Solar Boiler™ Installation Manual (OG-300), page 8 of 14
IN.410.06.DEC/99
Switch opens when
set point is reached
Set point control.
Set at 80°C (180°F)
Important: Disconnect ALL wires from
thermostat before connecting the wire from
the Solar Boiler™.
+ PV module
– PV module
Solar storage tank
top thermostat
Limit Control
Reset button
Solar Boiler™
terminal block
LCB (red)
LCB (white)
16
17
IN (RED)
OUT (BLUE)
on pump
Rear view of the Solar Boiler™
vent tube
pressure relief
valve
Solar Boiler™ cover
3/8" copper
tube
3/8" copper tube
(marked with
tape)
insulation
Connect to terminal block
•
The Solar Boiler™ module is precharged with the heat transfer fluid.
✍
❏
Remove the plugs from the brass fittings and retain. Replace with the nuts provided. Turn the nuts on
until finger tight.
❏
Insert the marked copper tube in the fitting located on the pump until it bottoms. Using two wrenches,
one on the fitting body and one on the nut, tighten the nut exactly one full turn.
❏
Repeat the above procedure for the other copper tube, which connects to the "IN"
(red) port under the pump.
Important: Do not over tighten the nuts. Failure to follow this procedure could
result in a leaky connection and/or cracked nut.
❏
Connect the photovoltaic module (PV) and solar storage tank thermostat to the
Solar Boiler™ terminal block as shown in the diagram.
Note: Not all tanks
have the same thermostat as shown in the diagram. Please refer to your tank
owners manual for a schematic of the thermostat.
❏
Set the top thermostat of the solar storage tank at 80
°
C
(180
°
F). Note: Some thermostats have a high limit which
is less than 80
°
C. If so, set the thermostat to its maximum.
Do not set the thermostat higher than 80
°
C.
CAUTION: NEVER CONNECT ANY OTHER WIRES
OR SOURCES OF ELECTRICITY TO THE SOLAR
STORAGE TANK THERMOSTATS!!! NO A/C POWER
IS TO BE CONNECTED TO THIS THERMOSTAT
Solar Boiler™ Start up
✍
❏
Pressurize the solar storage tank by opening the main cold
water supply valve and a hot water tap (near the Solar
Boiler™ if possible).
❏
As the solar storage tank fills with water, air will escape
through the open hot water tap. Check for leaks.
❏
When the solar storage tank is full, close the hot water tap.
❏
Ensure that the solar isolation bypass valves are in the
correct positions as indicated in step 15.
❏
Remove the pressure relief valve and brass cap from the
Solar Boiler. Some fluid may be visible.
❏
Connect the wires from the photovoltaic module to the
proper screws as shown in step 16. Ensure there is suffi-
cient sunlight. The pump will begin operation, and air
bubbling wwill be heard.
❏
When the pump has been running for a few minutes, you
will not hear any bubbling noise from the Solar Boiler.
Place a small container under the vent tube. Slowly, fill the
Solar Boiler with fluid until it comes out of the vent tube.
❏
Reinstall the pressure relief valve and brass cap. Pressurize
the system using a small pump. Pressurize to approximately
5 psi. (use a tire gauge to check the pressure).
❏
Check for leaks at all LifeLine® connections. If a leak is
observed, tighten the nut 1/4 turn. Remember to use two
wrenches, one on the fitting body and one on the nut.
vent tube
pressure relief valve
1/4" compression
nut
brass cap
air valve
fill tube