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Solar System Installation Guide
System Commissioning
Expansion Tank Commissioning
The pressure in the expansion tank may need to be adjusted based on several system parameters. There is a Schroeder
valve on the bottom of the expansion tank that is covered by a black piece of plastic. Remove this piece of plastic and
using a tire pressure gage check the pressure in the expansion tank. The tanks come charged to 36 psi.
If the height of the collector is less than 2 stories above, then the 36psi on the expansion tank is sufficient. The system
should be charged to 40-45psi (4-10 psi above the pressure in the expansion tank).
Filling the Solar Loop
The system is shipped with a premixed solution of glycol and water. The glycol solution cannot flow into the potable
water side of the tank because they are separated by the heat exchanger coil. All components within the system are
rated to withstand this fluid. Do not under any circumstance use any unauthorized fluid within the system as this may
damage the components within the system! The fluid provides a freeze tolerance limit of –49°F and is resistant of
temperatures of up to 250°F. Freeze tolerance limits are based upon an assumed set of environmental conditions. If it is
expected to be below the freeze tolerance limit, drain the glycol from the system.
Extended periods of cold weather, including ambient temperatures above the specified limit, may cause freezing in
exposed parts of the system. It is the owner’s responsibility to protect the system in accordance with the supplier’s
instructions if the air temperature is anticipated to approach the freeze tolerance limit.
The fluid will not deteriorate during normal system operation, but should be checked according to instructions on page
30 of the manual when at the prescribed service intervals. The system will take between 5 and 7 gallons of Tyfocor.
Before charging the solar loop with glycol, a leak test should be conducted. For this a hose bib to Schroeder valve
adaptor is required. The parts to construct this can be purchased at a hardware store. Connect this adaptor to the fill
port on the pump station and pressurize the system using an air compressor up to 40psi, or as local codes require
(caution do not exceed the relief pressure of the pressure relief valve of 87psi). Once the system is charged with air, let
the system sit for 10 minutes and see if the pressure has dropped. If so, this means that there is a leak somewhere in the
system. This can be wound by spraying connections with soap and water and looking for bubbles. Seal any leaks before
filling the system with glycol.
It is important that a motorized flush and fill center is used to fill and pressurize the system with Tyfocor as follows:
1)
Connect a glycol pump to the fill and drain ports of the pump station as shown on the following page.
2)
Open the fill and drain valves to allow the liquid to circulate around the solar loop
3)
Turn the hot and cold temperature gauges 45
o
clockwise to disable the check valves.
4)
Close the isolating valve above to the flow meter to ensure all air and liquid passes through the fill pump to filter
any air and contaminants (see diagram on following page).
5)
Run the fill pump to circulate the Tyfocor for approximately 5 minutes.
6)
Open and close the isolating valve intermittently to circulate air bubbles which may accumulate in the sight
glass. Open the air bleeder port to bleed the air out of the air trap once the fluid fills the loop.
7)
Return isolating valve to closed position.
8)
When the solar loop has been purged of air, close the bottom/drain connection – the fill pump will begin to
pressurize the solar loop. Continue to purge for another 5-10 minutes.
9)
Reopen the isolating valve above the flow meter fully.
10)
Fill the loop until the pressure gauge just exceeds the required pressure, close the valves on the pump station
and stop the pump. Check pipe joints on the solar loop for leaks and check that pressure is not lost over a 30
minute period.
11)
If there are no leaks, set the system pressure by opening the return connection to bleed a little fluid out until the
required pressure is met.
