Butler Sun Solutions SOLAR SIX PACK Series User manual

Butler Sun Solutions Revision 17
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Pictorial Installation Guide: Solar Six PackTM Water Heating System Plus Tankless Option
SOLAR SIX PACKTM
WATER HEATING SYSTEM
PICTORIAL INSTALLATION GUIDE
31 October 2018
Butler Sun Solutions
1545 S La Cienega Blvd
Los Angeles, CA 90035
213-533-1006
www.butlersunsolutions.com
The Butler Sun Solutions Solar Six PackTM water heating system is a state-of-the-art
solar
water heating system that augments your existing water heater. This system can save over 2,400
pounds of CO2 production per year compared to a conventional water heater, making hot water
from clean sunlight. It is like having an oil well on your roof producing 2.5 barrels of oil per year
(but without the pollution from burning the oil!).
The Solar Six PackTM system has been designed for easy installation by either a
professional contractor or a do-it-yourselfer. This guide is designed to lead you through the
installation of the system in a simplified manner. It includes a pictorial summary of the
installation steps, followed by explanations of each step. For a complete description with
detailed instructions, our System Installation Manual is available on our website. We hope you
enjoy bathing and washing with hot water provided by the sun!
Yoni Ghermezi, Licensed Manufacturer of Butler
Sun Solutions Products

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Contents
STEP 0. WAND & SYSTEM CERTIFICATIONS.......................................................................3
PICTORIAL SUMMARY OF INSTALLATION STEPS................................................................5
STEP 1. FAMILIARIZE AND PLAN ..........................................................................................7
STEP 2. SOLAR COLLECTOR ALIGNMENT AND MOUNTING ..........................................7
STEP 3. SPOCTM MOUNTING..................................................................................................8
STEP4. ROUTING THE UMBILICAL TO OR THROUGH THE ROOF .................................8
STEP 5. MAKING UMBILICAL CONNECTIONS ON THE ROOF.........................................8
STEP 6. COVER INSULATION & WIRES WITH UV PROTECTION.....................................9
STEP 7. INSTALL SOLAR WANDTM INTO HOT WATER TANK......................................10
STEP 8. MOUNT THE PUMP BOX..........................................................................................13
STEP 9. CONNECT UMBILICAL TO TOP OF PUMP BOX...................................................13
STEP 10. CONNECT PUMP BOX TO SOLAR WANDTM & INSTALL TANK TOP OVER-
TEMPERATURE SENSOR...........................................................................................................13
STEP 11. WATER FLUSHING SYSTEM & FILLING WITH ANTIFREEZE ......................14
STEP 12. TANK BLANKET THERMAL INSULATION.......................................................17
STEP 12.A OPTIONAL INSTALLATION OF TANKLESS WATER HEATER.....................17
STEP 13. CONNECT POWER TO PUMP BOX AND VERIFY OPERATION .....................18
APPENDIX 1. TOOLS OF THE TRADE...................................................................................19

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Pictorial Installation Guide: Solar Six PackTM Water Heating System Plus Tankless Option
STEP 0. WAND & SYSTEM CERTIFICATIONS
This product certified by:
Solar Rating & Certification
Corporation™
www.Solar-Rating.org
Butler Sun Solutions
1545 S. La Cienega Blvd
Los Angeles, CA 90035
USA
Solar Energy Factor
(SEFD)
SRCC Cert. No.
Model No.
1
1
1.1
0.9
1.4
1.4
1.4
30004257
30004258
30004260
30004271
30004274
30004272
30004273
B-BT1-40-I
B-SUN-TRB40-40-I
B-BT1-50-I
B-BT1-30-I
BT1-30-I-T
BT1-40-I-T
BT1-50-I-T
The installed system is marked above
An overview of the systems designated 30004257, 30004258, 30004260 and 30004271 are the same
solar systems with different sized existing tanks. The major components are shown for reference
purposes in Figures 0.2.1. An overview of the systems designated 30004274, 30004272 and 30004273
are the same solar systems with different sized existing tanks and a tankless water heater installed on
the hot water storage tank outlet to the house. The major components are shown for reference
purposes in Figures 0.2.2. The system has been engineered for easy installation. The system can be
configured two way to meet the ICC-SRCC OG-300 Certifications. The first is the solar only pictorial
version shown in Figures 0.2.1. This is the most common version of the systems that are installed and

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are fully represented in the step by step instructions. The second option, Figures 0.2.2 which has a
tankless water heater after the solar heated hot water storage tank. This version captures more solar
energy, because gas to the hot water storage tank in limited, so the solar wand is heating cooler water.
The tankless comes on to boost the temperature of hot water exiting the storage tank to the house, only
when needed, thus reducing the natural gas use and increases the amount of solar energy captured.
Figure 0.2.1 BSS Solar Six Pack™ Solar Hot Water System Overviews
Figure 0.2.2 BSS Solar Six Pack™ Solar Hot Water System Overviews Plus a Tankless Diagram

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PICTORIAL SUMMARY OF INSTALLATION STEPS

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STEP 1. FAMILIARIZE AND PLAN
Step 1A: Open the boxes, lay out all of the parts, and be sure that you can identify them all.
Look over the packing list to verify everything is included.
Step 1B: Check that the collector adaptor set (provided with the kit) is appropriate for the
collectors and configuration proposed for your system. If in doubt, contact us.
STEP 2. SOLAR COLLECTOR ALIGNMENT AND MOUNTING
Step 2A: Determine where you are going to mount the solar collector to minimize the distance
from the water tank to the collector and optimize the solar orientation of the system. The ideal
orientation of the solar collector for maximum annual energy delivery is tilted at your latitude
angle towards true South, with no shading of the collectors.
Step 2B: Determine how the collectors will be mounted, based on the type of roof you have:
flat or pitched, composition shingle, wood shakes, concrete tile, or clay tile. For flat roofs you
need a tilt kit for flat plate collectors or a rack for evacuated tubes. You should follow local
codes for attaching the solar collectors to the roof. Our complete installation manual on our
website shows the Housing and Urban Development Guidelines.
Step 2C: Mount the solar collectors sturdily to the roof, being sure that the highest point in the
solar collector is fitted with the SPOCTM connection. Steam only goes uphill, so “Landscape”-
oriented collectors must be tilted up by about 4”over 8 feet. This will ensure that steam can
escape from the nearly horizontal tubes without pushing a lot of water in front of it. “Portrait”
collectors must be tilted about 2˚(1 full bubble, or 0.5 in/ft). Some collector adapters need to be

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soldered to the solar collectors. It is easiest to do this before the collector is brought to the roof,
or at least before you tie down the solar collector. Adapters that screw on should also be
installed before the collector is tied down. The following pictures illustrate the collector
adapters used with Butler Sun 1 flat plate collectors.
Figure 1. Butler Sun Flat Plate Adapter Kit Usage
STEP 3. SPOCTM MOUNTING
Step 3A: After the collector is mounted, with the adapters in place, it is time to put the SPOCTM
in place. The SPOC™is mounted parallel and even with the top of the collector by placing lifting
brackets screwed into the collector side wall, self- tapping screws through the straps that hold the
SPOC™onto the lifting brackets, See Figure 3. The radiator cap must be at the top, and the
radiator section should slope slightly downward towards the collector connection.
Step 3B: Use the short length of black hose provided to connect the SPOCTM to the collector
outlet Tee-fitting. Be sure to put the hose on the port that is labeled SPOC™and not where the
collector outlet hose gets connected.
STEP4. ROUTING THE UMBILICAL TO OR THROUGH THE ROOF
Step 4A: Plan the route of the umbilical from the collectors to the water tank. This may mean
going through an attic or crawl space. Typically, the umbilical penetrates through the roof below
the bottom of the solar collector. In some cases, it is possible to avoid a roof penetration by
routing it around the eaves. Doing this properly will save time and money.
Step 4B: If you must make a roof penetration, use flashing found at your local building supply
store, which will meet local roofing codes. Commercial “Roof Jack” flashing is designed to
prevent rain water from entering the house and vermin from using the penetration as a pathway.
Make sure that the flashing is fitted and sealed to the roof properly with roof tar or proper
sealants that meet local code, See Figures 4 & 8.
STEP 5. MAKING UMBILICAL CONNECTIONS ON THE ROOF
Step 5A: First, make all of the fluid connections. Connect the outlet hose to the fluid outlet near
the highest point on the solar collector. Before installing the hoses put tape on one hose and

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blow through it to identify the other end, which should also be taped. Then you will be able to
distinguish which hose is connected from the collector outlet to the Solar Wand™top and which
is connected from the pump outlet to collector bottom inlet. Make sure that all hose clamps are
tight.
Step 5B: Now lay out the electrical connecting plug and see where you can conveniently mount
the PV panel. Once you have a location that allows the PV panel to be plugged into the umbilical
connector, mount the PV panel with the screws provided.
STEP 6. COVER INSULATION & WIRES WITH UV PROTECTION
Step 6A: Fit up the metal, ABS or PVC UV protection and elbows, being sure that you have
covered all exposed wires and umbilical on the roof and side walls; See Figure 6. The UV
protection is designed to support the umbilical and protect it from UV sunlight. We recommend
downspout material since it has 40+ year life in outdoor environments, is rigid, can be easily
fastened to walls, and can be painted to match the surroundings. If umbilical supports are needed
you will need to add them.
Step 6B: Tighten all of the hose clamp connections on the collector fittings. You should leave
them exposed so you can see them when you fill the system with fluid to verify that they do not
leak.
Step 6C: After you have verified that the connections are not leaking, secure the UV cladding

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with the screws provided.
STEP 7. INSTALL SOLAR WANDTM INTO HOT WATER TANK
Step 7A: Check for obstructions in the hot water tank’s hot water outlet port. Some tanks have
restrictions below the opening that will not allow the Solar WandTM to be inserted. If the tank
has a separate port on top for the sacrificial anode, there will not be an anode under the hot
water outlet. You will need to check the port, first turn the tank electric power or gas off, so it
does not heat while you are working on it. Next, turn off the cold water valve which pressurizes
the tank and open a hot water faucet to relieve the pressure. Then check the nipple from the hot
water outlet. If the nipple has a sacrificial anode attached to it, go to get a new tank. If it is just
a simple threaded nipple, then look in and (if the water is cool enough) stick your finger in the
opening to be sure that there are no obstructions under the fitting. If you do not find any
obstructions, clean the threads with a wire brush or a ¾” National Pipe Thread Tap. Once
cleaned out you may be ready to put the Solar WandTM in place after you complete the next step.
Step 7B: Check the sacrificial anode in the tank. If the tank is only a few years old this may not
be necessary. If the tank is more than five years old, it is strongly recommended. Replacing a
bad anode will add another five to seven years to your tank’s life. A good LED flashlight will
allow you to see the anode condition within the tank. If you have one, it is handy to use an
inspection scope such as the one shown in the following figure. The pictures to the left in the
picture below show anodes in various states of usage. The one on the far left is new, the one in
the center is well used but still providing protection to the tank, and the one on the right is down
to just the central wire. If the anode is showing the central wire, it should be replaced. If it is
down to just the wire , you might consider replacing the tank since the anode has stopped
providing any protection and the tank may be compromised.