HTP PH130-80S Owner's manual

Phoenix Solar
Water Heater
INSTALLATION
OPERATION
MAINTENANCE
Phoenix Water Heater Models
PH130-80S / 130-119S
PH199-80S / 199-119S
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.
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 product information.
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 Solar Water
Heater. 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.
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
INSTALLATION OR SERVICE OF THIS SOLAR WATER TANK 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.
INSTALLATIONS MUST COMPLY WITH:
Local, state, provincial, and national codes, laws, regulations and ordinances.
Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, from Solar Rating and
Certification Corporation, 1679 Clearlake Road, Cocoa, FL 32922-5703.
The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association
Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131.
In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale
Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian
Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.
Code for the installation of Heat Producing Appliances (latest version), 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.
NOTE: The Phoenix gas manifold and controls met safe lighting and other performance criteria when
undergoing tests specified in ANSI Z21.10.3 – latest edition.
This manual must only be used by a qualified heating installer/service technician. Read all instructions in
this manual before installing. Perform steps in the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.

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TABLE OF CONTENTS
PART 1: GENERAL SAFETY INFORMATION............................................................................................5
A. LOCAL INSTALLATION REGULATION...............................................................................................5
B. WATER TEMPERATURE ADJUSTMENT............................................................................................5
C. FREEZE PROTECTION/WINTERIZING..............................................................................................5
PART 2: GENERAL INFORMATION...........................................................................................................6
A. PREFACE .............................................................................................................................................6
B. INTRODUCTION...................................................................................................................................6
C. SYSTEM DESCRIPTION......................................................................................................................6
D. PHOENIX SOLAR WATER HEATER...................................................................................................6
E. SOLAR WATER HEATER LOCATION.................................................................................................6
F. INSPECTION OF THE SOLAR WATER HEATER...............................................................................7
G. SOLAR PIPING CONNECTION...........................................................................................................7
H. GENERAL SOLAR PANEL ORIENTATION.........................................................................................8
I. GENERAL SOLAR PANEL INSTALLATION..........................................................................................8
J. COLLECTOR LOOP PIPE INSULATION..............................................................................................9
K. COLLECTOR PIPING...........................................................................................................................9
L. COLLECTOR SENSOR PLACEMENT...............................................................................................10
PART 3: WATER HEATER INSTALLATION.............................................................................................10
A. INSTALLATION CHECKLIST .............................................................................................................10
B. POTABLE WATER PIPING ................................................................................................................11
C. SOLAR HEAT EXCHANGER PIPING................................................................................................12
D. TANK SENSOR PLACEMENT...........................................................................................................13
E. NECESSARY COMPONENTS FOR SOLAR WATER HEATER INSTALLATION.............................13
F. PHOENIX SOLAR PIPING WITH AIR HANDLER..............................................................................16
G. TANK CONTROL................................................................................................................................17
H. CIRCULATOR SIZING........................................................................................................................17
I.CHARGING THE SYSTEM...................................................................................................................18
J. COMMISSIONING THE SYSTEM.......................................................................................................18
PART 4: MAINTENANCE...........................................................................................................................19
A. SHUTDOWN PROCEDURES ............................................................................................................19
B. VACATION SHUTDOWN....................................................................................................................19
C. ESTIMATED LIFE OF COMPONENTS..............................................................................................20
PART 5: TROUBLESHOOTING.................................................................................................................24
MAINTENANCE NOTES ............................................................................................................................30

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HTP CUSTOMER INSTALLATION RECORD FORM ........................................................................31
PART 1: GENERAL SAFETY INFORMATION
INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.
USER – This manual is for use only by a qualified installer/service technician. Refer to user’s information
manual for your reference. Have this heater serviced/inspected by a qualified service technician annually.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL
PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
A. LOCAL INSTALLATION REGULATION
Installation of this solar water heater may be governed by individual local rules and regulations for this
type of product, which must be observed. Always use the latest edition of codes. The installation,
adjustment, service, and maintenance of the solar water heater must be done by a licensed professional
who is qualified and experienced in the installation, service, and maintenance of solar hot water systems.
B. WATER TEMPERATURE ADJUSTMENT
If the solar water heater is going to have a set temperature above 120oF, you must use an ASSE 1017
rated mixing valve to avoid severe burns or death from scalding temperature.
Households with small children, disabled, or elderly persons may require a 120oF or lower
temperature setting to prevent scalding.
C. FREEZE PROTECTION/WINTERIZING
NOTE: Consider piping and installation when determining heater location.
To winterize the heater, drain the entire system. Pump one gallon of non-toxic, NSF food grade propylene
glycol, FDA rated as GRAS (Generally Recognized As Safe), into the tank. Consult the glycol
manufacturer for specific instructions on concentration percentage as well as freeze and burst protection
methods. Check the concentration of antifreeze to assure protection is adequate to protect the bottom of
the heater from freezing.

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PART 2: GENERAL INFORMATION
A. PREFACE
By using the sun’s energy to heat water, solar hot water heating systems help reduce the nation’s
dependence on polluting fossil fuels. This reliable, efficient solar water heater meets the certification
requirements of SRCC-OG-300.
B. INTRODUCTION
Solar system performance and efficiency varies with factors such as: household hot water load, ambient
air temperature, roof pitch, collector orientation, and seasonal intensity.
Your solar system uses a circulation pump to circulate heat transfer fluid throughout the system.
Depending on system design, you may use distilled water (often used in drain back systems), or a
propylene glycol/water solution (in closed loop systems) as heat transfer fluid. Drain back and propylene
glycol systems provide freeze protection to the solar components.
This manual intends to familiarize you with the proper installation and maintenance of your solar water
heating system. This system must be installed by a licensed solar or plumbing contractor in accordance
with SRCC Standard OG-300 and all applicable national, state, and local codes.
NOTE: Failure to follow the procedures described in this manual voids the manufacturer warranty.
C. SYSTEM DESCRIPTION
Some of the components in the Phoenix Solar Water Heating System include: the solar collector(s), a
Phoenix Solar Water Heater, a circulator pump, a differential solar control, and an expansion tank.
Depending on the type of solar system, distilled water or non-toxic, FDA rated Generally Recognized As
Safe (GRAS) propylene glycol will be used as heat transfer fluid.
D. PHOENIX SOLAR WATER HEATER
The Phoenix Solar Water Heater has an internal solar heat exchanger for use with solar collectors. And
when there is not sufficient solar energy, the Phoenix Solar Water Heater utilizes a gas-fired backup to
provide hot water. (Refer to solar piping details in this manual for suggested piping application.)
E. SOLAR WATER HEATER LOCATION
Choosing a location for your solar water heater is an extremely important part of the installation process.
The heater location should be centralized to the piping system, in an area where it will not be exposed to
freezing temperatures. All piping should be insulated to protect against freezing and heat loss.
In addition, the solar water heater should be installed with plenty of clearance for service. If minimum
clearances are not met, it may not be possible to service the heater without removing it from its location.
Finally, the solar water heater should also be installed in a place where T&P discharge or a leak will not
result in damage to the surrounding area. If such a location is not available, install an auxiliary catch pan.

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F. INSPECTION OF THE SOLAR WATER HEATER
When receiving your solar water heater, inspect it for possible damage. Check markings on the rating
plate to be certain the power supply corresponds to that for which the water heater is equipped.
G. SOLAR PIPING CONNECTION
When making a connection to the heat exchangers, use Teflon tape and joint compound to prevent leaks.
The heat exchanger connections are 1” NPT. Do not apply heat directly to heat exchanger thread
connection when sweating fittings.
In closed loop glycol systems, freeze protection fluid must be non-toxic, propylene glycol, FDA rated as
GRAS. To protect the heat exchanger and other system components, regular scheduled maintenance
must be established to monitor and maintain proper heat transfer fluid pH levels.
Many heat transfer fluids are classified as toxic. Do not introduce heat transfer fluids into any fittings on
the heater except those clearly marked for that purpose.
The system components should carry temperature and pressure ratings equivalent to the design of the
solar collector. To ensure system is appropriate for installation climate, the solar collector ratings should
be verified against the collector manufacturer specifications. Collector and storage tank temperatures can
be read from the system controllers. Typical tank operating temperatures range from 40-80oF on the cold
supply line to the 175oF tank high limit. The collector temperature sensor should be 5-20oF higher than
the tank sensor during normal charging operation. During idle period, when there is no sun, the collector
sensor will read the ambient temperature; in full sun, the sensor will read as high as 250oF. Temperatures
vary depending on installation climate.
Using proper concentrations of glycol, solar systems can be operated at ambient temperatures as low as
-60oF. Freeze tolerance limits are based upon an assumed set of environmental conditions. Refer to the
DOWFROST specification sheet in the back of this manual for recommended concentrations.
Figure 1 - Clearances

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Depending on the controller model, the differential controller uses 10k ohm thermistors or 1k RTDs to
monitor the temperature difference between the collector and the solar water heater. The controller turns
on when the collector is 12-20oF above tank temperature and turns off when the differential drops to 4oF.
H. GENERAL SOLAR PANEL ORIENTATION
Part of the performance of your solar water heater is based on the correct orientation of the solar panels.
The collector should be mounted as close to the storage tank as possible to minimize heat loss in the
piping runs. In North America,
collectors should be oriented
facing due south. However, if
this is not possible, they may
be installed within 40 – 60
degrees of due south. Optimal
tilt is +/- 10ofrom the latitude of
the site. The solar collector
must be located in an area of
the roof that will be unshaded
for the majority of the day (from
9 AM – 3 P<) year round.
Adjacent buildings and trees
should be checked for possible
winter shading.
You must consult your solar
panel installation manual for
recommended mounting and
positioning of the panels.
I. GENERAL SOLAR PANEL INSTALLATION
The contractor shall obtain all required permits and approvals for installing the solar system. The
installation shall conform to all federal, state and local regulations governing solar water heating system
installations. The contractor shall adhere to sound building safety and trade practices. Special
consideration must be given to building code requirements for the penetration of structural members and
fire rated assemblies. Before the installation, the contractor shall inspect the condition of the roof and
notify the homeowner of any existing roof damage or necessary repairs. The most important structural
consideration is to securely anchor the solar collector and the solar strut mounting hardware to the
structural members of the roof with stainless steel hanger or lag bolts as detailed in figures below.
Consult with the panel manufacturer installation manual for proper guidelines in your application.
Preserving the integrity of the roof membrane is the most important roofing consideration. Ensure that all
roof penetrations required to plumb and mount the solar collector are properly flashed and sealed in
accordance with standard roofing practices. The recommended elastomer for sealing roof penetrations is
Tremco “POLYroof”.
Figure 2 – Example of Solar Panel Orientation – LP-199-O

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Figure 3 - This detail is an example of a typical solar roof mount application. All equipment should be
installed in accordance with all local codes and best practices as identified with National Roofing
Contractors Association (NRCA) or other qualified body.
J. COLLECTOR LOOP PIPE INSULATION
To minimize heat loss, the collector loop cold supply and hot return lines must be well insulated with high
quality flexible closed cell insulation. The wall thickness of the pipe insulation should not be less than ¾”.
A 1” wall thickness is required in all areas prone to annual hard freeze conditions. When it comes to pipe
insulation the rule is simple: thicker is better. The specified piping insulation material is Rubatex Insul-
Tube 180 or equal.
To the extent possible, slide the insulation material over the pipe without cutting or taping. All butt joints
must be sealed with contact adhesive. The use of rigid polyethylene pipe insulation is prohibited. The
temperatures generated by your collector in the summer months or under stagnation conditions can melt
this type of material.
Any above ground exterior pipe insulation is subject to UV degradation and must be wrapped with foil
tape or painted with two coats of high quality water-based acrylic resin coating as supplied by the
insulation manufacturer. The required coating material is Rubatex UV Protective Coating or equal.
K. COLLECTOR PIPING
Collector piping requires the use of all copper and brass fittings in the collector loop. In glycol loops, cast
iron is also acceptable. Couplings rather than unions should be used to join the collectors to avoid leaks
and fluid loss. Use only lead-free solder. Engelhard Silvabrite 100 or equal is required. Use of 50/50 lead
solder is expressly prohibited. Use of galvanized steel, CPVC, PVC, or any other type of plastic pipe is
prohibited.
Piping in new solar installations may have dirt, grease, solder flux, or other impurities in the piping that
over time affect the quality of the glycol HTF. A thorough cleaning is required before charging the system
with glycol.
All vertical piping between the storage tank and the collector shall be supported at each story or at
maximum intervals of ten feet (10’). Copper plumbers tape or tube strap is required. The pipe insulation
may not be compressed or crimped by the strapping material.

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The installation of all horizontal and vertical piping may not reduce the performance or rating of any
structural member or fire rated assembly. Adhere to all applicable local codes and ordinances.
L. COLLECTOR SENSOR PLACEMENT
The collector sensor must be located on the hot water return line as close to the collector as possible.
Some collectors have insertion areas to measure temperatures more accurately at the collector manifold.
Sensors are typically accurate to +/- 1/2oF if
properly installed and weatherized. To
maximize sensor accuracy, attach the
flanged portion of the sensor to the collector
header pipe with a stainless steel hose
clamp. Wire nuts used to connect the
sensor and low voltage wiring shall be all
plastic, sealed with silicone, and thoroughly
wrapped in electrician’s tape.
The low voltage wiring used to connect the
sensors to the controller should be a
minimum 18 AWG. The wiring should be
bare or tinned copper, two conductor, PVC
insulated, with a PVC UV rated gray jacket
suitable for exterior use. Use Eastman Wire
& Cable no. 5704, Beldon Wire and Cable
no. 8461 or equal.
The sensor “bundle” must be placed under
the rubber pipe insulation covering the
collector header. Thoroughly wrap and weatherize the insulation with electrician’s tape or insulation tape
as provided by the manufacturer (Rubatex Insul-Tape or equal).
PART 3: WATER HEATER INSTALLATION
A. INSTALLATION CHECKLIST
Location
•Sufficient room to service water heater
•Provisions made to protect area from water damage
•Centrally located to fixtures
•Protected from freezing temperatures
•Area free of flammable vapors
Potable Water Supply
•All related piping free from leaks
•Thermal expansion tank installed
•Water heater and fixtures have been properly purged of air
•ASSE 1017 rated thermostatic mixing valve (if water temperature is set above 120oF)
Relief Valve
•Temperature and Pressure relief valve properly installed and discharge line runs to open drain
•Discharge line not exposed to freezing temperatures
•Discharge line constructed of copper
Figure 4 – Sensor Placement – LP-199-O

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Solar Heat Exchanger to Solar Panel
•Anti-freeze (if required) is added and rated as non-toxic with copy of MSDS sheet for homeowner
•Solar heat exchanger completely purged of air
•Expansion tank and pressure temperature gauge operating properly
•Solar control shows circulators operating properly on the solar panels
Anti-Freeze Fluid
•Make sure freeze protection fluids are certified non-toxic
•Glycol percentage must be calculated per local area freeze level
•Provide glycol MSDS sheet to end user
B. POTABLE WATER PIPING
The design and installation of the solar water heating system should be done by qualified individuals. It is
important that good design and installation practice be followed to assure that your system will operate
properly. Failure to follow installation guidelines for you solar water heater system could cause
component failure and possible safety issues.
Many heat transfer fluids are classified as toxic. Do not introduce heat transfer fluids into any fittings on
the heater except those clearly marked for that purpose.
It is mandatory that all plumbing be done in accordance with all local and state codes or warranty will be
void. It is also necessary to use both thread tape and pipe dope on all mechanical connections. The
potable water piping is located on the side of your solar water heater and marked Hot and Cold. It is
recommended that unions or flexible copper connectors be used so heater can be easily serviced. Install
a shut-off valve on the cold feed near the solar water heater to isolate the tank for future service.
Provide clear access to the storage tank, pump, expansion tank, mixing valve, time clock and other key
components. The components on the potable side of the system may require future service or
maintenance, so it is recommended that the connections be made with brass unions. You must use
copper and brass fittings in plumbing the solar storage tank and expansion tank. The use of galvanized
fittings, nipples, dielectric unions, CPVC, PVC, or other plastic pipe is prohibited.
Hard copper connections to the city cold water supply line and home hot water feed lines are
recommended.
The gaskets in standard water heater flex hose connectors can become brittle and compressed over time
and begin leaking on the water heater. If not detected in a timely manner, a drip or leak may cause
serious damage to the tank’s electrical components, or, in extreme cases, cause the tank to leak from the
outside in.

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C. SOLAR HEAT EXCHANGER PIPING
Figure 5 - This drawing is meant to demonstrate system piping concept only.
Set up the primary balance of the system components following the piping detail in Figure 5.
Run ½” type M or larger copper pipes, or flex line sets, to and from the collector following the direction of
supports, penetrations, and other relative items.
Only copper, cast iron, or brass are to be allowed in the collector piping loop due to transient operating
temperatures that may reach as high as 300oF. PEX, PVC, CPVC, and other polymers are expressly
prohibited in the piping network.

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When making a connection to the heat exchanger, use Teflon Tape and joint compound to prevent leaks.
The connections to the heat exchanger are 1” NPT. Do not apply heat directly to the heat exchanger
thread connection when sweating fittings.
Line pressure and temperature gauge shall be installed in the collector supply and return lines to allow for
a simple diagnostic check of proper system operation. On a sunny day, the hot water return line should
be approximately 5 – 12oF warmer than the water in the collector supply line. Compare the temperature
readings in the two line thermometers. The ¾” cold water supply line to the storage tank must be
insulated with a minimum 7/8” x ½” pipe insulation to a minimum distance of 5’ behind the storage tank, or
to the wall if closer than 5’.
D. TANK SENSOR PLACEMENT
Make sure the sensor is secured on the stud located in the lower section of the water heater. Secure the
sensor by packing Rubatex insulation behind it. This will also help the sensor react to temperature
change.
Non-toxic freeze protection fluid must be used to protect the system from freezing. Use a mixture
appropriate for your climate. Do not use a higher glycol to water concentration than necessary, as this will
adversely impact heat transfer efficiency. See the DowFrost Data Sheet in the back of this manual for
recommended concentrations. A copy of the MSDS sheet must be left with the end user of the solar
system. See “EMERGENCY OVERVIEW” as part of the DowFrost Data Sheet in the back of this manual.
The collector loop must be charged with a mixture of heat transfer fluid and distilled or deionized water.
The use of regular tap water as a mixing agent is prohibited. Regular scheduled maintenance must be
established to monitor and maintain the proper pH level of the heat transfer fluid in the system to protect
the heat exchanger and other components in the system.
E. NECESSARY COMPONENTS FOR SOLAR WATER HEATER INSTALLATION
Listed below are components needed for installation of the solar water heater.
Solar Collector
Absorbs and transfers the sun’s energy into the solar heat exchanger located on the bottom of the solar
water heater.
Solar Air Release Vent
This air vent allows air contained in the solar system to release. The air vent valve must be designed to
work in high temperatures (as high as 350oF) with a glycol medium. (This is typical of solar systems.)
Solar Collector Sensor
This sensor is wired to the solar controller and automatically turns on the circulator pump when the
differential set point is reached between the solar water heater and collector.
Tank and Heat Exchanger Temperature and Pressure Gauge
The temperature and pressure gauge on the solar piping will show the user the actual temperature and
pressure supplied and returned to the solar collector.
Check Valve
Helps minimize convective heat loss at night when the system is not operating. If a check valve is not
installed, most of the heater energy stored during the day would be transferred into the panel and lost.
Collector Isolation Valve (Valve #6)
Valve #6 and 11 (for solar collector isolation) isolates the collector loop from the solar water heater.

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Pressure Relief Valve (for Solar System)
Releases pressure in the solar loop when it exceeds 75psi. If the valve opens and releases fluids, contact
your installation contractor immediately.
System Fill Valve (Valve #8)
Fills the system with heat transfer fluid. Also eliminates air from the system.
Expansion Tank
Pre-charged with air to allow for the expansion and contraction of heat transfer fluid.
Drain Valve (Valve #10)
Used to charge the collector loop with glycol, purge air from the loop and drain the solar water heater heat
exchanger of fluid.
Collector Isolation Valve (for system fill) (Valve #11)
Used to direct the flow of heat transfer fluid and to pressurize and eliminate air from the solar system.
Ball Valve (for circulator) Valve #12
Used to isolate the circulator pump for service. Close both ball valves to isolate pump.
Circulator (#13)
Circulates the heat transfer fluid from the solar collector into the solar heat exchanger.
Drain Valve (Tank) (Valve #14)
Flushes sediment which may accumulate on the bottom of the solar water heater and also provides a
means of draining the tank.
Tank Sensor
Is wired to the solar controller to measure the temperature on the bottom of the solar water heater in
conjunction with the solar collector sensor. Turns the circulating pump on and off at the solar control
preset temperature differentials.
Solar Controller
The solar controller turns on or off the circulator depending on heat gained from solar operation. The
controller also limits overheating in the solar water heater. Some controllers have various options. The
controller should always be set in the “auto” position so that it operates the array automatically when
there is solar energy to be collected.
Solar Heat Exchanger
The solar heat exchanger has an integral finned tube designed to transfer heated energy rapidly from the
solar collector into potable water. The heat exchanger is constructed in 90/10 copper nickel for superior
corrosion resistance and long-term reliability.
Hot Water Outlet
Each solar water heater has a hot water dip tube outlet which draws water from the top of the heater. This
helps to keep heat trapped inside the highly insulated storage tank.
Solar Tank Temperature and Pressure Relief Valve
The relief valve must comply with standards for relief valves (ANSI Z21.22) by a nationally recognized lab
that maintains periodic inspections of production listed equipment. No valve of any type should be
installed between the relief valve and tank. Local codes govern installation of relief valves.
The relief valve outlet must be piped to a suitable open drain so that the discharge water cannot contact
live electric parts to eliminate potential damage. Piping used should be approved for hot water
distribution. The discharge line must be no smaller than the outlet of the relief valve and must pitch

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downward to allow complete drainage. The end of the discharge piping should not be threaded or
concealed and must be protected from freezing. No valve of any type, restriction or reducer coupling
should be installed in the discharge line.
Mixing Valve (Rated ASSE 1017)
Automatically blends the hot and cold water feed lines to control discharge to an acceptable and safe
temperature. This also increases the amount of hot water that is drawn from the solar water heater by not
allowing the incoming water to fully temper the hot water stored inside the tank.
Ball Valve (for cold water shut-off) (Valve #24)
The cold water shut off valve should be used in the event of an emergency shutdown.
It is very important that you do the potable piping before you pipe into the solar system. Failure to do so
may damage your water heater.

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F. PHOENIX SOLAR PIPING WITH AIR HANDLER
Figure 6 - This drawing is meant to demonstrate system piping concept only.

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G. TANK CONTROL
Install the solar sensor onto the threaded stud provided
in the front of the water heater (sensor not included).
Additional equipment may be needed in order to wire
the control to the existing system. Controls also have
the ability to monitor and display solar collector
temperature and upper and lower tank temperatures.
H. CIRCULATOR SIZING
The circulator pump must be sized for the related piping and pressure drop of the heat exchanger. The
graph in Figure 8 represents the pressure drop of the solar heat exchanger. You must consult the solar
panel manufacturer for flow requirements to assist in pump selection
Figure 8 – Flow Chart – LP-200-L
0
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
Feet of friction
Flow in Gallons per Minute
Solar Heat Exchanger Pressure Drop
Figure 7

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I.CHARGING THE SYSTEM
Closed Loop Glycol
Solar Tank
Fill the solar tank with water. Do this by opening the cold water isolation ball valve to the solar tank.
Inspect all fittings for leaks. The solar collector loop should be pressure tested with air (25 lbs.) before you
pressurize the solar collector loop with glycol. Mix the DowFrost propylene glycol and distilled water in
accordance with the data sheet in the back of the manual. The charging process will require a low flow
diaphragm pump to fill and pressurize the collector loop.
Solar Collector
Connect the discharge side of the pressure pump to the fill valve. Place the pump suction side hose in the
glycol solution. Close the ball valve (#11). Connect a second hose to the drain valve (#10) and place the
other end of the hose in the empty bucket.
TOTAL COLLECTOR LOOP FLUID CAPACITY IN GALLONS*
1. One Collector System 3.5 gallons
2. Two Collector System 4.5 gallons
*Assumes a total 100’ pipe run using ¾” Type M hard copper tubing.
The solar heat exchanger has a 1.5 gallon fluid capacity.
Open the upper fill valve (#18) and allow the pressure from the expansion tank to push the water in the
glycol loop back to prime the pressure pump. When the hose in the bucket containing the glycol mixture
stops bubbling, you may begin charging the collector loop with glycol. With both fill and drain valves open,
run the low flow diaphragm pump until the glycol mixture begins flowing into the empty bucket. Quickly
switch the hose from the empty/return bucket to the bucket containing the glycol mixture. Continue to
circulate the fluid using the pressure pump until the bubbling has stopped and the air has been purged.
After charging the collector loop, shut the lower drain valve (#10) and let the pressure pump drive up the
loop pressure to the appropriate level (generally in the range of 25 psi). To more accurately calculate the
proper pressure, measure the height of the solar collector above the tank and divide this number by 2.31,
then add 20 psi to this number.
The pressure in the glycol loop should not exceed 45 psi when the system is in operation on a sunny day.
Contact your solar contractor if the collector loop exceeds the threshold.
After pressurizing the solar system, run the circulator and allow the air to purge out of the vent. Once
purged, monitor pressures and check for leaks before insulating pipes. Pressure should then be about 25
psi.
Above ground piping must be insulated with a wall thickness of at least ¾”. A 1” thickness is required in
areas prone to hard freeze conditions. Above ground insulation must be protected from ultraviolet
degradation. All piping must be supported at a maximum interval of 10’ and the piping supports must not
crimp or compress the insulation.
J. COMMISSIONING THE SYSTEM
Closed Loop Glycol
After the glycol loop has been charged and pressure is around 25 psi (check gauge on solar heat
exchanger) set the solar control to the desired settings. Solar controls come with default settings that will
work in most installations. If it is a cloudy day, you may have to activate the circulator pump. Once the

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pump is running and the system is fully purged, set the
control to the desired settings. It is recommended that
the storage tank high limit set point is not set any lower
than 160oF. A lower set point could lower the
performance of the solar water heater and cause
overheating of the collector system. You must install
an anti-scald valve on the hot water outlet as
temperature within the storage tank can cause injury –
please see warning label for outlet temperature
restriction.
PART 4: MAINTENANCE
A properly maintained solar water heating system can provide years of dependable, trouble free service.
It is suggested that a routine preventive maintenance program be established and followed by the end
user with the contractor. Below is the maintenance check list that outlines the primary components of the
solar system that need to be inspected annually.
1. Glycol – It is very important that the quality of the glycol heat transfer fluid is maintained to avoid
damage to the collector loop and related components which come in contact with the fluid. See
the DowFrost data sheet located in the back of the manual for further details.
2. Over time, water quality can affect the operation of the solar heat exchanger. In very hard water
areas, it is recommended you drain (#14) a few gallons from the tank to keep the bottom of the
water heater free of sediment.
3. Clean and inspect the solar collector (#1). Dirt or film which may have settled on the surface may
affect performance. Check collector supplier information for cleaning procedures.
4. Check insulation for deterioration.
5. Check solar tank sensors to assure they are secure and have not moved or loosened.
6. Inspect the T&P valve (#19) on the water heater. Lift the release handle lever and make sure
discharge is directed to an open drain.
7. The area near the water heater must be kept free of flammable liquids such as gasoline, paint
thinners, adhesive, or other combustible materials.
A. SHUTDOWN PROCEDURES
The solar system is designed to be easily isolated for emergency repairs or routine maintenance. To
isolate the water heater, simply shut down supply water shut off valve (#21) which isolates the water
heater from the pressurized cold water supply.
The collector loop can be isolated from the solar storage tank by closing (#6 and #11). If the pressure in
this loop drops, or you find a glycol leak, shut these valves and contact your installation contractor. Turn
the circulating pump off on your solar control.
B. VACATION SHUTDOWN
Solar water heaters can build up very high temperatures when there is no daily draw on the system. The
best way to dissipate heat in the system is set the control to run the circulator pump 24 hours a day to
cool off the storage tank at night. The collector will radiate heat back to the atmosphere at night,
preventing the system from stagnating at very high temperatures.

20
C. ESTIMATED LIFE OF COMPONENTS
Proper care and maintenance will determine the life expectancy of the individual components of the solar
system. Refer to manufacturer’s warranty information to determine coverage of individual components. To
obtain warranty service, call your local service or installing contractor.
Following installation of the T&P Relief Valve, the valve lever MUST be operated AT LEAST ONCE
A YEAR by the water heater owner to ensure that waterways are clear. Certain naturally occurring
mineral deposits may adhere to the valve, blocking waterways and rendering the valve inoperative. When
the lever is operated, hot water will discharge if the waterways are clear. PRECAUTIONS MUST BE
TAKEN TO AVOID PERSONAL INJURY FROM CONTACT WITH HOT WATER AND TO AVOID
PROPERTY DAMAGE. BEFORE operating lever, check to see that a discharge line is connected to the
valve, directing the flow of hot water from the valve to a proper place of disposal. If no water flows when
the lever is operated, replacement of the valve is required. TURN THE WATER HEATER “OFF” AND
CALL A PLUMBER IMMEDIATELY.
This device is designed for emergency safety relief and shall not be used as an operating control. A relief
valve functions by discharging water in an emergency. Therefore, it is essential that a discharge line be
piped from the valve in order to carry the overflow to a safe place of disposal. The discharge line must be
the same size as the valve outlet, must pitch downward from the valve, and terminate at least 6” above a
drain where any discharge will be clearly visible.