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 TABLE OF COruTENTS

SECTION TITLE PAGE NO.

lntroduct 1

System Operation 2

Control System Instaflation 13

Maintenance lmtructions 18

krsulation. 21
j!

f
 INTRODUCTION

INTRODUCTION

This manual provides installation, operation, maintenance, and troubleshooting instructions

for solar hot
(hereinafter
water systems incorporating the Grumman sunstreamrt Model cF100 Heat Exchanger Module
referred to as the Model CF100 Module) manufactured by Grumman Energy Systems, lnc',4175 Veterans
Memorial Highway, Ronkonkoma, NY 11779,
The Model CF100 Module combines with solar coll ors and a solar storage tank to create solar water
heating systems. These systems supplement the energy used during operation of conventional electric, gas,
or oif-fired water heating systems. Generally, the purchase of a Grumman SunstreamrM Solar Storage Tank
will be required in addition to the Grumman Sunstreamrt Solar Collectors to complete your solar system
installation. In some cases, your existing el ric water heater may suffice and a solar storage tank may
not be necessary. Check Lists and System Schematics are provided in later sections detailing the require-
ments of each type of installation.

THE ASSEMBLY AND INSTALLATION INSTRUCTIONS

DESCRIBED IN THIS MANUAL HAVE BEEN CARE-
FULLY PREPARED. READING THEM THOROUGHLY
BEFORE PROCEEDING WILL PROVIDE YOU WITH ALL
THE INSTRUCTIONS NECESSARY FOR A TROUBLE-
FREE INSTALLATION PROCEDURE. DO NOT PROCEED
WITH INSTALLATlON WITHOUT READING THIS
MANUAL IN ITS ENTIRETY.

Dissimilar Metals
I

Galvanic Action is a form of corrosion that occurs from the contact of dissimilar metals, either indirect
or direct, under a specified set of conditions. Therefore, in the assembly of any system, CARE should be
taken to avoid the use of dissimilar metals within the heat transport loop.

I SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE;

sEcTroN 1

SECTION 1. SYSTEM OPERATION

The function of the Model CF100 Modular Svstem is to preheat the water entering an existing domestic 3
system requires less energy to heat ineorning water to the temperature required.
This section describes the functions of the Modei CF100 Module in the sotar heating sy

a, LIOUID LOOPS. There aib two separate liquid loops in this system. The first liquid loop is the piping
between the sslar co[[ectors and the collector fluid side of the heat exchanger contained within the Modet
CFlOO Module (the collector loop). The second liquid loop is the connecting piping between the solar
storage tank and the water side of the heat exchanger contained within the Model CF10O Module (the
water loop).
To obtain solar-heated water with the Model CF1O0 Module, the first loop icollector loop fluid
described in S ion 1), is heated by the sun via the sotar panels. This heated mixture is then circulated
through the counterflow heat exchanger in the Model CFl0O Module by a self-contained, low horsepo
circulator. As the mixture flows, its heat is transferred to the water circulated through the Model CF100
Module in the opposite direction by a second self-contained, low horsepower circulator (see figures 1,2,
and 3).
The expansion tank in the Model CFl0O Module serves to maintain collector loop pressure at acceptable
levels. The pressure relief valve backs up the expansion tank and will operate only in the unlikely event of
multiple system failures.
The heated water produced by the Model CF100 Module is u to replenish the water removed from
the existing system by domestic hot water demands. Since most existing systems are thermostatically
controlled, the existing energy source {electric, gas, or oil) will only energize if the replacement water is
not hot enough for use.
b. CONTROL SYSTEM. The circulators contained within the Model CFl0O Module will circulate
collector loop f luid and water whenever a zufficient input of solar energy is available to add heat energy
to the water in the domestic hot water system. The circulators are activated by the differential controller
within the Model CF100 Module. A solar collector sensor. a storage tank sensor, and the controller make
up the control system.
The controller is activated by the front panel selector switch which selects three different modes of
operation, being; (1) ON, (2) OFF, and (3) AUTO, The function of each position is as follows:
(1) With the switch in the ON position, the circulators are manually activated.
(2) With the switch in the OFF position, the circulators are inoperative.
(3) With the switch in the AUTO position, the controller automatically activates the circulators when
pre-set conditions are met. (lf the collector sensor is 20'F above the temperature of the tank
seRsor, the system is turned on. When these sensors are within 3'F of each other, the system is
turned off.)

c. SYSTEM MONITORING.
(1) An indicator light, located on the front panel of the Model CF10O Module, when on will indicate
that solar energy is available and that both circulators are operating.
(21 A Pressure/Temperature Gage, also on the front panel of the Model CF10O Module, will indicate
any leakage by a resultant pressure drop and also verify that energy is being collected while the
system ts operatrng.

d. SYSTEM PRECAUTIONS.
(1) Do not operate circu lators dry since pump6 are f luid- lubricated. This can resu lt in
permanent circuiator damage. :\l

2
 SECTION 1

tzl Entire system must be leak tight and free of air to obtain maximum efficiency of operation'
(anti-freeze) and 50% distilled water. The
t3) Collector loop fluid is composed of 50% ethylene glycol
ethylene glycol used must contain certain corrosive inhlbitors for protection of the collector loop.
The following list of brand name anti-freeze products is approved by Grumman Energy Systems, lnc.
The use of anti-freeze other than those listed below may involve a risk of damage to elastomeric
seals and is not recommended.

Shellzone
Grumrnan SunstreamTM
Texaco P.T.
Wilco
Zerex
Permaguard

IITI E
ln order to maintain adequate corrosion protection,
collector loop fluid should be changed every two years.

INOTE
The average installation will require approximately
46 gallons of collector loop fluid (example: 3 gallons
of anti-freeze mixed with 3 gallons of distilled water).

a
sEcrloN 1

COLLECTOR INSTALLATION
(SEE FIGURE 5I
I I

I I
17

coL LE
LV _J
COLLEC
OUT IN

MODEL
II'ATEB IN cF-100
MODULE

EXISTING
COLD WATER
COLLECTOR
FTUID
OUT OF
MODULE

PBE RETEMP y'

RELIEF VALVE
WATER OUT
THERMOMETEB
(OPTIONAL}
WATER
s
COLLECTOR
FLUID
IN TO
MODULE PB UBE TEMP
RELIEF VALVE

NOTE DIP TUBE FOR

ELECTFIC TANK
MUST EXTEND
BELOW ELEMENT

EXISTING TANK
{CUSTOMER SUPPLIED) (LOWER ELEMENT
MUST BE
DISCONNECTED'
COLD
CoLLECTOR LOOP@t
a-wATEF WATEF LOOP I--I
IN

TANK SENSOR
(CLAMPED TO PIPEI
A
\7
FIGUEE 1 - INSTAI.I-ATIOII WITH EXISTIiIG EI.ECTRIC HOT WATER HEATER

4
o
f- (SEE FIGURE 5I
I

I
r- - - -t
ICCTOR,
lgpl

L
COLL ECTOR
OUT

MODEL CF-I(X}
WATER MOOULE
IN

THEBMOMETEB WATER OUT

(OPTIONALI

HOT YYATEF OUT COLOWATER

'N

SOLAR
our

ELECTRIC
ELEMENT
& T}t€ STAT

TANK SENSOR WIRE

coLLECTfON LOOP@
WATER LOOP
TANK ORAIN

-l
DIP
TI.'BES GRUMMAN SUNSTREAMTM
SOLAR STORAGE TANK
(82 OR 12O GALLONI

FIGUBE 2 _ IilSTATLATIOI{ WITI{ GRUIIIMAII SUilSTREAMTM SOLNR STOBAGE TAflK

 sEcTloN I

r COLLECTOR INSTALLATION
ISEE FIGURE 5I
-l
---
I I

I-
G CTOR

rv
I 1

I
sRl
L
COLL ecftaT
OUT

MODEL CF-1OO
COLLECTOR MODULE
WATER
FLUID IN TO
IN
MODULE

COLLECTOR
FLUID OUT
oF MODq.|]E-+

SOLAR
OUT

HOT
WATER a-
OUT COLDWATER IN

HOT

(ruT
ELECTRIC
ELEfrfENT
EXISTING &THER AT
HOT
WATER
sgM
STORAGE TANK
(cusroMFR TANK S€N
"S LIED) WIRE

COLLECTOR LOOP
TANK ORAIN WATER LOOP_
GRUMMAN
SUNSTREAITTM
SOLAR
STORAGE
TANK
166GAL'

:F-:
 I

sEcTtoN 2

SECTTON 2. MODEL CF1OO MODULE PACKAGE

A" LIST OF MODEL CF1OO MODULE COMPONENTS'

NE OTY,

(1) Heat Exchanger AssemblY 1

{2} Glyeol PumP AsemblY 1

(3L Water Pump AsemblY 1

(4) Differential Controller I

(5) Expansion Tank 1

(6) Flockete Swi 1

(71 Ligfrt 1

18) Pressure Relief Valve 1

(9) Tank'Sensor (not sh n) 1

{10} Check Valve 1

(11) H Bibs 2
(121 Warning Label (not shown) 1

(13) Pr relTemperature GagF 1

114l Unions 4

FIGUBE 4 - MODEL GFIO|! MODULE DETAILS

 SECTION 2

b. LIST OF MANUFACTURERS.

CODE NAME ADDRESS

GES Grumman Energy Systems, I nc, 4175 Veterans Memorial HighwaY

Ronkonkoma, New York 1 1 779

Rho Sigma 1'1922 Valerio Street

North Hollywood, CA 91605
94 East Water Street
GRD Grundfos Torns Biver, NJ 08753

MF Mor-Flo 18450 South Miles Road

Clevefand, OH 44128

1400 Oivision Road

West Warwick, Rl 02893

c. MATERIAL CHECK LIST. The materials listed in paragraph d of this section are not supplied as part
of the Model CFlOO Module. Materials should be purch d, if required, prior to starting assembly and
installation, The choice of materials and amount will be dependent upon the type of structure and
component locations at the installation. This information will be evident to you when you prepare a
sketch in Section 3 of the installation hook-up of the storage tank and tubing.
I CAUTION
Use only copper tubing and fittings in plumbing
of the Model CF100 Module. Do not use any
polyvinyl chloride (PVC), chlorinated polyvinyl
!
t
chloride (CPVC), poly butylene, or alumtnum
tubing or fittings in this system'

d. MATERIALS LIST.
o 112" or 3/4", for glycol side of module {refer to section 3d)
. Copper Tubing, 314", tor water connections to module
r Copper Fittings (adapters, elbows, tees, etc,l
. Electrical Wire to t 15V AC, 60 Hz, if required. (Gage size depends upon iocal code' I
o 18'gage Outdoor Electricai Wire
. G.E,S.l- Collector Mounting Hardware (to attach collectors to structure)
o Tube Insulation (outdoor 314" wall minimum);3/8"wall fortubes runthrough inside (heated) space
c SuPports (collector piping system)
o Emery Cloth (used to clean copper tubing and fittings)
'. Solder Flux
Solder (S5/5)
. Collector loop fiuid (approximately 3 gal. approved anti freeze mixed with 3 gai. distitled de-mineralized water)
o Wire Cable Connectors
. Solderless Wire Connectors
e Wire Staples
o Mixing Valve (if required by local codes)
o Shut-off Valves
o Pressure/Temperature Relief Valve
. 314" C x C Unions (2) (rnust be Mueller Brass Streamline Fittings)
. 314" Boiler Drains (2) (Nibco No. 54 or equivalent)
. 3/q" Female Street Adapters (2)
o Garden Hoses
r Washing Machine Hose (female connections at both ends)

.-t=
 SECTION 3. MODEL CF1M MODULE INSTALLATION AND PIPI

a. GENERAL. This section presents instructions for installing the Model CF100 Module in an el rirc,

lf you presently heat water with an electric hot wa

tion will resemble figure 3. If the installation is on ne

of hot water, a Grumman storage tank with an electric element will be used with the Model cFl0o Module
as in figure 2.
prior to the start of any installation, it is recommended that a sketch of the Wecific system be drawn
showing detailed connections of the module {storage tank if required) and the existing hot water
heatef.
This sketch will help determine the specific additional material requi to complete the installation. Any
be purchaed prior to beginning the installation. (See Materiat Ch
required additional material should
List, Section 2, ParagraPh c.l

b. GUIDELTNES FOR COLLECTOR INSTALLATION.

(11 Coli or orientation should be as close to south as practical. Deviations more than 45o from true
south are not recommended. Collector tilt should not exceed t l50 from local latitude-
(2,t Collector shading should always be avoided, but particularly during the hours of 10:00 A.M. - 2:00 P.M.
(3) Collector banks may be piped in either a parallel reverse-return mode or a series mode with direction
of flow in both instances from bottom to top (see figure 5)'

re

PARALLEL
INLET

LET

fEs

fr
w

sl I

I
sEcTtoN 3

(4) It is suggested that an air vent be placed at the highest point of the system for use during the
initial filling process and for routine maintenance. This vent should be normally closed.
i5) "Traps or U-shaped low spon in the collector loop piping should be avoided. lf collectors are
in a trap, a drain should be placed atthe lowest pornt.
(6) For collector mounting instructions, refer to Mounting Instructions contained within the collector
box.
INOTE
The Model CFlOO Module is designed to
maintain acceptable pressure limits in a
system with a maximum collector area of
64 sq. ft. of selectively coated collector
area ltwo,4x8 Grumman SunstreamrM
collectors).

GUIDELINES FOR INSTALLATION PREPARATION AND PLANNING.

(1) Modute and storage tank should be loca as near as possible to the existing hot water system ard
the storage tank should be raised off the floor on a suitable support such as bricks.
(21 All tube routing should be as short as possible with a minimum number of fittings (elbows, tees,

size). Water side piping should always be 3/4"-

(3) Tubing offsets should conform to good plumbing practices to allow for thermal expansion.
(4) Plan tubing support spacing. as required.
(5) Bead Data Sheet pages 1 through 3, for detailed instructions on rking with copper tubing. Data
Sheets are bound at rear of this manual.
(6) Insulate all straight tubing runs prior to soldering joints.

d. COLLECTOR LOOP PIPING REOUIREMENTS.

TOTAL PIPE LENGTH

TYPE NO. OF @LLECTORS
50' 100' 150',

Parallel ?-3 1/2 1/2 1/2 314

+ *
Series 2 vt 3t4

3 3t4 3/4 + *
Series
*Contact an authorized Grumman Sunstreamrfl Dealer.

INOTE
The above chart applies to MOD3OO/400;121/132
and 6OF series collectors en used with CFl@Modufe.

e. T LS REOUIRED. The following is a list of tools required for this installation:

(1) Two adjustable wrenches
Ql Adiustable plier
(3) Standard plier

to
 sEcTroN 3

(4) File
(5) Hammer
.h (6) Standard Screwdriver
(71 Roll 95i5 Solder
(8) Can Solder Flux
(9) Roll Pipe TaPe
(10) Can PiPe DoPe
(1 1) Emery Cloth
(12) Propane Torch
(13) Tube Cutter
(1 4) SharP Knife
(15) Paint brush (21, inexpensive'
I NOTE
All plumbing work performed during this
installation should be in accordance with
all local codes.

f. STORAGE TANK INSTALLATION.

(1) One tank system using homeowncr's existing electric hot water tank.
(a) lf your existing electric tank has two (2) elements and you choose to have a one-tank system,
then the lower element must be disconnected for proper solar system operation. lf the tank
volume is below that recommended for a one-tank system ( minimu m [ 1 ] tank system should
have a 66 gal, tank) Vou can switch the lower element on so you can reactivate the lower element
during higl water dernand periods (see figure 6). A licensed electrician should do any wiring
associated with installation of this disconnect switch.
, .,f
DOUBLE ELEMENT HEATER - 2 WIRE

4
. !b' FIGUBE 6 - HEATER ELEMENT SCHEMAT]C

11
 -t

SECTTON 3

(b) Tank sensor location on an existing electric tank is on the water line leading from the bottom
of the tank to the module. Clamp this sensor to the water .line as close to the tank as possible
and insulate {see figure 1).
(2) One tank system using Grumman SunstreamrM Solar Storaqe Tank.
{a) The Grumman SunstreamrM Solar Storage Tanks contain one electrical element which must be

connected to a 22OV AC Power sou

lruoru
Do not energize the electrical circuit until
heater is completely filled with water. Even
momentary operation in a dry tank will
damage the heating elements.
(b) Tank sensor mounting location on the Grumman Solar Storage Tank is behind the round access
ptate located on the lower side of the tank. After removing access plate, attach sensor to the
stud on the tank wall' The tank has been pre'wired with two (2) conductor wires leading
down to this stud. Attach wires to sensor leads with wire nuts. Replace access plate, Sensor
leads protrude from the top of the tank and will be connected to the controller from this
point (see figure 2).
I ruore
Tank sensor is shipped with module'
(3) Two tank systems using Grumman Solar Storage Tank (see figure 3).
(al In a two-tank system, the tank between the Model CF10O Module and the existing hot water
rystem acts as a preheat tank. lt stores the solar heated water. This tank will not be
connected to a po ; however, the tank sensor is still necessary and will be mounted (
on this preheat tank in the same manner as Section 3, paragraph 2b above.
No alterations will be made to the existing tank (system) except to lower the aquastat
setting to approximately 120oF, if you wish to maximize solar's participation in heating
your water-

s. INSTALLATION INSTRUCTIONS.
(1) Purchase all parts required which are not supplied as part of the Model CF100 Module system
(refer to Section 2, paragraPh cl.

-heater. The system is designed to be mounted on a sturdy wall or structure through the use of
rthe teardrop holes located on the rear of the unit.
INOTE
The Model CF100 Module should be mounted
in a horizontal position. The piping run
between the Model CFlm Module and the
storage tank must not exc 5O feet
round triP.

12
 sEcTloN 4

a1\ a. GENERAL. This section presents instructions for electrical installation of the control system for the
(2)temperature sensors and the controller which
Model cF 100 Module. This control system employs two

installations: electric, gas, or oil. The sensors have a

I NOTE
All electrical work performed for this installation
shall be in accordance with ali | | codes'

b.GU|DELINESFoRINSTALLATIoNPLANNINGPRECAUT|oNS.
( i) study wiring diagram (figure 7). lf hook-up is not clear, consult
your dealer and/ot vour el rician'
(2) Plan your wire and cable runs to be as short as possible'
(3) Do not work on any circuit until you have disconnected the circuit by tripping the circuit breaker
or removing the fuse.
(4) Provide a properly grounded and protected 115V AC, 60Hz power input to the controller via cord
attached or Permanent wlrlng.
(5) Do not stand 9n a damp floor when working on anv electrical circuit; stand on a wooden platform
or wear rubber overshoes,

c. CONTROL SYSTEM HOOK-UP.

(1) Ftemove module cover.
T
(2) Remove control box cover'
(3) Locate a pair of red wires and a pair of blue wires and separate.
(41 ach red wires to the solar coilector sensor with 18-gaqe wire and eap off with wire nuts.
INOTE
Do not solder wires to her as this will
introduce unwanted resistance.
INOTE
The wire nuts used on the solar collector
sensor should be encased in a silicone glue
to Prevent moisture erosion,
(5) Attach blue wires to the sensor on the storage tank (figure 7) with 1&gauge wire' Cap off with wire
nuts.

(6) At service box, connect service line to service.

INOT€
connectlons to seruice should
All 115-volt
conform to all local codes
INOTE
The glycol purnp is delivered with a 2-speed
switch mounted on the terminal box. Make
sure this switch is on the higher speed (position lll)'
"rl
TJ
sEcrtoN 4

WATEB CIRCULATOR

RHO - SIGMA
504 SH(180)

YELLOW

rlF-\l _ wHlrE

ANTIFREEZE CIFCULATOR

TO TANK
SENSOR

LIGHT
r25V AC

FIGURE 7 - MOIIET GFIOO MODffi.E WIFIfIG DTAGftAM

14
 SECTION 5. FLUSH PBOCEDURE AND LEAK CHECK.

filings, or debris that could become lodged withi

I f,NING
Failure to flush the collector lines may
result in cl ing the glycol passages,
Module performance may be seriously
affected.

a. MATERTALS REOU|RED.
2- 3/4" Unions c x c (must be Muelrer Brass streamrine Fitti )
2 _ Boiler Drain Valves, 3/4 lpS x Hose (Nibco Boiler Drai.n No. 54 or equivalent)
2- 3/4" Female Street Adapters
2- Garden Hose
1- washing Machine Hose (Femare connections at both ends)

b. FLUSH PROCEDURE.
(1) Uncouple the two unions marked coLLEcToR FLUTD INLET and coLLEcToR FLUTD
OUTLET.
(2) Attach halves of 314" union with adapters & Boiler Drains to collector lines.
(3) Attach hoses to Boiler Drains on these lines (see figure g).
(4) Connect one hose to suitable spigot (laundry sink or outside spigot) other hose to
; suitable drain.
-n (5) Flush system (warm w r, if possible) for 10 minutes with Boiler Drain Valves open.
i'

c. LEAK CHECK.
(1) Close Boiler Drain on the drain hose. This will pressurize collector loop.
(2) Check for leaks. lf any are found, fix and leak check again.
(31 Drain loop; remove hoses, boiler drains, unions.
(4) Reconnect Modet CF100 Module to collector looo.

SWEAT HALF UNION

I
I

3/4' FEMALE STFEET ADAPTEB

FIGURE 8 - MATEBIAL MAXEUP FOB FLUSH PROCEOUBE

15
sEcTtoN 6

a. GENERAL. This section presents the procedure used for f illing and leak checking the heat transport
loop {the collector loop}. The procedure used is called the Bottom Fill Method. Using this method, the
collector loop is filled using a pumping rig descri below. The Model CF100 Module System contains a
fill valve and a return valve in the collector loop (see figure 4),

WARNING
THIS SYSTEM CONTAINS ETHYLENE GLYCOL ANTI.
FREEZE WITH CORROSION INH]BITORS. ALL SUCH
SOLUTIONS CAN BE HARMFUL OR FATAL IF
SWALLOWED. IF SWALLOWED, CALL THE POISON
CONTROL CENTER, OR A PHYSICIAI\.
]F THEY ARE UNAVAILABLE, INDUCE VOMITING AS
FOLLOWS:
CHILDREN 1 YEAR TO 5 YEARS _ ONE TABLE.
SPOON OF SYRUP OF IPECAC,
OVER 5 YEARS TWO TABLESPOONS OF
SYRUP OF IPECAC.
KEEP ETHYLENE GLYCOL OUT OF REACH OF CHILDREN

b. MATERIAL RECIUIRED. The following is a list of the materials needed to perform the filt procedure. j

SunstreamTM dealer.
(3) Two (2) clean hoses with hose connections.
(4) Collector loop f luid (approximately 5 gallons of fluid).

c. FILL PROCEDU,RE.
INoTEI
Collectors should be covered for two hours :

prior tto filling the system. Water loop should

be hooked up and filled with water.

hose bib.
(2) Fill container with collector loop fluid.
(3) Set controller sel or switch to OFF position (see figure 4).
l4) Open fill and return valves. Open collector air vent,
(5) Turn on pumping rig.
(6) Turn selector srpitch on Model CF10O Module to ON ( figure 4). When fluid has reached the
collector air vent, close air vent,
(7) Continue punrping for about 30 minutes. No air bubbles should be seen returning to the container.

16
 sEcrroN 6

tB) When air butrbles stop, close return valve and allow system to pressurize (see figure 4)'

, (9) Close filt valye and turn off pumping rig. System is now pressurized. Pressure can be as high as
$ 40 pst,

(101 Crack coupling on thermometer/pressure gage (see figure 4)' This wi!!vent any trapped air'
Retighten couPling'

(1) Estimate the overall height from the Model cF100 Module to the top of the solar collectots'
(2) Divide this height bV 2.3 and add 5; this will provide you with required system pressur€.
Example: ta) Overall height - 30 ft.
(b) 30 + 2.3 = 13 psi
(c) 13 * 5: 18 psi required Pressure
I NOTE
Presure should not be less than 15 psi.
(3) Slowly open return valve and bleed system until required pressure is indicated at the pres$ure gage
( figure 4).
(4) Ctose return v'alve and remove ho
ICAUTIION
After the fill and purge procedure is finished,
remove the handwheels from the fill and
return valves and instalf plastic caps on tfre
outlets, This is neces$ry to prevent accidental

17
 sEcTroN 7

SECTION 7. M/AINTENANCE INSTRUCTIONS

a' GENERAL. This section provides instructions for operational readin checks, maintenance, and
troubleshooting procedures for Grumman SunstreamrM Model CF100 Module. An ohmmeter is the onlv
test equipment required to support these instructions

b. OPERATIONIAL READINESS CHECK. With the system installation completed, the system is now
ready to be turnrad on. However, before the system is to be turned on, the following checks should be
maoe:
(1 ) Operational Readiness Checklist.
(a) System filled with collector loop fluid (refer to Secrion 6).
(b) Set controller selector switch to OFF position (see figure 4).
(c) Solar storage tank filled witi water.
(d) All shut-off valves are opened (see figures 3 and 4).

(2) Electrical Operational Check.

{a) Set controller selector switch to ON position.
(b) Pumps should start and run.
I
ruore
To check for circulators' operation, touch
circulators houslng with your hand: a
slight pulsing should be detected.
(c) lf circulators do not run, refer to paragraph d, Troubteshooting Checks.
(3) Normal Operation Checks. Two checks are needed here; the first should be made at night or before
E
E sunrise, and the second after the solar collectors have been exposed to the sunlight for a period of
I time.
(a) At night or before sunrise.
t 1. Set controller selector switch in AUTO position.
2. Circulator should not run.
3. lf circulator runs, refer to paragraph d, Troubleshooting Checks.
(bl Solar colfectors exposed to sunlight.
1. Set ontroller selector srrritch in AUTO position.
2, Circulator should start and run.
3. lf circulator does not run, refer to p€ragraph d, Troubleshooting Checks.
c. MAINTENANICE.
(1) Cleaning. The glazing of your solar collectors will not require cleaning in a climate having periodic
rainfall. ,A light coating of dust will not seriously affect performance. In areas where climate is
dry and dlusty, the solar collectors should be cleaned with mild soap and water mixture, whenever
dust or diirt accumulation is visible.
(21 Circulatorc and Gontroller. No sheduled maintenance is required for the circulators or controlhr
system. fhe circulators are fluid-lubricated and should not require any maintenance. In the event
of a circulator or controller malfunction, reler to paragraph d, Troubleshooting Checks.

d. TROUBLESHOOTING CHECKS. lt is not expected that any system matfunctions will develop with
the Grumman Sunstreamru Model CFl(F Module System; however. should this be the case, refer to the
following proceduresr

t8
 sEcTloN 7

(1) Circulators do not start

(a) Assure supply vor is available to module; if not, check circuit breakers or f uses.
{b) Place controller tor switch to ON position; this will allow current to f€ed circulators.
(c) lfproper vottage {1 V) is available to clrculators and they do not run, contact your
authorized Grum SunstreamTM Dealer.
(d) lf voltage is not lable, re-check all connections within controller and rockette switch
on f ront of modu all connecting wiring between controller and circulators.
(e) lf voltage cannot made available to circulators, contact your authorized
TM
Grurnman Sunst Dealer,

tzt Girculators run in ON not AUTO position:

NOTE
CIRCULATO SHOULD RUN IN AUTO POSITION PROVIDED THERE IS A
7 SUF FICIENT T MPE RATURE D I F FE RENCE (2OOF) B ETWEEN COLLECTORS
AND STORAG TANK.

{a) Re-check all sensor collector and tank) connections.

(b) lf circulators stillnot run in AUTO. check collector sensor circuit for an open (lack of
continuity) or tank circuit f or a short (low resistance, less than 1 OHM).
(c) lf sensclr circuits correctly (refer to Temperature/Resi nce Chart, Page 24); check
controller ooer step (d).
ru) With controller swi in AUTO oosition and both collector and tank sensor circuits
disconnected f rom troller, shorting with a jumper across the collector terminals should
cause the ci to operate. lf circulators are still inoperative in the AUTO mode.
contact your G rumman SunstreamTM Dealer.

r'?
19
 I
sEcTloN 7

(3) Circulators run constantly with switch in AUTO position:

(a) Check for oppositecondition as in Step (b) of "Circulator Runs In ON But Not in AUTO o
Position". That is, check for short in the collector sensor circuit or an open in the tank
sensor circuit, if sensors circuits read correctly (check Pg.24l , proceed to step (b).
(b) Disconnerct both collector and tank sensor circuits from controller; if circulators continue
to operate in the AUTO position, contact your Authorized Grumman Sunstreamrn Dealer.

\
20
 sEcTroN 8

SECTION 8. LLTION.

A, GENER Therrnal insulation is necessary for efficient operation of the Grumman SunstreamrM
Model CF100 odule. lnsulation should be applied to all exterisr fittings of the Modet CF10O
Module, and t ing from the storage tank to the existing hot water system.
For added ividen<ls and improved availability of hot water, the tubes and fittings of the basic hot
water system also be insulated.
r|)N
f an underground installation of af l heat
anspoft loop pipes is required, the heat
ansport loop pipes must be insulated
ith 3/,1-inch wall Armstrong Armaflex
ion, and placed within Orangeburg
PVC pipe to protect against ground
ter seepage.
Batt and t insulation is available allowing for fast, easy application. Tube insulation can be slipped
before tubi is in place.
The follow material and tools are required to complete this installation:
(1) Ar Armaflex tube insulation or equivalent (3/4-inch wall thicknessl.
(2) Fiberg insulating strips (3/zl-inch to f -inch thick).
(3) Water f tap,g.
(41 (Armstrong 52D or equivalent).
(5) lnsulati tape.
I
ill and leak checks should be completed
insulation is installed on fitti
r to Section 6).

b. SLIP-ON M THOD, This method is used when you insulate new tubing prior to connecting it into the
system.
OTE
not sitretch tube insulation.
ion to length {slightly longer than tube being covered).
TE
of tube insulation is
insicie surface
with a powdered lubricant to aid
llation.
t2l Slip tion over tube figure g).
(see
(3) I nsu lati can b,e slipped over bent tubing, 45 degree elbows, and couplings.
(4',1 For e over 45 degrees, miter'cut the insulation, butt, and glue against each srde of fitting (see
figure 1

(5) Where is not possible, cover exposed fittings with insulating tape (refer to paragraph d).
c, SNAP-ON M This method is used when tube is insulated after it has been installed and
connected. u t or slit tube insulation is available and either can be used for this method,

21
 sEcTloN 8

Iruorr
Do no't stretch tube insulation,
(1) Cut insulation to length (slightly longer than tube being covered). #
(2) With unslit tubular tube insulation, use a sharp knife and slit the insulation lengthwise on one side
(see figure 1 'l).
(3) Snap insulation over tube (both types of insulation).
INOTE:
Follow instructions of adhesive manufacturer
for gluing.
(4) Brush adhesive on slit surfaces.
(5) Butt slit surfaces
(6) Paragraph b, steps (3), (4), and (5) apply here, except insulation must be slit and glued along slit
surfaces.

d. INSULATING TAPE METHOD. Insulating tape provides a fast, easy method of insulating tubes and
fittings in cramped areas and coverings for complicated pafts or contours difficult to handle with tube
insulation.
(1) Remove protective backing on tape as tape is spiral wrapped around tubing or fittings, using a 507o
overlap (see figure 12).
l2l To insulate or other complicated parts, cut short lengths of tape and press in place
v,alves, tees,
where necessary. Be sure no metal or plastic shows through tape {see figure 12).

-l
 sEcTroN 8

FIGURE I- SUppilfG ilusutATtoil otu Tu8llrc FIGURE tt - suTTtitc TuBtilG ttsut-ATtot [EilcTHwtsE

,n

FIGUBE IO-- BUTTIflG TUEIIIG IflSUTATIOIU AGAIIIST

FITTIilGS

INOTE
When using Armaflex-type insulation on exterior
lines, it is required that the insulation be painted
with an exterior enamel to protect against exposure
a- from the sun. FIGUBE 12 - IilSULATIttIG TAPE APPIICATIOTI

23
f
r

RESISTANCE vs. TEMPERATURE SPECIFICATIONS

OF RHO SIGMA SENSORS

RESIST. RESIST. RESIST.

oc oF oc oF oc oF
EOUTV. EOUTV. EOUIV.
0 32.0 32.65K u 93.2 6.807K 68 154.4 1.876K
1 33.8 31.03K 35 95.0 6.530K 69 156.2 1.813K
2 356 29.50K 36 96.8 6.267K 70 158.0 1.752K
3 37.4 28,05K 37 98.6 6.017K 71 159.8 1.693K
4 39.2 26.69K 38 1(X).4 5.797K 72 161.6 |.636K
5 41.O 25.39K 39 1V2.2 5.547K 73 163.4 1.582K
6 428 24.17K 40 104,0 5.327K 74 't65.2 1.530K
7 44.6 23.0 t K 41 r05.8 5.117K 75 167.0 1.492K
I 46.4 21.52K 42 107.6 4.917K 76 168.8 1.431K
I 48.2 rc.88K 43 109.4 4.727K 77 170.6 1.s84K
10 50.0 19.90K 44 '111.2 4.543K 78 172.4 1.340K
't1 5r.8 18.97K 45 1r3.0 4.370K 79 174.2 1.297K
12 53.6 18.09K 46 114.8 4.200K 80 176.0 1.255K
13 55.4 17.25K 47 1r5.6 4.040K 8t 177 I r .21 5K
14 57.2 16.46K 48 118.4 3.8{f0K 82 179.6 r.177K
15 59.0 15.7lK 49 120.2 3.743K 83 181.4 1.140K
16 60.8 15.tr)K 50 122.O 3.603K 84 r83.2 1,104K l

17 62.6 14.32K 5l 123.8 3.467K 85 185.0 r.070K

18 M.4 13.68K 52 125.6 3.340K 86 186.8 1.036K
19 66.2 13.07K 53 127 -4 3.217K 87 r88.6 1.004K
20 68.0 12.49K 54 129.2 3.099K 88 190.4 .9745K
21 69.8 1 'r.94K 55 't31 .0 2.986K 89 192.2 .9445K
22 71.6 11.42K 56 132.8 2.878K 90 194.0 ,9155K
23 73.4 ro.92K 57 134.6 2.774K 9l 195.8 .8885K
24 75.2 10.45K 58 136.4 2.675K 92 197.6 .8615K
25 77.O r0.00K 59 13a-2 2.579K 93 199.4 .8355K
26 78.8 9.573K 60 140.0 2.488K 94 201.2 .8105K
27 80.6 9.1 67K 61 141.9 2.400K 95 203.0 .7875K
28 82.4 8.777K 62 143.6 2.316K 96 244.8 .7A35K
29 u.2 8.407K 63 145.4 2-235K 97 206.6 .7415K
30 860 8.057K il 147.2 2.157K 98 208.4 .7195K
31 87.8 7.723K 65 149.0 2.083K 99 210.2 .6995K
32 89.6 7.403K 66 150.8 2.011K 100 212.O .6785K
33 91.4 7.097K 67 152.6 1.942K 101 2r 3.8 .6595K
Accuracy of sensors is 1.4oC over range of Oo-70"C. Maximum operating temperature is 220"C (428'F). Sensors having
tighter tolerances are available,

24

-i.:

3\
,c

HERE ARE S E TIPS AND SUGGESTIONS FOR

RKING WITH COPPER TUBING. READING THE*I
CAREFULLY BEFORE STARTING WILL BESULT If{
A NEATER INSTALLATION WITI{ LESS WASTE, AND
SAVE YOU TIME, MONEY, AND EFF T.

I. TYPES OF COPPER I'UBE 3. CUTTING COPPER TUA€

a There are 2 basic rVPOr crt copper tubing. One is rigid while the
the olher is sott and tlexible-
t Rigid tube is usuallv installed in new homes. Since it is more
rigid it u3ually make3 a n€ater tn3tallation but it is much moie
difficulr ro handle and in3tall than soft, tlexible copper rube.
I Flexible coFper tube is best lor repair work aroutld the house- lt
can bE run around obstacles without connBctions or cuts'
r Copper tube is available in 3 basic types: Type M is than walled;
Type L is medium watlsd; Tvpe K is thick wetled' ln most cas€s
I,ype L, the t?tedium wallecl iube, is perfectly adequate lor horne
u5t.
r Copper tube can be cut with a hacksaw (Fig.2) or wrth a copper
tube cutter. Atthough both the saw and the culter will make a
satisfactory cul, the cutter assules a square cu t every time
t lflhen cutting c , tube with a hack$w lFig.21. it rs wise ro
use either a iig as illustrated or a miter box. Either the iig or the
miter box asiureS a squate cut in the tube.
a A iig lFig. 2) can be made from a wooden board or block witha
vee noich 3 out to hold tl'le tube in pl-"'
r A slot can bc made in the iig {Fig.2) to gude the saw at right
arqles to the vee notch. This makes it easy to hold the tube whtle
cuning. lr also helps assure that important square cut'

2. COPPER TUBE FITTIINGS

I When curting copp€r tubing with a tube culter (Fig' 2), tt is a

good idea to hofd the lub€ in place with a pipe or tube vise or some
I Fis. I illusuates 2 bmic categories of cop9er tube fittings. The
other holding device.
tirst consists of fittings desillned for making be^ds and turns in the
tube, The second category is made up of fittingg lor ioining or
branching copper tube. FIGURE Z
r,rliE v-cuT rN
r Th€ f itrings shown in Fi1|. 1 are by no means rhe complete array WOOD BLOGK OR
of coppcr rub€ f ittingq lf yrlu 63vo a ?ecial tubing problem orh€r A MITER BOX
tittangs are rwailable to help $olve them.

FIIiUBE I

CO R TUEE FITTINGS| FOB MAKING BENDS AND TUBNS

F]TT S FOF .{)ININC OR BRANCHIilG TUBES

tl COPPER TUEC CAN BE CUT WI?H HACKSAh' OB

TUBE CTJTTER
I Atter cqtting rhe tub€. Tpmove lhe bsrrs instde the tube wth a I Now apply a ltght coar oi soldeting p6te ot flux (Fig.5) to rhe
hCf-routrd tile. A rube cutcr usually leaws more burrs in the tube cteaned end of the copper tube, An old toothbru$ or aren 0
thsn a h*k58w. urooden paddle can be used for sgreading the flux.

I I Flux or sofdering paste a$ures a g bord bet,tten the c@per

When cutting $be for a tpscific run, be sur? to make allowances
ard rhe solda. Apply tn le quantitv,
for the distance th€ tube fits into th€ fittings. Rernember to add the
exrrr length which inretting f itrings may give the ectire run of tube.
This is usraliV atrout 1/2-inchr on each fitting' FIGUBE 5
SBUSH
4. S:WEATING A JOINT IN COPPER TUBE
I When the copper tub€ irBt b€6n cut to prop€r length. clean the
end ot tho rubs (Fig. 3l witlr fine sandpager or steel v\lool.Sind or
rub i'ie area to be in3eiled in the fitting until it is bright all around.
r Th€ simpl€st and easiest way to brighten the ends ot the tube is
to hold th6 sandPiler or stearl $ool sround the ond of the tubs witll
a light Pressure and thsn lurfl the tube back 3nd forth a few titfi€s in
both clirecrions.

FrcUNE 3

SPREAD FLUX EVENLY ON CNDS OF TUBE

! Soldering psle or flux should also be rubbetl into the cleaned

firtings (Fig. 61. This can b done with th? fingor, a brudr, or 8
$Foden pa&le,
I The ba5ic gurPose of tirc llux or soldering past€ i3 to keeP the

r f*ver use acid core toldet for sY|Gating c€pper iuba.

CLEAN END OF TUBE WITH FINE sAT{OPAPEB

Ofl STEEL $f,X)L

a Th€ inside ot all fittin$ must lr claand with steel u\pol (Fig.4,
or saftlpaFt. Tate titno to Glean thD insid. ot rh3 filtitlg6
thorqudrly. Any (bbrit or foruign mailcr lcft in thg tuba will cause
a poor Eeal.

FI6URE 4

Rt,3 FLUX INTO THE CLEANED FITTINGS

CLEATTI IiISIDE OF ALL FIITTINGS WITII STEEL WOOL r The copper fining should be placed on rhe rube after it is
ON SANDPAPER thoro.lqhly claansd and coald with soldering paste. Vvhen the
t;rrl.E i3 lirmly io placo on lhe tube, rotate bori the tub€ and rhe
fining seireral tirl3s to spread rh€ llux evenly inside thc tirtingand
on tha trrb3.

6
 r A propane tcrch (Frg' 7) mares an ideal toot fcr swe3ting
cooper tube. However, if you are installlng copper iub€ cf extremelv
bnn,o them up ro soiderlng hea: Do nol applv rhe ilame dtrect/y
1ga;nsr the solder or rgarnst an a'ea ih3r has been fiuxed- Direct
fiame aqarnst a fluxed area reduces or eliminates the value oi the
oi lhe solder-
I The ridge in the center ol the standard coupling [Fi9. 8) causes
the staodard gqtipling to center automaticaliy when il is usec fo'
making a splice in tube Since the slip coupiing has no rldge, it can
be slrd along the tube but it must be centered by measuring at each
lornl-
I tf a :mall leak appears in a copper tube, il can usuallY be
corrected bV sawing the tube directly ar ihe poinr where the leak
occu r s.

I Oo nol overheal the coFtOer rube. You can tell when tne tube is ! Drarn a'i lhE tlurd from the tube; prepale ruOe and couplrngs, ano
'ot enough for soldelng by iouching the solder to the heated aube. sweat soider as desctibed ln slep 4.
ll the soider begins to .un, the tube ts at the proper solderrng heat ! ln some cascs, a Fctron of tub€ musr be totally cui away and
removed. ln this cas, you wiii need to saw away the section oF
FIG URE 7 damaged tub€ and cut a new piece of tube ol ihe Same slze and
leoqth-
I Removc damaged tube and replace ryrth new sectlon o f tube and
and couplings. Use tube of exactly the same size ard type as
SOLDER rcmoved {F g. 9) Prepare tube and couplrnqs and sweat sold€r as

descflbed ln sreD 4.

I PFoPANTi roBcH
I
i
l

APPLY HEAT WITH PBOPANE TOBCH REMOVE OLD TUBE AND REPLACE WITH SECTION
OF NEW TUBE
r As Vou apply ?he solder to rhe tube where it lorns wrth the
frtt,ng (Frg.7). the solder will llow into the filtinq bY capillar! 6, CONNECTING COPPER TUBE TO METAL TUBE
aciror Keep melling lhe sclder and iettrQg it flow rnto the frtt'ng I Monv crder homer were orlgrnaliy piumbed wtth galvanrzed
t unlrl the solde( apfpars a( ali points completeiy around the tilring.
I Warnrngl We repeat Never ure acid core 5ulder tor sweatrn€
prpe This does not mean lhJt vou cannot u5c copper tube when
feFarnn9 the plumbrng system
c,lpper tube. Use 60.140 wire solder onlV. I
Soecial adapters ( Frg. 10) ate avatlatlle to help convert galvanrzed
I Where it is necessary to solder a second lolnt near one you have sreel pipe plumbing systems into copper tube systems.
iust sold€red. you can keep the f irst iornt cool whtle worktng on rhe t Alrhough onty one adap rer rs iiiustrated (Fig. 10). you wiL iind
second by wrapp)ng rhe soidered ioiot in a dampctolh. This iloids manv different types of covplrngs and fittings. designed specitically
:he danger of damaging a ioini previous{v soldered. tor converting galvanized steel plumbing svstems anto copper
t You can expertment with different taps on your propane torch svstems.
Jntli Vou irod the pr')per one to spread lhe heal evenly aiong the t As il'uslrared iFrq 10i, srmply screw the adaprer on!o the
slze of tube you are using. threaded tub€, then prepare rube and adapter and sweat solder as
dererrbeci itep 4.
5 MENDING COPPER TUBE 'n
t Sometines it is nressary To reoDir a leak tn copper tube or to
FIGURE 10 SOLDEF HERE
cut frt a damagEd or deca'lred !€ction rn a tube and replace rt wrth
3 new plece.
a Either a standard coDper couPlrng of the gropet srze. o{ a slip
coupling iFtg;8) can be used lor maklng reParrs or insertlng a new
seclron In coPFer tuDe,
a The basic drllerence In a slrp couplrng and a standard coupllng rs
a cenrpr rrdge burlt into lhd slandard coupling. Both littlngscan &
u5e{ tor lhe same mendlnq purpose bul the center ridgp In the
standard couplrng makes it easier to center the filting on a repair
rob.

COPPEB TUBE CAN BE OONNECTED TO STEEL PIPE

'l I
II WITH ATi ADAPTER