HTP HP-30SC User manual

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com
Evacuated Tube
Solar Collector
INSTALLATION
MANUAL
HP-30SC
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held
liable for typographical errors in literature.

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The following defined terms are used throughout this manual to bring attention to the presence of
hazards of various risk levels or to important information concerning the product.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
FOREWORD
This manual is intended to be used in conjunction with other literature provided with the Evacuated Tube
Solar Collector. This includes all related control information. It is important that this manual, all other
documents included with this system, and additional publications including Solar Water Heating System
Design and Installation Guidelines, be reviewed in their entirety before beginning any work.
“The solar energy system described in this manual, when properly installed and maintained, meets the
minimum standards established by the SRCC. This certification does not imply endorsement or warranty
of this product by the SRCC.”
Installation should be made in accordance with the regulations of the local code authorities and utility
companies which pertain to this type of water heating equipment.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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FOR THE INSTALLER
For your safety, please read through this manual carefully before installation to minimize the risk of fire,
property damage, and personal injury. Solar hot water system shall be properly installed in accordance
with this manual before use.
INSTALLATION OR SERVICE OF THESE SOLAR PANELS IS REQUIRED TO BE PERFORMED BY
LICENSED PROFESSIONALS WHERE SOLAR, PLUMBING AND ELECTRICAL WORK IS REQUIRED.
The installer should be guided by the instructions furnished with the tank, local codes and utility company
requirements. Preference should be given to codes and requirements where they differ from the furnished
instructions.
Additional publications which should guide the installer include:
Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, from Solar Rating and
Certification Corporation, 1679 Clearlake Road, Cocoa, FL 32922-5703.
Code for the installation of Heat Producing Appliances (latest version), is available from American
Insurance Association, 85 John Street, New York, NY 11038.
The latest version of the National Electrical Code, NFPA No. 70.
In Canada, refer to Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

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TABLE OF CONTENTS
INTRODUCTION...........................................................................................................................................7
ABOUT YOUR EVACUATED TUBE SOLAR COLLECTOR ..................................................................7
PART 1: GENERAL SAFETY INFORMATION............................................................................................7
A. METALLIC COMPONENTS .................................................................................................................7
B. EVACUATED TUBES...........................................................................................................................7
C. HIGH TEMPERATURES......................................................................................................................8
D. HEALTH AND SAFETY........................................................................................................................8
PART 2: IMPORTANT INFORMATION .......................................................................................................9
A. SCOPE OF MANUAL...........................................................................................................................9
B. LOCAL STANDARDS...........................................................................................................................9
C. AUTHORIZED PERSONS....................................................................................................................9
D. TERMINOLOGY...................................................................................................................................9
E. POSSIBLE SYSTEM DESIGNS...........................................................................................................9
1. OPEN LOOP SYSTEMS...................................................................................................................9
2. CLOSED LOOP SYSTEMS..............................................................................................................9
3. DRAIN BACK SYSTEMS................................................................................................................10
F. FLUID QUALITY.................................................................................................................................10
G. METALLIC CORROSION...................................................................................................................10
H. FREEZE PROTECTION.....................................................................................................................11
I. COLLECTOR DIMENSIONS & WEIGHTS..........................................................................................11
J. WIND STRESS ...................................................................................................................................11
K. SNOW LOAD......................................................................................................................................12
L. STORAGE TANKS..............................................................................................................................12
M. HAIL RESISTANCE...........................................................................................................................12
PART 3: INSTALLATION INFORMATION................................................................................................12
A. TRANSPORT, UNPACKING, AND INSPECTION .............................................................................12
1. COMPONENT LIST ........................................................................................................................12
2. TUBE AND HEAT PIPE INSPECTION...........................................................................................14
B. SYSTEM DESIGN..............................................................................................................................15
C. DELTA-T CONTROLLER SETTINGS................................................................................................15
D. STAGNATION AND OVERHEATING................................................................................................15
E. CORRECT SYSTEM SIZING TO AVOID OVERHEATING ...............................................................15
F. SOLAR FOR CENTRAL HEATING – PREVENTING OVERHEATING .............................................16
G. COLLECTOR ANGLE, PLANE, AND DIRECTION............................................................................16

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1. COLLECTOR ANGLE.....................................................................................................................16
2. COLLECTOR PLANE .....................................................................................................................16
3. COLLECTOR DIRECTION .............................................................................................................16
4. TO EASE OVERHEATING .............................................................................................................16
H. AVOID SHADE...................................................................................................................................16
I. LOCATION...........................................................................................................................................16
J. EXPANSION TANK: MINIMIZING WATER WASTAGE .....................................................................17
1. OPEN LOOP SYSTEMS.................................................................................................................17
2. CLOSED LOOP SYSTEMS............................................................................................................17
3. DRAIN BACK SYSTEMS................................................................................................................17
K. LIGHTNING PROTECTION................................................................................................................17
L. PIPE CONNECTIONS AND PIPE SIZE .............................................................................................17
M. CONNECTION OF MULTIPLE COLLECTORS.................................................................................17
N. POTABLE WATER.............................................................................................................................17
O. MOUNTING FRAME..........................................................................................................................18
P. CUSTOMIZING THE FRAME.............................................................................................................18
Q. GALVANIC REACTION BETWEEN STAINLESS AND ZINC GALVANIZED STEEL.......................18
PART 4 – COLLECTOR INSTALLATION .................................................................................................18
A. INSTALLING CLAMP TO MANIFOLD................................................................................................18
B. INSTALLING CLAMP TO BASE TUBE FRAME ................................................................................19
C. INSTALLING MANIFOLD AND BASE TUBE FRAME TO MANIFOLD ARMS..................................19
D. INSTALLING TRIANGLE PLATE ASSEMBLY...................................................................................20
E. INSTALLING LEGS TO ASSEMBLY..................................................................................................21
F. INSTALLING FEET TO ASSEMBLY..................................................................................................21
G. INSTALLING THE SUPPORTS .........................................................................................................22
H. FLUSH / FLAT MOUNTING ...............................................................................................................23
I. INSTALLING EVACUATED TUBES....................................................................................................23
PART 5 – ROOF/WALL ATTACHMENT SUGGESTIONS........................................................................24
A. ROOF ATTACHMENT........................................................................................................................24
B. FLUSH PITCHED ROOF INSTALLATION.........................................................................................25
1. TILED ROOF ATTACHMENT.........................................................................................................25
2. CORRUGATED IRON ROOF ATTACHMENT ...............................................................................25
3. ASPHALT SHINGLE ROOF............................................................................................................25
C. LOW PITCHED ROOF INSTALLATION ............................................................................................25
D. FLAT ROOF INSTALLATION.............................................................................................................26

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E. WALL MOUNTING .............................................................................................................................26
PART 6 – PLUMBING CONNECTIONS ....................................................................................................26
A. TEMPERATURE SENSOR INSERTION............................................................................................26
B. HEADER CONNECTION....................................................................................................................27
C. AIR PURGE........................................................................................................................................27
D. PLUMBING CHECK...........................................................................................................................27
E. GLYCOL FREEZE PROTECTION .....................................................................................................28
F. INSULATION ......................................................................................................................................28
G. PUMP SELECTION............................................................................................................................28
PART 7 – SYSTEM PIPING DIAGRAMS...................................................................................................30
A. DRAINBACK TANK WITH BACKUP WATER HEATER ....................................................................30
B. CLOSED LOOP SYSTEM WITH ELECTRIC BACKUP AND STORAGE TANK...............................31
PART 8 – MAINTENANCE.........................................................................................................................32
A. CLEANING .........................................................................................................................................32
B. LEAVES..............................................................................................................................................32
C. BROKEN TUBE..................................................................................................................................32
D. INSULATION......................................................................................................................................32
E. DRAINING THE COLLECTOR...........................................................................................................32
F. OTHER COMPONENTS.....................................................................................................................33
G. STAGNATION....................................................................................................................................33
PART 9 – TROUBLESHOOTING...............................................................................................................33
A. NO HOT WATER................................................................................................................................34
B. REDUCED SOLAR CONTRIBUTION................................................................................................34
C. REGULAR WATER DUMPING..........................................................................................................34
D. INSTALLED COLLECTOR DETAIL...................................................................................................35
1. ANGLED COLLECTOR ..................................................................................................................35
2. FLUSH COLLECTOR .....................................................................................................................35
PART 10 – INSTALLATION CHECKLIST .................................................................................................36
MAINTENANCE NOTES ............................................................................................................................37
HTP CUSTOMER INSTALLATION RECORD FORM........................................................................38

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INTRODUCTION
ABOUT YOUR EVACUATED TUBE SOLAR COLLECTOR
Your Evacuated Tube Solar Collector is designed to offer reliable hot water heating in mild to cold
climates. Evacuated tubes provide insulation around heat pipes, and work with both glycol and drain back
solar systems, making these solar collectors an ideal choice in cold climates where flat panel collectors
are not an option.
Perhaps most important of all, if an evacuated tube (or tubes) should break, there is no need to shut
down your system. The Evacuated Tube Solar Collector will continue to function until the damaged
tube(s) can be replaced.
Job site conditions will require your installation contractor to supply some or all of the following:
•Plumbing Connections
•Piping and Insulation
•Valves Between Your Backup Water System and the Solar System
NOTE: HTP reserves the right to make product changes or updates without notice and will not be held
liable for typographical errors in literature.
PART 1: GENERAL SAFETY INFORMATION
NOTE: OBTAIN ALL APPLICABLE PERMITS AND OBEY ALL LOCAL CODES.
Only use this solar hot water system as intended and described in the installation manual; use other than
described will void warranty and may lead to fire, property damage, and personal injury.
Install all system components and piping in such a way that does not reduce the performance of any fired
rated assembly.
A. METALLIC COMPONENTS
Always wear leather protective gloves when handling solar collector components. All efforts have been
made to make the metal components safe to handle, but there may still be some sharp edges.
B. EVACUATED TUBES
Be careful when handling the evacuated tubes, as they will break if knocked heavily or dropped.
If exposed to sunlight, hot, and have internal pressure built up, the tubes may explode rather than
implode if knocked and broken. This is a rare occurrence, but safety precautions should be taken.
When installed, evacuated tubes may break if struck by a hard object with enough force (e.g. branch
falling on roof). DURING INSTALLATION, CONSIDERATION SHOULD BE TAKEN AS TO THE

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POSSIBLE PATH ANY BROKEN GLASS MAY TAKE. Where possible, protection should be provided to
prevent broken glass from reaching ground level where somebody could walk on it.
THE HOMEOWNER SHOULD BE MADE AWARE BY THE INSTALLER THE LOCATION OF THE
SOLAR COLLECTOR AND THE POSSIBLE VICINITY OF BROKEN GLASS IN THE EVENT OF AN
EXTREME STORM OR OBJECT FALLING ON THE COLLECTOR.
C. HIGH TEMPERATURES
In good sunlight, the heat pipe tip on the evacuated tube can reach temperatures in excess of 392oF.
Thick leather gloves must be worn when handling hot tubes and heat pipes to prevent serious burns.
Keep solar hot water system and components away from children and animals.
In an installed, fully plumbed system, if the pump is stopped during good sunlight, the collector header
and piping close to the solar manifold can easily reach temperatures in excess of 320o F. Caution should
be taken when handling such components.
DO NOT STORE COMBUSTIBLE MATERIALS (DRY LEAVES, TREE BRANCHES, GASOLINE, ETC) IN
VICINITY OF THE SYSTEM.
D. HEALTH AND SAFETY
•ALWAYS WEAR SAFETY GLASSES WHEN HANDLING EVACUATED TUBES.
•WEAR LEATHER GLOVES WHEN HANDLING METAL COMPONENTS.
•WEAR THICK LEATHER GLOVES IF HANDLING HOT HEAT PIPES.
•ADHERE TO SAFETY REGULATIONS WHEN WORKING ON ROOFS (OR AT A HEIGHT).
•ALWAYS OBTAIN ENGINEER APPROVAL FOR INSTALLATIONS IN HIGH WIND REGIONS.
•ASSEMBLY OF THE SOLAR HOT WATER SYSTEM REQUIRES TWO PERSONS WITH THE
ABILITY TO LIFT 50 POUNDS EACH.
•BEST TO INSTALL ON A COOL, CLOUDY DAY.
•STORE EVACUATED TUBES IN DARK OR SHADED PLACES UNTIL INSERTION INTO THE
MANIFOLD.
If any system components are exposed to the following, do not operate until the affected component has
been inspected by a qualified serviceman.
1. FIRE
2. DAMAGE
3. SUBMERSION IN WATER
Any claims for damage or shortage in shipment must be filed immediately against the transportation
company by the consignee.
Use of lead solder is expressly prohibited. Use of galvanized steel, CPVC, PVC, PEX, or any other type
of plastic pipe is prohibited.

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PART 2: IMPORTANT INFORMATION
A. SCOPE OF MANUAL
This manual pertains only to the installation and operation of the HTP Solar Collector. Details for the
installation, operation and maintenance of the complete solar gas/electric water heating system including,
but not limited to storage tank, gas/electric booster, pump, system controller, valves and other plumbing
components should be provided separately by their respective manufacturers.
NOTE: This manual is primarily a reference document for installation officers, as the solar collector is not
permitted to be installed by non-authorized persons.
B. LOCAL STANDARDS
Installation must be completed in accordance with local standards and regulations.
C. AUTHORIZED PERSONS
Installation must be completed by a qualified tradesperson who holds relevant industry licenses or
certificates. The term “authorized person(s)” used throughout this document refers to a suitably qualified
professional. Unless otherwise specified in section 3, no part of the HTP solar collector may be inspected,
repaired, or maintained by anybody other than an authorized person.
D. TERMINOLOGY
The terminology used from region to region differs. To avoid confusion please note the following:
Supply - The plumbing line running from the outlet of the collector back to the tank.
Return - The plumbing line running from the tank (or heat exchanger) to the inlet of the collector. This
line incorporates the circulation pump.
Insulation - Solar radiation level, expressed in kWh/m2/day or Btu/ft2/day
E. POSSIBLE SYSTEM DESIGNS
1. OPEN LOOP SYSTEMS
For open loop systems, the normal operating pressure should be < 72.5 psi via use of a pressure limiting
(pressure reduction) valve on the main cold supply line.
It is acceptable for the system design to allow the solar collector to stagnate to prevent additional heating
of the storage tank (i.e. pump stoppage once tank temperature reaches 177o F). The pressure relief valve
must be able to release the pressure increase that occurs when the manifold stagnates, and should be
rated to meet the maximum possible heat output of the solar collector(s). Please see Part 6, Section F
regarding insulation of piping for high temperatures, and Part 3 for sections regarding overheating.
2. CLOSED LOOP SYSTEMS
For closed loop systems, the solar loop must operate at < 72.5 psi, and have an expansion vessel
installed to control water expansion. The system design MUST NOT allow stagnation of the collector as a
standard form of controlling tank temperature, as this may cause damage to the glycol.
Any system design must provide means for allowing pressure release at no more than 113 psi. It is
recommended that the lever on pressure and temperature relief valves (PTRV) on main pressure hot
water storage tanks be operated once every 6 months to ensure reliable operation. It is important to raise
and lower the lever gently, and be careful as the water released will be HOT. Failure to operate the

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PTRV on a regular basis could lead to failure of the component and the possibility of the storage tank
exploding.
It is recommended, and may also be a local regulation, that the PTRV have a copper pipe connected,
running the expelled hot water or air to a safe and appropriate drainage location. The PRTV and the drain
outlet pipe must not be sealed or blocked. It is normal for the valve to release small amounts of water
during heating cycles.
3. DRAIN BACK SYSTEMS
For drain back systems, the solar loop usually operates at < 25 psi, far lower than open or closed loop
systems. Drain back systems require larger pumps to move water up and into the solar collectors. But
when storage water temperature settings are reached, or freezing outdoor temperatures are detected, the
pump shuts off, allowing the heat transfer fluid to drain back into the tank. Thus, the drain back method
provides effective overheating and freeze protection, making these systems well-suited for cold and mild
climate operation.
Since drain back systems don’t operate at high pressures, an expansion vessel is not required. Install a
PTRV on the drain back tank, with a copper pipe running expelled hot water and air to a safe and
appropriate drainage location. The PRTV and drain outlet pipe must never be sealed or blocked.
NOTE: The collector and collector plumbing should be sloped down toward the drain back reservoir at ¼”
per foot minimum to allow the system to drain.
F. FLUID QUALITY
Water in direct flow through the manifold header must first meet potable water requirements and, in
addition, the following:
TOTAL DISSOLVED SOLIDS <600 ppm
TOTAL HARDNESS <200 ppm ÷ 17.1 = 11.7 grains
CHLORIDE
<40 ppm
FREE CHLORINE <5 ppm
MAGNESIUM
<10 ppm
Table 1
In areas with “hard” water (> 200 ppm), lime scale may form inside the header pipe (where a direct flow
format is used). In such regions, it is advisable to install a water softening device to ensure the long term
efficient operation of the collector, or use a closed loop for the solar circulation loop.
In order to meet health and safety regulations, glycol used should be food grade polypropylene glycol,
FDA rated as “generally recognized as safe” (GRAS). If using a glycol/water mix, the water must meet the
above requirements, and the glycol content of the liquid must not exceed 50%, unless the manufacture
specifies that a different ratio is recommended for use with solar water heaters. Glycol should be
checked periodically to prevent it from becoming acidic; please refer to the guidelines provided by the
glycol manufacturer regarding maintenance of glycol.
G. METALLIC CORROSION
Both copper & stainless steel are susceptible to corrosion when, amongst other factors, high
concentrations of chloride are present. The solar collector may be used for heating of spa or pool water,
but levels of free chlorine must not exceed 5ppm, otherwise the copper header could corrode.
NOTE: HTP DOES NOT WARRANT THE SOLAR COLLECTOR AGAINST CORROSION RELATED
DAMAGE.