MAINTENANCE
21
S O L A R H O T W A T E R
6. O&M
Motor
Bolts
Close Ball Valves:
Rotate 90° CW
6.0. Annual Operational Checks and Troubleshooting
Every year the solar system should be checked to ensure optimal performance; these annual checks performed by a qualified professional
should not take the place of good operation overview by the systems owner.
Annually or more often, the following should be verified:
6.0.0. Check collector and water side pumps for operation
With proper operation, the hot or red gauge should read 10-20
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°F hotter than the blue gauge.
With a temperature difference greater than 20°F, set the pump speeds to a higher level. For a difference less than 10°F, set the pump
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speeds to a lower level.
Loud operation or squealing means air in the system, follow filling guidelines for re-pressurization.
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No temperature difference could mean a pump failure, test pump supply voltage at pump electrical box, listen and feel for OP.
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No temperature difference could also mean a diptube wasn’t installed correctly, or at the right length. Review tank schematics in this
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manual for proper length.
The hot and cold ball valves could be turned incorrectly; ensure the slots on the top and bottom of the plastic red or blue colored handle
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are aligned vertically.
The filling valve bypass could be turned incorrectly; ensure the slot aligns vertically.
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6.0.1. Check pressure gauge
Pressure gauge on HPAK should be no less than 30 psig when system is cold. Follow filling guidelines for re-pressurization.
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Inspect system for leaks.
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6.0.2. Check expansion tank pressure
The expansion tanks have a shraeder valve (like a bicycle tube valve) for pressurization; it should be charged with approximately 25
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psig.
6.0.3. Check the glycol color, concentration and pH.
Heliodyne has glycol testing kits that perform the required analysis. Review the data sheet for Dyn-O-Flo HD in this manual for proper
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levels.
Glycol should be a bright green color; anything else needs to be replaced. Use only Dyn-O-Flo HD or equivalent.
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6.0.4. Check the control and sensors
Ensure the sensors are giving proper readings by either viewing the software in the Delta-T Pro, or using a multimeter to measure
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resistance. See the control manual for further details.
Check wiring to ensure it is undamaged and continuous.
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6.1. Maintenance
To replace parts on the HPAK, close the hot and cold ball valves for servicing equipment
underneath them such as pump, heat exchanger, flow sensor, etc. For servicing PRV,
pressure gauge, expansion tank or collectors and piping, the system should be drained
in the direction of flow via the fill valve. If the fluid is good, drain it to a bucket for reuse.
Estimated time per component: 1-2 hours.
To replace any of the combo valves, unscrew appropriate valve, and replace gasket with
valve; torque connections to 30 lb-ft. Estimated time per component: 2 hours.
To service a pump, the motor housing only needs replacing, as volutes have no moving
parts. Disconnect electricity from HPAK, then disconnect the pump wiring with the spring
clamps. Unscrew the two allen-keyed bolts and replace motor and electrical connections.
Torque bolts to 80 lb-in. Estimated time per component: 2 hours.
To service the controller, disconnect the electricity from the unit and remove the box
housing, unplug all connections and power wiring, and replace the board. After reinstalling
a new controller, test operation by turning the control on manually.
Estimated time per
component: 1 hour.
