HelioMaxx Prepackaged Kits

HelioMaxx Prepackaged Kits

HelioMaxx Part List

Quantity (model)

Sku

50g

80g

120g

Description

Picture

Vacuum Tube Kits: ThermoPower-VHP

1x VHP20

1x VHP30

2x VHP20

SRCC OG-100 certified Vacuum Heat Pipe Collector

Flat Plate Kits: TitanPowerPlus-SU2

SRCC OG-100 certified Flat Plate Collector

UniMaxx-Plus

Solar Hot Water Pump Station

Etank-s-6g

6 gallon Solar expansion tank with piping and mounting bracket

HelioMaxx Prepackaged Kits

StorMaxxPTec Tank

1 x 50g

1 x 80g

1x 105g

Solar Storage Tank. Sizes vary based on kits.

FlowMaxx-5880 (Pro Kit Only)

80 ft. roll of 5/8" pre-insulated line set

FlowMaxx-QC58-M (Pro Kit Only)

Line set fitting with male 3/4" NPT

FlowMaxx-QC58-F (Pro Kit Only)

Line set fitting with female 3/4" NPT

FlowMaxx-MMSM (Pro Kit Only)

Bag of 4 Line Set Mounting Clips

Glycol-2_5GHT

2.5 gallons of High temperature Propylene Glycol heat transfer fluid

Valve-MixingAM101-US-1

Honeywell 100-145 F anti-scald valve

HelioMaxx Prepackaged Kits

Valve-TP-150psi

210F/150psi T & P Valve

Valve-34-F-F

3/4" Brass Ball Valve with Female NPT

Flat Plate - Balance of System Components

ConnectMaxxTPPSU2-Connect-F

Universal Connection Set with Female NPT

Vacuum Heat Pipe - Balance of System Components (Pro Kit Only)

Elbow-BRA-34-190D-FF

1" to 3/4" Brass Elbow Female NPT

Tee-BRA-1-34-34-FFF

1" to 3/4" to 3/4" Brass TEE

Union-BRA-1-F

1 Brass Union Female NPT

HelioMaxx Prepackaged Kits

Valve-34-F-F

3/4" Brass Ball Valve with Female NPT

Nipple-BRA-34-2

2" Long Brass Nipple 3/4" NPT

Bushing-BRA-34-12

3/4" to 1/2" Brass Bushing

Vent-HY-B-18-M

1/8" Automatic Air Vent

WARNING!
For your safety, please read through this manual carefully before installation to minimize the risk of property damage and personal injury! Any work you perform must be adapted to suit conditions on site and must be in accordance with technical and local regulations. Installation must be carried out by technically qualified and authorized professional personnel who possess the required licensing, if applicable.

Table of Contents
1.0 Safety Precautions ........................................................................................................................................................... 8 1.1 Evacuated Tubes ..................................................................................................................................................... 9 1.2 Flat Plates................................................................................................................................................................... 9 1.3 System ......................................................................................................................................................................... 9 2.0 Introduction ..................................................................................................................................................................... 10 6

HelioMaxx Prepackaged Kits

2.1 Features .................................................................................................................................................................... 11 2.2 Benefits ..................................................................................................................................................................... 11 3.0 Before You Begin ............................................................................................................................................................ 11 3.1 Tools You May Need ............................................................................................................................................ 12 3.2 Positioning the Collectors ................................................................................................................................. 12 4.0 Main Components in HelioMaxx Systems: ........................................................................................................... 14 4.1 Vacuum Tube Collectors .................................................................................................................................... 15 4.2 Flat Plate Collectors ............................................................................................................................................. 15 4.3 UniMaxx Pump Station ....................................................................................................................................... 16 4.4 Pre-Insulated Lineset .......................................................................................................................................... 16 4.5 Automatic Air-Bleeder Valve .......................................................................................................................... 16 4.6 Expansion Tank ..................................................................................................................................................... 16 4.7 Solar Storage Tank ............................................................................................................................................... 16 4.8 Other Components .............................................................................................................................................. 17 4.9 Mounting Kits ......................................................................................................................................................... 17 5.0 The Pump Station ........................................................................................................................................................... 17 5.1 Mounting the Pump Station ............................................................................................................................. 17 6.0 Piping .................................................................................................................................................................................. 20 6.1 Overall Diagram .................................................................................................................................................... 20 6.2 Collector Fittings................................................................................................................................................... 21 6.2.1 Flat Plate Fittings ........................................................................................................................................ 22 6.2.2 Flat Plates in Array ..................................................................................................................................... 24 6.3 Vacuum Tubes........................................................................................................................................................ 25 6.3.1Vacuum Tube Fittings ................................................................................................................................ 25 6.3.2 Mounting Vacuum Tube Collectors in Series .................................................................................. 25 6.4 Pressurized Storage Tank ................................................................................................................................. 26 6.5 Preparing the FloMaxx Lineset ....................................................................................................................... 26 6.4.2 Roof Penetrations ....................................................................................................................................... 29 7.0 Configuring the Controller ......................................................................................................................................... 32 7

HelioMaxx Prepackaged Kits

7.1 Sensors and Wiring .............................................................................................................................................. 32 7.2 Programming the Controller............................................................................................................................ 34 8.0 Charging the System ..................................................................................................................................................... 34 8.1 Pressurizing the System .................................................................................................................................... 34 8.1.1 Determining System Pressure ............................................................................................................... 34 8.1.1 Pressurizing with Air ................................................................................................................................ 34 8.2 Flushing the System............................................................................................................................................. 35 8.3 Preparing the Heat Transfer Fluid ................................................................................................................ 35 8.4 Filling the System ................................................................................................................................................. 35 9.0 Performance Assessment ........................................................................................................................................... 37 9.1 Starting Tank Temperature .............................................................................................................................. 37 9.2 Determining Solar Potential............................................................................................................................. 37 9.3 Determine Collector Array Yield .................................................................................................................... 37 9.4 Determine Heat Transfer Across Collector Array ................................................................................... 38 9.5 Determine the Heat Transfer Across Collector Array ........................................................................... 38 10.0 Operations and Maintenance.................................................................................................................................. 38 10.1 Measuring Glycol Concentration ................................................................................................................. 38 10.2 Measuring Glycol Acidity ................................................................................................................................ 38 10.3 System pressure ................................................................................................................................................. 38 10.4 Piping Insulation ................................................................................................................................................ 38 10.5 Inspection of broken tubes (Vacuum Tube Systems Only) .............................................................. 38 10.6 Cleaning the Collectors ....................................................................................................... 33 10.7 System Commissioning and Maintenance.....33 11.0Troubleshooting.35

1.0 Safety Precautions

IMPORTANT SAFETY PRECAUTIONS. READ CAREFULLY!

HelioMaxx Prepackaged Kits

1.1 Evacuated Tubes 1. The tip of the heat pipe can reach temperatures in excess of 392F (200C) when the tube is exposed to sunlight. It is recommended that you use leather gloves when handling vacuum tubes and that you install the tubes during cloudy days or during nighttime hours. Thick leather gloves should also be worn when handling hot heat pipes. 2. The vacuum tubes are relatively fragile, and will break if struck by a hard object or are dropped. Care must be taken when handling broken glass from the tubes, and wherever possible protection should be used to prevent breakage. It is also highly recommended that you consistently be on the lookout for broken glass in the vicinity of the collector array in the event of a storm or object falling on the collectors. 3. If they have internal pressure built up, tubes may explode if broken rather than implode when broken. This is an uncommon occurrence but one that should be taken into consideration. 4. In areas prone to large hail (>3/4 (20mm)), it is recommended that the collectors be mounted at an angle 40 or greater so as to minimize the impact force 5. Always wear safety goggles when handling vacuum tubes. 1.2 Flat Plates 1. The glass panel of the flat plates is relatively fragile, and great care should be taken to ensure that no hard objects fall onto it and cause breakage 2. When exposed to sunlight, even when empty of heat transfer fluid, the threaded fittings at the input and output of the collector can become extremely hot. Leather gloves are recommended when installing piping and plumbing components to the flat plates. 1.3 System 1. It is important that the system you install is fully planned out and dimensioned before installation to avoid unforeseen and possibly dangerous circumstances as well as to have a more efficient installation. 2. Leather gloves should be worn any time when handling hot components. 3. When charged, the heat transfer fluid WILL become hot. Any leakage can cause serious scalding and steps should be taken to make sure that the system is thoroughly sealed before charging.

HelioMaxx Prepackaged Kits

4. It is important that use appropriate safety measures when working on a roof. Safety harnesses should be worn at all times when installing collectors onto a pitched roof and proper footwear should be worn to prevent slippage. 5. Do not install collectors during times of high wind velocities. Obtain approval from an engineer before installing collectors in high wind regions. 6. Installation must be completed in accordance with relevant local standards and regulations. 7. Installation must be completed by a qualified tradesperson who holds relevant industry licenses or certificates required that are valid during the installation. 8. Unless otherwise specified, no part of the HelioMaxx system may be inspected, repaired, maintained, or commissioned by anyone who is not authorized personnel. 9. Always be sure that everything you do is in compliance with OSHA regulations NOTE: SunMaxx Solar reserves the right to make product changes or updates without notice and is cannot be held responsible for typographical errors in literature.

2.0 Introduction
The HelioMaxx prepackaged kit is the solar industrys leading domestic hot water solution. The basic kit, complete with high performance SunMaxx Vacuum Tube or Flat Plate Collectors, StorMaxx storage tank, and UniMaxx pump station, is designed to provide more that 50% of a households hot water needs. Also available is the HelioMaxx Pro kit, which contains an exhaustive set of components including FlowMaxx pre-insulated piping, mounting hardware, and additional valves and fittings. Developed by experienced industry professionals with installers in mind, these kites combine cutting-edge solar equipment and hydronic accessories to minimize set up time and streamline the installation process.

2.1 Types of HelioMaxx Kits

HelioMaxx Kits with TitanPower Plus-SU2 Collectors Model/SKU HelioMaxx-50FP HelioMaxx-80FP HelioMaxx-120FP Daily Hot Water Consumption 50 Gal 80 Gal 120 Gal 1 2 3 Number Of Collectors

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HelioMaxx Kits with ThermoPower Vacuum Heat Pipe Collectors Model/SKU HelioMaxx-50VHP HelioMaxx-80VHP HelioMaxx-120VHP Daily How Water Consumption 50 Gal 80 Gal 120 Gal Number of Collectors 1 1 2

2.2 Features SRCC OG-100 certified collectors Unimaxx integrated pump station Leading performance among OG-100 collectors Comprehensive, turn-key package Retrofits virtually any existing system

Hassle-free installation StorMaxx Premium storage tank Innovation, patented components

2.3 Benefits HelioMaxx kits feature collectors that are among the most efficient SRCC rated vacuum tubes and flat plates. HelioMaxx Kits eliminate 50%-80% of a homes hot water bills, can pay for themselves in 2-7 years, and provide free hot water for up to 30 years.

3.0 Before You Begin

Be sure the following equipment is ready at the job site: SunMaxx collectors Mounting hardware Roof Penetration Hardware FloMaxx Lineset Component fittings and unions for collectors, pump station, storage tank, and lineset Propylene Glycol (high temp or mixture) 11 Pump Station w/controller Isolation valves, tempering valves StorMaxx solar storage tank

HelioMaxx Prepackaged Kits

Temperature sensors

Make sure water tank has been depressurized. Do this by cutting off the cold water supply to the tank and allowing the pressure to leave the system. Leaving a faucet on, for example, will accomplish this. Make sure that the roof has full traction. If it is wet from a recent rainfall or has ice buildup you should not be doing collector installations. Make sure that each component of the system is present and unbroken. If anything is broken or missing, contact SunMaxx to see what options are available to you in terms of replacement. 3.1 Tools You May Need Electric Drill Hack Saw Tubing Cutter Tin Snips 16 Tape Measure Ladder High Traction Work Boots Harness, Safety Line Adjustable Ratchet Adjustable hex wrench for 1.25 thru 1.875 hex sizes. Philips screw driver (for tank sensor installation) 1/4 drill bit for 3/8 lag screws 1/8 drill bit for 1/2 lag screws Teflon Tape or Pipe Dope 1/2 wrench/socket for 3/8 bolts and nuts 3/4 wrench/socket for 1/2 hanger bolts and nuts

3.2 Positioning the Collectors The collector is positioned in terms of its azimuth angle and inclination angle.

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Azimuth angle refers to the lateral angle between true south and the perpendicular of the face of the collector. Ideally, this angle should be zero, for when the collector faces due south is receives the maximum amount of incident radiation from the sun. However, due to conditions such as the direction an inclined roof faces and objects that produce shade, deviations are usually present and are usually acceptable. In order to determine the proper azimuth angle, it is necessary to ascertain the direction of true south. True south is the direction pointing to where the sun is highest in the sky, or zenith. True south differs from magnetic south due to the fact that the magnetic poles do not precisely match up with the geographical north/south poles of the earth. Determine your magnetic declination in your region before you decide on an azimuth! Inclination angle refers to the angle between the collector and the horizontal ground. Determining the proper inclination angle involves understanding a little bit about how the position of the zenith changes throughout the year. The change in zenith angle is based on the fact that the axis of the earths rotation is tilted approximately 23.5. Because of this, the maximum zenith angle for any particular location is the latitude plus 23.5 (June 22), whereas the minimum zenith angle is the latitude minus 23.5 (December 22). In order to get the best year-round solar fraction, it is recommended that the inclination of solar collectors be as close to you latitude as possible. This represents the average of the zenith throughout the year. However, if a majority of your heat load is during a particular time of year, it would be a good idea to adjust the inclination accordingly (less for high summer usage and more for high winter usage). See the table below for recommended dimensions for mounting hardware and collector spacing in order to accomplish proper inclination angles.

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Once you have determined the required dimensions and orientation for you collectors and mounting hardware, refer to the our guide on roof mounting.

4.0 Main Components in HelioMaxx Systems:

There are a variety of HelioMaxx Prepackaged systems to meet almost any domestic situation you may have. The component list is shown below (keep in mind not every component is available in every kit). 14

HelioMaxx Prepackaged Kits

4.1 Vacuum Tube Collectors Overall Length: 79 (1980mm) Overall Height: 6.14 (155mm) (for manifold and standard frame) Brand name: ThermoPower VHP

# of tubes

10

20

25

30

Width Aperture Area Gross Dry Weight Fluid Capacity

37.5

70.2

86.2

102.9 30.04 ft2 (2.79m2) 252

10.01ft

20.03ft

25.03ft

88

170

212

.29 gal

.54 gal

.66 gal

.79 gal

4.2 Flat Plate Collectors

Brand Name: TitanPower Plus-SU2

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Dimensions

79.4 x 38.78 x 3.03

Absorber Area

20.16ft2

Aperture Area

20.16 ft2

Gross Area

21.37 ft2

Gross Dry Weight

79.96 lbs

4.3 UniMaxx Pump Station The pump station is the enclosure that contains the flow meter, pressure gauge, variable speed pump, pressure relief valve, piping connection to the expansion tank, manual air separator, and the controller itself. It is mounted to the wall using an included set of hardware. It is essentially the brain of the entire system and controls how the system operates. 4.4 Pre-Insulated Lineset In order to make the piping of the solar loop much simpler, SunMaxx provides pre-insulated flexible lineset in every prepackaged kit. This lineset will, with the right fittings (also included), connect directly from the tank to the pump station and onwards from the pump station to the collectors. 4.5 Automatic Air-Bleeder Valve This device is placed at the uppermost point of the system and will purge the system of small air bubbles as the heat transfer fluid circulates. This component is only present in the fitting set for the flat plate collector kits. 4.6 Expansion Tank In times of collector stagnation (when the solar production is high and the demand is low) temperatures within the collectors will reach very high temperatures. This causes the water in the system to evaporate and expand, creating an increase in system pressure. The expansion tank absorbs an amount of this fluid expansion and will help to prevent the pressure relief valve from going off. Included with the expansion tank is a specialized mounting bracket and braided lineset. 4.7 Solar Storage Tank This is where heat exchange between you collectors and potable water takes place. The StorMaxx pressurized tanks offered by SunMaxx provide an internalized heat exchanger, so all that necessary is to affix the linesets from the solar 16

HelioMaxx Prepackaged Kits

loop to the designated inlet and outlet of the tank. It also has an inlet and outlet for use in auxiliary heating, which is necessary in virtually all systems, as well as an additional opening for recirculation. 4.8 Other Components HelioMaxx Prepackaged kits come with 3 temperature sensors, one of which is a high temperature resistant sensor. These are used to measure the temperatures at various points in the system and send the data back to the controller, which reacts according to the data it receives. 4.9 Mounting Kits These kits include the hardware necessary to mount your collector(s) to the roof. Depending on the amount of collectors and preferred mounting style, your kit may have differing mounting hardware. This manual does not cover manual mounting installation, however, so refer to the appropriate document when attempting to mount a collector.

5.0 The Pump Station

All connections are pre-assembled by the manufacturer. Check for leaks when commissioning the station (pressure test).

5.1 and 5.2 Mounting the Pump Station and Expansion Tank 1. Determine where to mount the pump station; remember to include space for the expansion vessel! 2. Take the complete station out of the packing. 3. Remove the front half of the insulation by pulling it. The thermometers loosen from the ball valves. Do not unscrew the pump station from the back part of the insulation! 4. Mark the fastening holes and drill holes; insert the enclosed dowels. 5. Fasten the complete pump station with the wall mounting bracket to the wall (depending on the pump version, upper or lower holes in the insulated casing) and tighten the screws. For this purpose, use a positive crossrecessed screwdriver! 17

HelioMaxx Prepackaged Kits

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Wall Bracket Back Housing IntelliMaxx Controller Front Housing Flow Meter Drain Valve Pump Ball valve (supply) Ball valve (return) Safety Head Piece Pressure Gauge Safety Valve Expansion Vessel Set Air Bleeder Valve

Wall Mounting: 1. Determine where to mount the pump station. Be sure that it is easily accessible and does not interfere with any other machinery. Keep in mind you will need to leave space for the expansion vessel.

2. Take the pump station out of its packaging. Remove the front half of the insulation by pulling it. The thermometers loosen from the ball valves.

3. Mark the fastening holes on the wall and drill the holes. Insert the enclosed dowels.

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4. Fasten the complete pump station with the wall mounting bracket to the wall (depending on the pump version, upper or lower holes in the insulated casing) and tighten the screws. For this purpose, use a positive cross-recessed screwdriver.

5. The default settings on your controller are most likely valid and will allow your system to function efficiently. If you wish to engage in any reprogramming, it is highly recommended that you read the product manual for the controller. 5. Attach the mounting bracket to the expansion tank to the wall at least 6 inches away from the pump station using the mounting screws provided. It can be mounted with the bracket facing up or down. Connect the expansion tank to bracket using the union provided in the expansion tank hardware. This union attaches directly to the braided expansion tank lineset which subsequently attaches to the designated port on the pump station.

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6.0 Piping
6.1 Overall Diagram The fully assembled and piped system should follow the guidelines of the diagram below:

HelioMaxx DHW Kits with Flat Plates

*collector array varies with kits

HelioMaxx DHW Kits with Vacuum Heat Pipes

NOTE: IT IS CRITICAL THAT YOU UTILIZE TEFLON TAPE OR PIPE DOPE TO ENSURE A PROPER SEAL. NEGLECTING THIS WILL CAUSE YOUR SYSTEM TO LEAK SCALDING HOT FLUID

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HelioMaxx DHW Kit with Vacuum Heat Pipe

*Collector array varies with kits

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6.2 Collector Fittings 6.2.1 Flat Plate Fittings The fittings of SunMaxx TitanPower Flat Plate collectors are BSP threading. The fittings on the left side of the collector are male, whereas the fittings on the right side are female.

Female Fitting Male

Male Fitting

Female

Depending on how you pipe your collectors, the inlet and outlet can be on either side of the collector. Just keep in mind that the outlet must always be on the top port and the inlet must always be on the corner diagonal from the it. See below:

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1. At the outlet of the flat plate collector, attach the ConnectMaxx-TPPSU2 as shown below. Be sure that you place a carbon gasket between the components to maximize the seal. NOTE: The outlet of the collector is always at the top!

2. Seal off every unused port of the flat plate using a brass cap and a carbon gasket.

At the outlet at the top of the flat plate, you will attach a manual air bleeder valve. Be sure to use a carbon gasket when installing the manual air bleeder valve assembly

Caps must be attached to each open fitting of a flat plate collector. Likewise, a carbon gasket must be inserted in order to maintain a proper seal.

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6.2.2 Flat Plates in Array

In order to have multiple collectors in the same solar loop, it is necessary to mount the collectors as an array. Because the Collectors have both male and female fittings, it is possible to simple attach one to the other. You must use a carbon gasket ring for the connection, however.

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HelioMaxx Prepackaged Kits

6.3 Vacuum Tubes 6.4 6.3.1Vacuum Tube Fittings The outlets and inlets of a SunMaxx ThermoPower VHP collector are both 1 NPT male nipples. All that is needed to allow for them to be compatible with the lineset is a simple 1 to reducer.

6.3.2 Vacuum Tubes in Array

When Mounting Several VHP collectors in series, all that is necessary is a 1 union.

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6.4 Pressurized Storage Tank When installing the pressurized storage tank, be sure that it is level and stable, and that all of the ports are easily accessible. The StorMaxx Pressurized storage tanks have NPT nipples for the inlet and outlet of the solar loop, indicated below. 1 NPT Male are used for the domestic loop. At the Inlet and outlet of the solar heat exchanger in the tank, attach a ball isolation valve.

Solar Loop Inlet/Outlet

Insert the gray pt1000 sensor into the sensor port in the lower portion of your tank. Attach the wire leads into the S2 terminals on the controller.

For the relay to the pump, wire the 115v line to the terminals labeled lead/ground/neutral. Only strip a short part of the sheathing (less than in) to minimize loose wiring.

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HelioMaxx Prepackaged Kits

6.5 Preparing the FlowMaxx Lineset Based on the piping diagram, you will need four lengths of insulated piping. 2 will lead from the pump station to the StorMaxx pressurized tank, where the other 2 will be the supply and return leading from the pump station to the collectors. Determine the necessary lengths for each section and cut them using a hacksaw. Be sure to cut to at least 12 feet longer than is necessary, for it is better to have a little slack in the line than to fall short. To complete the piping of your system, it is now necessary to connect every component together using the FlowMaxx Insulated line sets provided. The ends of the linesets should all have male fittings, and if you have attached all the adapters for the rest of the components correctly, everything else should have female fittings.

1 Place nut over the corrugated line set

2 Bend C clamp around 1st corrugation in front of Nut

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3 Place aluminum slug at the end of the corrugated line. Bring the nut up to position holding the slug in place.

4 Tighten down the fitting, compressing the slug

5 Remove the fitting and slug. The end of the corrugated line set should now be flattened and ready to be fitted.

6 Reattach the fitting to the nut, inserting a graphite washer between it and the nut.

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HelioMaxx Prepackaged Kits

Repeat this process for each end of the lineset. Keep in mind that each span of lineset will have a male fitting at one end, and a female fitting at the other. This procedure only illustrates the male fitting, but the procedure for the female fitting utilizes the same process albeit with a different apearance.

6.4.2 Roof Penetrations 6.4.2a Roof Hooks The roof hooks represent an essential component of our universal roof mounting hardware. Whether you are installing flat plates or vacuum tubes you will need to utilize these roof hooks to properly mount your collectors. 29

HelioMaxx Prepackaged Kits

If installed correctly, the roof hook flashing system provided by SunMaxx Is waterproof Will not cause excessive shading of Is in compliance with all codes put forth other collectors in array by the National Roofing Contractors Association Will not compress insulation Is secure against insects and vermin Will not reduce fire resistance below code Is capable of supporting TitanPower Plus-SU2 or ThermoPower VHP Will isolate roof and construction collectors at all recommended tilt and materials from the high temperatures azimuth angles generated by the collector array. Before you begin, it is important that you are well aware of the required spacing between the mounting feet as well as their locations on the roof. The feet will be bolted directly in to the rafters, so it will also be necessary to locate where the rafters lie. One way to do this is to locate the rafter overhang at the side of the house and mark out the rafters path on the roof using chalk. Another is to locate an eyebrow vent on the roof and measure off its center equally in both directions. It is also possible to find rafters using a density meter. During frosty conditions the rafters perimeters will be visible from the roof. If all else fails, youll have to go into the attic.For instructions on mounting the roof hooks, read the procedure below: 1.The solar hook fastens directly into a rafter without the need to pre-drill any holes. The first bolt to be screwed in should be the one with the elongated hole, as this will allow for easier vertical alignment

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2. Slide the tail of the flashing under the head lap of the roofing material directly above the installed mount and rotate the flashing down so that its final position is centered horizontally. Fasten the flashing to the roof using NRCA approved roof sealant.

3. It may be necessary to cut out sections of overlapping tile to make room for the flashing. Use a utility knife or equivalent to accomplish this.

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3. Repeat this process for all of the mounting feel required. Make sure that the horizontal spacing between the feet is less than the length of the mounting rail. If you are flush mounting, the vertical spacing is already determined, but if you are utilizing a tilt mount, it will be necessary t o pre-assemble the collector mounting frame and record down the spacing required for the back leg to be perpendicular to the roof.

4. Depending on the type of kit you have and the roof layout you have available

7.0 Configuring the Controller

7.1 Sensors and Wiring Insert the Black pt1000 sensor into the supply side of your last collector in series using the sensor wells built in to the collector. Attach the wire leads into the S1 terminals on the controller. This sensor wire should be routed through the pre-insulated lineset alongside the piping. For ThermoPower Vacuum Tube Collectors, locate the sensor port on the side of the manifold and directly insert the high temperature sensor with a generous amount of adhesive sealant.

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For the SunMaxx TitanPower Collectors, you will use the sensor housing included with the flat plate fitting assembly. Insert the sensor through the fitting cap and then into the housing, screwing the fitting cap into place and securing the sensor in place.

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Insert the gray pt1000 sensor into the sensor port in the lower portion of your tank. Attach the wire leads into the S2 terminals on the controller.

For the relay to the pump, wire the 115v line to the terminals labeled lead/ground/neutral. Only strip a short part of the sheathing (less than in) to minimize loose wiring. 7.2 Programming the Controller The default settings on your controller are most likely valid and will allow your system to function efficiently. If you wish to engage in any reprogramming, it is highly recommended that you read the product manual for the controller included or contact our engineering/technical support department.

8.0 Charging the System

8.1 Pressurizing the System 8.1.1 Determining System Pressure The overall pressure of the system should be between 17-90 psi. The pressure of your system will not necessarily affect its performance, but a general rule of thumb in determining a good system pressure (in psi) is to take the vertical height of your system (in feet), divide it by 2.31, and add 15. 8.1.1 Pressurizing with Air A compressor with at least hp should be used to pressurize the system with air. 1. Attach a Schrader valve to the female end of a standard garden hose to allow it to fit into the fill valve of your pump station. Close the drain valve. 2. Activate the compressor. Observe the pressure gauge on the pump station and make sure that the pressure is increasing. 34

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3. Deactivate the pump and seal off the system and observe the pressure gauge on the pump station. If the pressure remains constant for around 10 minutes, your system is most likely leak free. If the pressure falls search for leaks around the piping. A trick to doing this is to lather all joints and fittings with soapy water. If there is a leak at that location the soap will bubble. 4. Depressurize the system by depressing the Schrader valve 8.2 Flushing the System Flushing involves running water into the fill valve and having it circulate around the system before being expelled at the drain valve. It is recommended that you use the SunMaxx filling station to do this. Flushing removes any existing fluid and loose particulates that can otherwise cause stress to the system over time. Be sure the water flowing out of the drain valve is contained in a proper receptacle (such as a 5gal barrel) Another application of flushing is closing the drain valve and allowing the system to fill. When it is full and the pressure gauge starts to increase, deactivate the filling station and let the water drain into a receptacle. By measuring the amount of water in said receptacle, the overall system volume can be determined. 8.3 Preparing the Heat Transfer Fluid In most situations it is necessary to use a 40-50 percent mixture of glycol and water as your heat transfer fluid. The addition of glycol is meant to prevent freezing, which has the potential to seriously damage the system. Based on the volume you determined from flushing, create the appropriate mixture. It is advisable to make an extra 10-20 percent of the solution as to ensure there will be no shortage of fluid. Place the mixture into the SunMaxx fill station. 8.4 Filling the System 1. Close the Butterfly valve between the fill and drain valves with a flat head screwdriver. 2. Connect the return hose from the SunMaxx fill station to the filling valve of the pump station, and the supply hose to the drain valve. 3. Activate the fill station. The fluid being supplied to the system will circulate and exit at the drain valve, where it will reenter the fill station. Continue allowing the pump to circulate the fluid until the fluid coming out of the drain valve ceases to bubble. 4. When the bubbling ceases, close the drain valve while leaving the pump on. Continue to fill the system until the pressure gauge reaches the pressure level you determined earlier. At which point, close the filling valve and quickly open the butterfly valve. 5. Activate the solar pump to ensure the system is running.

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8.5 Inserting the Vacuum Tubes Note: Inserting the tubes should be the last step in installing and commissioning a vacuum heat pipe collector system.

Slide the heat pipe approximately 6 inches out from the glass tube and aluminum fin. Then, insert the bulb of the heat pipe into the manifold. To insert the glass tube, Apply lubricant to the end of the glass tube, as it will make insertion much easier and breakage less likely. Once the glass tube is in place, affix the rubber gasket to the manifold by slipping it over the tube.

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9.0 Performance Assessment

After the system has been installed, it is important that you make sure that it is performing as well as it was expected to. It is better to find errors right away than to find them on your next fuel bill.

To properly assess the performance of your system, follow the steps below: 9.1 Starting Tank Temperature Record the starting temperature of your tank as seen on the controller. Write this number down, as it will be necessary for future calculations.

9.2 Determining Solar Potential Determine the solar potential for your area. You can do this by downloading RETscreen4: http://www.retscreen.net

1.Find the closest location in the database. Write down the insolation data for the month you are installing the system. 2.Multiply that number by 317.1 to convert to btu/ft2/hr. 3.Multiply that product by the total number of square feet of absorber (one tube equal 1 ft) 4.Multiply this number by the efficiency of the tubes (.73) or the efficiency of the flat plates(.7) 5.This product should be the total btus produced by your system per day if mounted to ideal conditions 6.Reduce by 10% if mounting is more than 30 degrees of appropriate incline angle. 7.Reduce by 10% if mounting is more than 15 degrees off of true south.

9.3 Determine Collector Array Yield 1.At the end of the day, record the temperature of your tank. Find the difference between this temperature and the starting temperature. This is the temperature differential.

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HelioMaxx Prepackaged Kits

2.Multiply this differential (heat gain) by gallons of storage and multiply that by 8.3. This number represents BTU production yielded by collector array during that solar day. 9.4 Determine Heat Transfer Across Collector Array Compare temperature difference from collector inlet temp and collector supply temp. There should be a 4-7 degrees difference per collector. 9.5 Determine the Heat Transfer Across Collector Array Determine the difference in temp across the exchanger. This should equal the temperature gain across collector. Adjust flow rate accordingly with isolation valve or pump speed to compensate for inconsistencies

10.0 Operations and Maintenance

10.1 Measuring Glycol Concentration Each year it is important to make sure the concentration is consistent with manufacturers recommendation to ensure the warranty is upheld. Use a spectrometer or hydrometer to gain accurate results. 10.2 Measuring Glycol Acidity Measure the acidity of the glycol by use a pH kit or digital pH tester and measure the pH of the glycol loop. Be sure the reading falls between 7.0-8.8. 10.3 System pressure Ensure that the system is still operating at the target pressure set at step 8.1.1 10.4 Piping Insulation As time goes by and the system is exposed to more and more contact with external sources, the insulation of the various components of your system, most notably the piping, will depreciate. It is recommended that you check periodically to ensure that the insulation is still affixed in its proper location and is free of holes and tears. 10.5 Inspection of broken tubes (Vacuum Tube Systems Only) The vacuum tubes on the roof are susceptible to damage over time from various environmental and physical elements. A quick periodic check from ground level to make sure that the tubes aren't broken is recommended. The tubes are also at risk of losing their vacuum seals. This can easily be inspected for by checking the base of the tubes. If a white powdery substance is present in the tube, the seal is compromised and the tube will need to be replaced. 38

HelioMaxx Prepackaged Kits

10.6 Cleaning the Collectors Over time the collectors can accumulate buildup of sediment and dust particles that will cause the system to lose efficiency. It is a good idea, therefor; to clean off the collectors on a regular basis (annually is recommended). 10.7 System Commissioning and Maintenance Follow these guidelines in order to properly commission your system. 1) Safety First a) OSHA standards must be observed and practiced i) http://www.osha.gov/index.html a. When handling Glass you must wear protective eye wear and gloves 2) Pressurizing Line Set a) With air compressor i) Using an air compressor of hp pump, you must first pressurize the system, not exceeding 90 psi. Visually inspect lines for leaks, watch pressure gauge. ii) convert a hose thread female fitting with a schrader valve that will allow you to connect your compressor to the fill port. Be sure all valves are closed that would allow air to escape. b) Determine the system pressurei) Your system will function between 17-85 psi. Pressure will not affect the collector performance but should not exceed 85 psi. ii) To find the proper pressure for your system take the total vertical height and divide by 2.31 and then add 15 psi to that. The result will be your target pressure. Do this before charging your system and remember your target pressure. Typically, the average domestic hot water system is set between 15-20 psig (gauge pressure) 3) Flooding and Purging a) Mixing glycol i) You must use a 40-50% glycol mixture (for a closed loop glycol system)in most climates north of 35N latitude. ii) If you are using a premix solution then you can simply pump the solution in (see filling system section). iii) If you are NOT using a premix then you must first determine the total system volume. The simplest way to accomplish this is by filling the system with water (this helps to clean the pipes as well). Then drain the system down and determine the total volume. You can also determine the volume that you added and subtract the volume that comes out to find total. If you add 100% glycol to the water in the pipe it WILL mix in the loop. b) Filtering/Flushing i) Filter your system before closing it in commission. Small particulates can put stress on your system over time. This can be accomplished by using the Sunmaxx solar filling station with a built in filter. c) Filling system - The pump station has fill/drain valves above and below the pump. Between the valves is a butterfly valve with a flat head screw. Together these make up your filling station. i) Make sure you know what pressure you are trying to accomplish in your system for reference; See 2.b.ii. ii) You must first close the butterfly valve with a flat head screwdriver. 39

HelioMaxx Prepackaged Kits

iii) Open the valves and connect your hoses to each of the hose fittings. iv) Make sure your solar filling station is full with the appropriate amount of fluid and with the correct concentration. v) Turn filling pump on. vi) Observe the return and watch as the volume of bubbles decreases. vii) When the system is full and bubbles have diminished, then close the return side valve while pump is still on. Watch your pressure gauge until you reach your target pressure. viii) Close the supply from filling station and shut off the filling station as soon as possible. ix) Make sure to open the butterfly valve. x) Activate your solar pump to be sure the pump is running. See the controller manual to learn how to manipulate the controller settings in order to activate solar pump. xi) Use the butterfly valve to adjust the circulation to the target flow rate. xii) In case of exceeding pressure above target, release pressure via solar filling station until target psi is reached. 4) Programming the Controller (Refer to the controllers manual for programming and maintenance) a) Setting Differential i) Typically, most controllers are pre-programmed with a Temp. Differential On of 12F and Temp. Differential Off of 5F. Based on your regions insolation levels, you may want to adjust these parameters in order to increase your systems efficiency. Most often the Differential on is set between 10-20F. b) Setting Tank High Limits i) Make sure to check the tank temperature high limit. HelioMaxx systems are designed for the solar tank high limit to be between 170-180. ii) Check the existing DHW tanks high limits to be sure the solar system does not exceed their parameters. iii) If you decide to raise the tank limit above 145F, it is mandatory to include an anti-scald mixing valve before the water reaches the buildings hot water fixtures. 5) Operations and Maintenance (should be inspected at least once per year) a) Measuring Glycol concentration i) Each year it is important to make sure the concentration is consistent with manufacturers recommendation to ensure the warranty is upheld ii) Use a spectrometer or hydrometer to gain accurate results. b) Glycol Acidity i) Use a pH kit or digital pH tester and measure the pH of the glycol loop. ii) Be sure the reading falls between 7.0-8.8 iii) Replace as needed following the steps in step 8 c) System Pressure i) Ensure that the system is still operating at the target pressure set at step 7 d) Piping Insulation i) Inspect insulation for gaps, UV exposure and possible destruction from vermin. Replace when needed 6) Maintaining Collectors 40

HelioMaxx Prepackaged Kits

a) Yearly Inspection i) collectors should be cleaned of dust, debris etc using soft cloth or soft bristle broom with hose and soapy water ii) Inspect all hardware to make sure nothing has loosened over time b) Flat Plate Collectors i) Inspect the glass for any possible cracks c) Vacuum Heat Pipes - Inspection of broken tubes i) Observe the chrome coating on the bottom of tubes, if turned to a powdery white, replace tube with new replacement EVT. When removing the heat pipe be careful not to destroy as this can be re-used. If heat pipe is destroyed you will need replacement tube WITH heat pipe. Check all the gaps in insulation to be sure any tape or fasteners are still intact, replace or repair as needed.

11.0 Troubleshooting
Problem Cause
1. Mains/Pump wiring is faulty 2. Pump rotor damaged Pump will not run 3. The pump control selector P is in the manual OFF position 4. TC is incorrectly set 5. TC and T not satisfied 1. Collector temperature is below TF temperature Pump runs continuously

Action
1. Check wiring at Mains/pump 2. See pump manufacturer's instructions 3. Check SMT unit and return pump control to automatic mode 4. Reset to 25 C 5. No action Required 1. No action required. TF Flashes

2. Loose connection or faulty sensor on the 2. Check connection and sensor wires collector 3. Collector temperature at maximum 1. Pump isolating valve closed 3. No action required 1. Open valves 2. Open auto air-vent and replace if necessary 3. Twist cap at pressure relief valve and vent air 41

No circulation in system

2. Automatic air-vent closed 3. Air lock at pressure release valve

HelioMaxx Prepackaged Kits

4. Air lock in system 5. Non-return valve jammed 6. Pump is not running 7. System in stagnation

4. Check all pipework rises on return side, falls on flow side - clear manual vents 5. Free valve or replace 6. See above 7. Wait until system reaches normal operating conditions 1. Check collars on all tubes for leaks - tighten if necessary 2. Check all joints 3. Close fully 4. Clean or replace if necessary 5. Replace 6. Replace 1. See above 2. Divert heat to heat dump 1. Replace broken tubes (this does not need to be done immediately to maintain operation) 2. Replace damaged parts 3. Drain and clean system thoroughly

1. Leak at manifold 2. Leak in system Pressure drops in system 3. Drain/filling valve not closed 4. Auto air-vent passing water 5. Faulty pressure relief valve 6. Damaged expansion vessel pressure fluctuation and relief valve to open 1. Pump does not run Overheating 2. Prolonged period of low hot water consumption 1. Broken tubes Performance Loss 2. Damaged insulation 3. Buildup of limestone around heat exchanger/tube condenser

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