid direct contact between the two metals by
using rubber/plastic separators.

PART 4: COLLECTOR INSTALLATION

A. INSTALLING CLAMP TO MANIFOLD

1. Place the manifold flat so the bolts are
facing up.
2. Remove nuts attached to bolts on manifold.
3. Secure clamps to the bottom of the manifold
using a ½” ratchet.

Figure 1 – Clamp to Manifold

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Summary of Contents for HP-30SC

Page 1: ...n MA 02717 0429 www htproducts com Evacuated Tube Solar Collector INSTALLATION MANUAL HP 30SC NOTICE HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature ...

Page 2: ...RD This manual is intended to be used in conjunction with other literature provided with the Evacuated Tube Solar Collector This includes all related control information It is important that this manual all other documents included with this system and additional publications including Solar Water Heating System Design and Installation Guidelines be reviewed in their entirety before beginning any ...

Page 3: ...mpany requirements Preference should be given to codes and requirements where they differ from the furnished instructions Additional publications which should guide the installer include Solar Water Heating System Design and Installation Guidelines SRCC OG 300 from Solar Rating and Certification Corporation 1679 Clearlake Road Cocoa FL 32922 5703 Code for the installation of Heat Producing Applian...

Page 4: ...ED LOOP SYSTEMS 9 3 DRAIN BACK SYSTEMS 10 F FLUID QUALITY 10 G METALLIC CORROSION 10 H FREEZE PROTECTION 11 I COLLECTOR DIMENSIONS WEIGHTS 11 J WIND STRESS 11 K SNOW LOAD 12 L STORAGE TANKS 12 M HAIL RESISTANCE 12 PART 3 INSTALLATION INFORMATION 12 A TRANSPORT UNPACKING AND INSPECTION 12 1 COMPONENT LIST 12 2 TUBE AND HEAT PIPE INSPECTION 14 B SYSTEM DESIGN 15 C DELTA T CONTROLLER SETTINGS 15 D ST...

Page 5: ...S AND ZINC GALVANIZED STEEL 18 PART 4 COLLECTOR INSTALLATION 18 A INSTALLING CLAMP TO MANIFOLD 18 B INSTALLING CLAMP TO BASE TUBE FRAME 19 C INSTALLING MANIFOLD AND BASE TUBE FRAME TO MANIFOLD ARMS 19 D INSTALLING TRIANGLE PLATE ASSEMBLY 20 E INSTALLING LEGS TO ASSEMBLY 21 F INSTALLING FEET TO ASSEMBLY 21 G INSTALLING THE SUPPORTS 22 H FLUSH FLAT MOUNTING 23 I INSTALLING EVACUATED TUBES 23 PART 5 ...

Page 6: ... 30 B CLOSED LOOP SYSTEM WITH ELECTRIC BACKUP AND STORAGE TANK 31 PART 8 MAINTENANCE 32 A CLEANING 32 B LEAVES 32 C BROKEN TUBE 32 D INSULATION 32 E DRAINING THE COLLECTOR 32 F OTHER COMPONENTS 33 G STAGNATION 33 PART 9 TROUBLESHOOTING 33 A NO HOT WATER 34 B REDUCED SOLAR CONTRIBUTION 34 C REGULAR WATER DUMPING 34 D INSTALLED COLLECTOR DETAIL 35 1 ANGLED COLLECTOR 35 2 FLUSH COLLECTOR 35 PART 10 I...

Page 7: ...aphical errors in literature PART 1 GENERAL SAFETY INFORMATION NOTE OBTAIN ALL APPLICABLE PERMITS AND OBEY ALL LOCAL CODES Only use this solar hot water system as intended and described in the installation manual use other than described will void warranty and may lead to fire property damage and personal injury Install all system components and piping in such a way that does not reduce the perfor...

Page 8: ...ling such components DO NOT STORE COMBUSTIBLE MATERIALS DRY LEAVES TREE BRANCHES GASOLINE ETC IN VICINITY OF THE SYSTEM D HEALTH AND SAFETY ALWAYS WEAR SAFETY GLASSES WHEN HANDLING EVACUATED TUBES WEAR LEATHER GLOVES WHEN HANDLING METAL COMPONENTS WEAR THICK LEATHER GLOVES IF HANDLING HOT HEAT PIPES ADHERE TO SAFETY REGULATIONS WHEN WORKING ON ROOFS OR AT A HEIGHT ALWAYS OBTAIN ENGINEER APPROVAL F...

Page 9: ...inlet of the collector This line incorporates the circulation pump Insulation Solar radiation level expressed in kWh m 2 day or Btu ft 2 day E POSSIBLE SYSTEM DESIGNS 1 OPEN LOOP SYSTEMS For open loop systems the normal operating pressure should be 72 5 psi via use of a pressure limiting pressure reduction valve on the main cold supply line It is acceptable for the system design to allow the solar...

Page 10: ...n back reservoir at per foot minimum to allow the system to drain F FLUID QUALITY Water in direct flow through the manifold header must first meet potable water requirements and in addition the following TOTAL DISSOLVED SOLIDS 600 ppm TOTAL HARDNESS 200 ppm 17 1 11 7 grains CHLORIDE 40 ppm FREE CHLORINE 5 ppm MAGNESIUM 10 ppm Table 1 In areas with hard water 200 ppm lime scale may form inside the ...

Page 11: ...tubes are not susceptible to damage in cold weather and heat pipes are protected against damage that could result from the freezing of the water inside NOTE HTP DOES NOT WARRANT THE SOLAR COLLECTOR AGAINST FREEZE RELATED DAMAGE I COLLECTOR DIMENSIONS WEIGHTS MODEL HP30SC OF TUBES 30 WEIGHT LBS 252 DIMENSIONS INCHES 101 X 79 X 58 NET APERTURE AREA FT 2 30 04 STORAGE TANK SIZE GALLONS 70 NOMINAL FLO...

Page 12: ...gle of 40 o or greater are able to withstand impact from hail larger than 1 in diameter The ability of evacuated tubes to withstand hail impact is greatly influenced by the angle of impact so installing the collectors at low angles does reduce their impact resistance It is recommended that in areas prone to large hail 3 4 the solar collector should be installed at an angle of 40 o or greater to pr...

Page 13: ...BRACE 4 LONGER THAN PART C PART C HORIZONTAL SUPPORT BRACE 3 SHORTER THAN PART B PART D MANIFOLD ARM 3 LONGER THAN PART A PART E CLAMP 6 PART F TRIANGLE PLATE 3 PART G FEET 6 PART H NUT 50 PART I 1 SMALL BOLT 40 PART I 2 LARGE BOLT 10 PART J BASE TUBE FRAME 1 ...

Page 14: ...er time This mild surface oxidation happens when the pipe is exposed to air This reaction is completely normal and does not affect the integrity of the pipe Do not remove and or expose the tubes to sunlight until ready to install otherwise the heat pipe tip will become hot enough to cause serious burns NOTE HTP DOES NOT WARRANT THE TUBE OR HEAT PIPES AGAINST FAILURE AS A RESULT OF DAMAGE INCURRED ...

Page 15: ...stem is designed to allow stagnation as a means of preventing tank overheating the collector and plumbing in close proximity may reach temperatures of 200 o C 395 o F components that may be exposed to these high temperatures such as valves plumbing or insulation should be suitably rated If the system is designed to allow stagnation of the collector when the tank reaches a set maximum level steam m...

Page 16: ...the Northern hemisphere this is due south and vice versa Facing the collector in the correct direction and correct angle is important to ensure optimal heat output A deviation of up to 10 o from due North or South is acceptable and will have minimal effect on heat output Given the formula above a solar collector installed at 30 o N latitude should face due south at an angle of 40 o 4 TO EASE OVERH...

Page 17: ...tion of banks of collectors larger pipe sizes should be used as required for the given application with consideration made to flow rates pressure drop and pump sizing The material used for the solar loop must be able to withstand the operating temperatures and pressures to which the system may be exposed due to normal or extraordinary conditions e g pump failure or power outage Copper pipe is the ...

Page 18: ...TION BETWEEN STAINLESS AND ZINC GALVANIZED STEEL Zinc galvanized components should NOT be installed in direct contact with stainless steel as galvanic reaction between the two metals can cause premature oxidation of the zinc coating and steel underneath 1 If roof surface is galvanized steel refer to Corrugated Roof installation guidelines 2 Avoid using galvanized steel bolts Use stainless steel co...

Page 19: ...ten the bolts with ratchet C INSTALLING MANIFOLD AND BASE TUBE FRAME TO MANIFOLD ARMS 1 Space out manifold arms so the rails line up with the clamps on the manifold and the base tube frame 2 Slide in the short bolts in the arms first 3 Slide small bolts into the rail before securing any nuts Align so the ends of the clamps are flush along the end of the rails 4 Secure manifold to manifold arms Fig...

Page 20: ... and tighten with ratchet D INSTALLING TRIANGLE PLATE ASSEMBLY 1 Slide two short bolts in the manifold arm 2 Align the edge of the triangle plate to the edge of the manifold arm 3 Secure the triangle plate to the manifold arm with nut tighten with ratchet 4 Repeat for the next two arms Figure 4 Manifold to Base Tube Detail Figure 5 Assembly and Detail Figure 6 Triangle Plate Assembly Detail ...

Page 21: ...should be able to pivot about the bolt without interference FOR FLAT MOUNTING SKIP TO PAGE 23 PART H TILT ANGLED MOUNTING F INSTALLING FEET TO ASSEMBLY 1 Place feet on the side of the manifold leg facing outward The foot on the middle leg can be placed on either side 2 Align so bottom of the foot is flush along the bottom of the manifold leg Figure 7 Leg Installation Detail Figure 8 Feet Installat...

Page 22: ... 1 Attach back brace across manifold legs 2 Align so both are 11 inches from the edge of the manifold legs 3 Attach the remaining back brace supports across the previous ones creating an X 4 Affix the back brace supports together with a large bolt through the middle of both supports Figure 9 Installation Detail Figure 10 Support Detail Figure 11 Back Brace Installation ...

Page 23: ...the middle support can face either side I INSTALLING EVACUATED TUBES NOTE DO NOT INSTALL EVACUATED TUBES UNTIL COLLECTOR MOUNTING AND SYSTEM PLUMBING IS COMPLETE 1 Unscrew plastic end caps 2 Insert fit ring into hole in manifold 3 Apply a small amount of liquid soap or other non flammable lubricant around the marked area to ensure smooth insertion Figure 12 Horizontal Support Installation Figure 1...

Page 24: ...rnessing equipment may be required for installation on higher pitched roofs and can provide a greater degree of safety for lower ones Be sure that the roof is dry before you begin installation Be sure that any ladders used are set firmly against the side of the building and mounted properly Have someone hold the ladder for you while you climb Be aware of any electric or water lines before drilling...

Page 25: ...eal the drill hole Use a standard corrugated iron roofing screw to secure the collector front feet directly to the roof s wooden frame additional holes may need to be drilled in the frame front track to properly secure the collector If the roofing screw is zinc galvanized steel it should have a rubber nylon washer to prevent direct contact with the stainless steel frame The rubber pad will form a ...

Page 26: ...tem design to minimize summer heat output Another advantage of installing under an eave overhang is to minimize snow buildup on the collector in areas with regular snowfall Even with snow sitting on the bottom of tube the heat pipes will work effectively to conduct heat as the inner tube temperature becomes fairly even for the full length of the tube due to heat transfer by the aluminum fins If in...

Page 27: ...alve on the tank side With the ball valve closed the drain valve can be opened to allow air to escape as water pressure forces through the line Released water may be hot Steam may release as well Once the drain valve no longer releases air close it Then open the ball valve so that normal operation can begin If an auto air vent is installed on the outlet of the collector air will automatically elim...

Page 28: ...allation should be sealed with watertight UV stabilized material such as adhesive backed aluminum foil Circulation pumps can be a source of significant heat loss and should be insulated Some pumps come standard with a molded foam casing which has good insulation properties If the pump does not have any insulation the same foam insulation used on the pipe can be used to cover the pump secured in pl...

Page 29: ...ssure Drop through HP 30SC with 40 Propylene Glycol Solution After determining gpm flow rate and total system head loss a properly sized pump can be chosen See recommendation from pump supplier to determine the proper pump for your job Incorrect pump size will reduce or fail to deliver solar contribution To further increase solar production use a variable speed solar pump controller p n 8600 047 ...

Page 30: ...AINBACK TANK WITH BACKUP WATER HEATER Figure 18 Drain Back Tank with Solar Water Heater LP 204 C This drawing is meant to show system piping concept only The installer is responsible for all equipment and detailing according to local codes ...

Page 31: ...TRIC BACKUP AND BOILER Figure 19 Closed Loop System with Electric Backup and Boiler LP 199 S This drawing is meant to show system piping concept only The installer is responsible for all equipment and detailing according to local codes ...

Page 32: ...ontacted B LEAVES During autumn leaves may accumulate between or beneath the tubes Please remove these leaves regularly to ensure optimal performance and prevent a fire hazard The solar collector will not cause the ignition of flammable materials Such cleaning may only be completed by the homeowner if the tubes are easily and safely accessible The following maintenance may ONLY be completed by AUT...

Page 33: ...ter may be scalding hot Take care when opening the drain valve Failure to do so could result in property damage serious injury or death due Table 4 F OTHER COMPONENTS Other parts of the system such as the pump and storage tank should be serviced inspected according to the manufacturers own maintenance guidelines G STAGNATION When going on vacation or not using your solar water heating system for a...

Page 34: ...lled the system INVESTIGATION H 1 Does the circulation pump appear to be operating In sunny weather the circulation pump should come on for 1 2 minutes every 3 5 minutes The pump may run very quietly so you may need to touch the pump or piping running to and from the pump with a solid object to feel for motor operation slight vibration NOTE Do not use fingers The pump may be hot H 2 Are all the ev...

Page 35: ...35 D INSTALLED COLLECTOR DETAIL 1 ANGLED COLLECTOR Figure 21 Angled Collector Views 2 FLUSH COLLECTOR Figure 17 Flush Collector Views ...

Page 36: ...LL INSULATED Y N 9 INSULATION ABOVE ROOF LEVEL IS PROTECTED AGAINST SUNLIGHT WITH FOIL WRAP OR EQUIVALENT Y N 10 CONTROLLER IS CONFIGURED CORRECTLY WITH FREEZE SETTING ON IF REQUIRED Y N 11 SYSTEM IS FITTED WITH PRESSURE RELIEF VALVE ON THE COLLECTOR OUTLET AND OR STORAGE TANK Y N 12 PRESSURE RELIEF VALVE WILL DUMP ONLY ONTO HIGH TEMPERATURE RESISTANT MATERIAL AND WILL NOT POSE A DANGER OF SCALDIN...

Page 37: ...37 MAINTENANCE NOTES ...

Page 38: ...Product Serial Number s Comments Installer s Phone Number 1 Signed by Installer Signed by Customer 2 IMPORTANT NOTES 1 Please only sign if you are happy with the service provided by the installer and the system is working properly If you are not satisfied call your HTP Sales Representative 2 In the case that the system has any problems please call the installer If you are unable to make contact or...

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