Solar Boiler SB32-9PV User manual

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E C O L O G I C A L
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A F F O R D A B L E
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E C O L O G I C A L
E C O N O M I C A L
A F F O R D A B L E
S E N S I B L E
E C O L O G I C A L
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E C O L O G I C A L
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A F F O R D A B L E
S E N S I B L E
Solar Boiler
TM
INSTALLATION MANUAL FOR MODELS:
SB32-9PV AND SB64-9PV
WARNING
The approved heat transfer uid is 40% Propylene Glycol USP and 60% distilled
water. The substituion of any other heat transfer uid can cause irreparable dam-
age and create a health and safety hazard.
The Solar Boiler™ module conatins 3.75 liters (1 US gallon) of heat transfer uid
when full.
The installation of the Solar Boiler™ system should be installed by a qualied
technician.
Assemblies and materials shall meet requirements of the applicable codes and
Standards for re safety.

Solar Boiler™
Congratulations on the purchase on your new Solar Boiler™ system by Thermo
Dynamics Ltd. The Solar Boiler™ is the newest and most advanced concept in
residential solar domestic water heating systems.
This manual outlines all of the steps necessary for a quick trouble free installation.
Read the entire manual carefully before any installation attempt is made.
Be sure to follow all local codes when installing the Solar boiler system.
Quantity System Model Description
1 SB64-9PV only S32A-P 4’ x 8’ S Series Serpenitne Collector, “A”, 4 ports
1 SB32-9PV
SB64-9PV
S32B-P 4’ x 8’ S Series Serpentine Collector, “B”, 2 ports
1 SB32-9PV
SB64-9PV
SBM13DC Solar Boiler Module
- Solar Pump (complete with Delta-T Booster II and temp sensors)
- Heat Exchanger
- Expansion Tank
- Glycol Resevoir (Complete with 4 liters of glycol)
- Glycol inlet/outlet ports
- Water inlet/outlet ports
1 SB32-9PV
SB64-9PV
PV20 Photovoltaic Module, 20 Watt
1 SB32-9PV only K1050 Serpentine Collector Mounting Kit (for 1 S Series - mounts ush to roof)
1 SB64 9PV only K1055 Serpentine Collector Mounting Kit (for 2 S Series - mounts ush to roof)
1 SB32-9PV
SB64-9PV
K1060 Photovoltaic mounting kit (mounts to Serpentine Collector)
1 SB32-9PV
SB64-9PV
K2030-50 Copper Tube Kit (3/8” Copper tube, 2 x 50 ft, Insulation, 100 ft, 18/4 LVT
wire, 60 ft
1 SB32-9PV
SB64-9PV
GLYUSM Propylene Glcyol USP, (mixed 40% glycol 60% water), 4 liters
1 SB32-9PV
SB64-9PV
Tank Connection Fittings, (Brass)
SB32-9PV and SB64-9PV Solar Boiler™ System Components
K1050
K2030-50K1055
K1060
1
A 270 liter, (60 IG) Storage tank is required for the installation and is not included.
In Canada, the tank must be CSA approved and all plumbing ttings must comply
with CSA B.125
S32A S32B
Solar Collectors
S Series (Micro-Flo®)
Solar Boiler™ module

Installation Manual for SB32-9PV and SB64-9PV
• Solar collectors absorb sunlight and convert it to heat.
• When there is sufcient sunlight, the photovoltaic module pro-
duces electricity and turns the pump.
• The pump circulates heat transfer uid, (HTF), through the
solar collectors.
• Heat is transferred to the HTF in
the solar collector.
• The HTF is returned to the heat
exchanger in the Solar Boiler™
module.
• The heat is transferred to the wa-
ter which circulates naturally to the
top of the solar storage tank.
• Solar heated water is stored in the
solar storage tank until water is
drawn from the auxiliary tank (in
this case an electric water heater).
• As hot water is drawn from the
electric water heater it is replaced
with solar heated water.
• The electric heaters increase the
temperature of the solar heated
water, if necessary.
• The electrical energy required
to heat water is signicantly less
when water is preheated by the
solar water heater.
• In this manner, the solar water heater saves electrical energy.
S32 A
Solar Collector
[Optional]
S32B
Solar Collector PV module
Wire - supplies 12 VDC
from PV module to
Solar Boiler™
Cold Water IN
Hot Water OUT
Solar Storage Tank Auxiliary Water Heater
Solar Boiler™
module
Solar Pump™
Ball valve #1
Ball valve #3
Ball valve #2
Normal Operation
Ball valve #1 - Close
Ball valve #2 - Open
Ball valve #3 - Open
[Inside the Solar
Boiler™]
solar heated water IN
cold water IN
solar heated water IN
HTF [heat transfer fluid]
Domestic Water
How the Solar Boiler™ Works
NOTE:
The Solar Boiler™ is designed to shut off when a temperature of 70°C (158°F) is at-
tained in the solar storage tank.
The heat transfer uid is a 40/60 % by volume mixture of Propylene Glycol USP and
distilled water. The Solar Boiler™ module contains 3.75 liters (1 US gallon) of heat
transfer uid. An additional 3.75 liters (1 US gallon) is supplied with the system for
lling the system during start up.
The maximum safe working pressure of the heat transfer uid is 60 psi, (410 kPa).
The Solar Boiler™ system is inherently grounded through copper piping connected
to the main water supply. Ensure that household ground is adequately electrically
grounded.
2

Solar Boiler™
System and Installer Details
Installer
Address
Tel:
Fax
Email:
System Details
Solar Boiler Model
Solar Collector Serial#(s)
Solar Boiler Serial#
Storage Tank Serial#
Orientation E or W of South
Collector Slope
Collector Mount (Flush or Inclined)
3

Installation Manual for SB32-9PV and SB64-9PV
S o ut h
A
B
Inclined mount
H
L
Flush mount
South
H/L
0.25
0.33
0.42
0.50
0.67
1.0
Angle
14°
18°
23°
27°
34°
45°
Rise/Run
3/12
4/12
5/12
6/12
8/12
12/12
Micro-Flo® solar collectors are de-
signed to work with the Solar Boiler™
module and other Micro-Flo® systems.
Locate the solar collectors on the roof
of your home that is oriented true south
or as close as possible. There are no
major losses up to 45° east or west of
true south. If your orientation is not in
this range, consider a ground mounting
system. The solar collectors are to be
installed such that they are not shaded
for at least 5-6 hours during the middle
of the day.
The recommended slope is equal to the
local latitude plus or minus 10°. For
example, Halifax, Nova Scotia is at a
latitude of 45°. Therefore the recom-
mended collector slope for a home lo-
cated in or near Halifax is between 35°
and 55°. For effective snow removal
in the winter a slope of at least 45° is
recommended.
To calculate the slope of your roof,
measure the dimensions “H” and “L”
as shown in the gure. Calculate the
quantity H/L and compare it to the table
to determine if an inclined mount is
required.
Inclined Mount
The inclined mounting kit allows the
collectors to pivot in the front and uses
aluminum channel to support the solar
collector at the rear. Instructions are
provided with the rack mount kit.
Solar Collector Location
4

Solar Boiler™
Locate the rafters directly under the
solar collectors, and at least 8” from
the ends of the solar collectors. In
the case of 4’ x 8’ solar collectors and
24” rafter spacing, the clips should be
mounted six feet apart (that is, one
foot from the edge of the collector).
To nd the center of the rafters, lift the
shingle and use small nails to nd the
two edges of the rafter.
Drill a 1/4” pilot hole in the rafter for
each of the front mounting clips.
Fill the holes with silicon sealant and
secure the two front clips to the roof
using lag bolts. Seal the perimeter of
each mounting clip base with silicon.
Take the “A” solar collector and slide
two 3/8” bolts in the bolt track.
Loosely fasten these bolts to the bot-
tom hole of the front mounting clips
using a lock washer and nut.
Center the solar collector so that the
spacing from the end of the solar col-
lector to the mounting clip is equal on
both ends. The solar collector ports
must be on the right hand corner of
the solar collector when, viewed from
below.
1 – Locating Roof Rafters
2 – Flush Mounting Micro-Flo® Solar Collectors
5
3/8” Bolt,
nut, lock
washer
3/8” lag
screw
Mounting Clip

Installation Manual for SB32-9PV and SB64-9PV
If you have a two solar collector system,
place the B solar collector above the A
solar collector. Make sure that the ports
are on the right hand side.
Using the aluminum channel, fasten col-
lector B to A as shown in the gure.
Fasten the upper mounting clips (not
shown) to the top of the collector(s),
and use lag bolts to secure them to the
rafters in the same manner as for solar
collector A.
Tighten all nuts that secure the
collector(s) to the mounting clips.
Silicon seal all roof attachments.
lock
washer
bolt track
3/8" bolt
aluminum
channel, (6")
3/8" nut
A
B
IN
IN
OUT
OUT
3 – Optional Second Solar Collector
4 – Copper Tube Kit Installation
LifeLine® tubin g
A
B
The copper tube kit is used to connect
the Solar Boiler™ module to the solar
collectors.
All of the copper tubing should be
sleeved with the insulation provided.
The insulation is Elastomeric Expanded
Closed Cell with a 0.5” thickness. Mark
one copper tube at both ends with tape
to identify the supply and return lines.
Run the copper tube and PV Sensor
wire (LVT 18/4) to the solar collectors
via an unused space or closet. If the
bundle is run outside along the house, sleeve it in a plastic
conduit such as down spout. Note: All copper tube installed
in the horizontal position must slope down 1/4" for every hori-
zontal foot. Secure the Copper tube at intervals of 6 feet with
clamps. Use caution when bending the tube to avoid kinking.
6

Solar Boiler™
5 – Copper Tube at Solar Collectors
The copper tube roof penetration is made adjacent
to the “A” collector for the SB64-9PV system and
the “B” collector for a SB32-9PV system.
Make a roof penetration at a position 8" - 10" hori-
zontally away from the “A”, (“B”) collector bottom
ports. A 3/8” hole for each tube and the wire is
sufcient.
Pass about 2 feet of Copper tube through the roof
penetration from below. Clamp the copper tube to
the truss. Do not crimp the copper tube.
Seal the roof penetration with silicon sealant.
If the copper tube has been installed on the outside
of the house, a roof penetration is not necessary.
Simply bend the tubing bundle around the soft
and up to the solar collectors
Connect the 3/8" copper tube to the "IN" (blue) port using a 5/8" and 11/16”
wrench. Be sure to hold the bulkhead union from moving during this process.
Connect the other 3/8" copper tube to the "OUT" (red) port.
6 – Copper Tube Connection to Collector
7
Bulkhead Union
3/8” Compression
Nut
IMPORTANT: The 11/16” wrench is required to pre-
vent the bulkhead union from rotating while turning
the nut with the 5/8” wrench.
As of January 2010, S Series collectors are
equipped with Bulkhead Union locking plates. This
eliminates the need for an 11/16” wrench. Bulkhead Union Locking Plate

Installation Manual for SB32-9PV and SB64-9PV
Place the 3/8" compression nuts
on the tting body nger tight.
Insert the copper tubes into the
ports as shown, until they bottom
out.
Using a 5/8" and a 11/16" wrench,
tighten the nuts one full turn.
IMPORTANT: The 11/16" wrench is required to prevent the
tting body from rotating while turning the nut with the 5/8"
wrench.
As of January 2010, S Series collectors are equipped with
Bulkhead Union locking plates. This eliminates the need
for an 11/16” wrench.
IN
OUT
IN
OUT
Attach the two large aluminum brackets
to the photovoltaic module using the
3/8" bolts, nuts, and lock washers sup-
plied. Make sure that the junction box on
the back of the PV panel is at the top.
Make sure both aluminum angle brackets
are securely fastened to the photovoltaic
module.
Grounding: The photovoltaic module is
inherently grounded through the mount-
ing hardware attached to the solar collec-
tors.
A
B
PV
3/8" nut and
lock washer
3/8"
bolt
Photovoltaic module
junction box
8 – Preparing the Photovoltaic Module
7 – Connection Between Collector A and B
8
Bulkhead Union Locking Plate

Solar Boiler™
Open the junction box located on the photo-
volatic module, and note the positive terminal
marked "+" and the negative terminal marked
"-".
Drill 2 small holes and insert the 18/4 LVT wire
in the box. Connect the “RED” to “+” terminal
and the “BLACK” to “-” terminal.
If your “B” solar collector is equipped with a
sensor enclosure as pictured in step 10a, pro-
ceed to step 10a.
Feed the white and green wires out of the
junction box and connect them to the collector
sensor using pinch connectors supplied.
Locate the photovoltaic module as
shown in the diagram, along the port
side of the “B” collector. Using the
3/8" bolts, washer, and nuts, attach
the photovoltaic module to the "B"
collector bolt track as shown in the
diagram. Ensure that all the nuts
are tightened securely in order to
provide proper grounding of the PV
module.
Insert the temperature sensor into
the “B” collector. It should go in
about 6 to 8 inches. Seal with
silicon.
Using the connectors provided,
crimp the sensor wires to the green
and white wires.
Photovoltaic module
"B"
Collector
bolt
track
3/8" bolt, washer,
nut
9 – Wiring the Photovoltaic Module and Collector Sensor
10 – Locating the Photovoltaic Module
9
Temperature Sensor
Compression Nuts
Service Plug
Collector Temperature Sensor
Pinch
Connectors
Dart Clips
PV/Sensor wire

Installation Manual for SB32-9PV and SB64-9PV
10 a – Temperature Sensor Enclosure (some models)
10 b – Wiring the Photovoltaic Module and Collector Sensor
As of May 2010, some models of the S32B-P
solar collector are equipped with a tempera-
ture sensor enclosure. A picture is shown to
the right.
The temperature sensor has been installed in
the solar collector and is located in the sensor
enclosure. The wire coming from the sensor
enclosure goes to the PV panel junction box.
Using the pinch connectors provided, connect
the green and white leads from the PV sensor
cable, to the wire leads from the sensor enclo-
sure. Polarity is not important.
Close the PV panel junction box and mount the
PV panel as shown in the picture to the right.
Sensor Enclosure - STSE
PV Panel Junction Box
wire from sensor enclosure
PV Sensor wire from Solar Boiler™ Module
10

Solar Boiler™
Place the Solar Boiler™ module and solar
storage tank next to your auxiliary water
heater.
Remove the drain valve from the solar storage
tank. Install the bottom tank assembly. Posi-
tion the tee such that one end points toward
the Solar Boiler™.
Apply teon tape to the hose bib and attach it
to the end of the tee that is pointing away from
the Solar Boiler™.
Connect the tee to the Solar Boiler™ module
using 3/4" copper pipe.
Connect the top outlet of the Solar Boiler™ module
to the top tank Temperature Pressure Relief Valve,
(TPRV), port using 3/4" copper pipe and the 3/4"
vented 90° elbow supplied.
Wrap teon tape around the short nipple of the top
tank tee, and thread it into the “hot outlet” port of
the solar storage tank. This tee becomes the “hot
outlet” port of the solar storage tank.
Plumb the TPRV to a drain.
(We recommend a licensed plumber integrate the
Solar Boiler™ module and solar storage tank with
your existing domestic wate system.)
11 – Setting Up the Solar Boiler™ Module, (Bottom Connections)
12 – Setting Up the Solar Boiler™ Module, (Top Connections)
11
Cold Water Inlet

Installation Manual for SB32-9PV and SB64-9PV
Close the main cold water supply valve to the existing water heater.
Install two copper tees and a ball valve #1 as shown in the diagram. Label this ball
valve: BALL VALVE #1.
Insulate all hot water pipes and the 5 feet of cold pipe leading to the solar storage
tank. All insulation should be Elastomeric Expanded Closed Cell with a minimum
thickness of 0.5”
Connect the main cold water supply to the cold inlet of the solar preheat tank.
Install a ball valve in this line. Label this valve: BALL VALVE #2.
Connect the hot outlet of the solar
storage tank to the cold water
supply of the existing water heater.
Install a ball valve in this line, and
label it: BALL VALVE #3.
Install two heat traps as shown in
the diagram to minimize heat loss
from the solar storage tank. Please
note that the domestic hot water
supply line must have a mixing
valve installed as shown in the
diagram.
Insulate all hot water pipes.
For normal solar operation, the valves should be opened or closed as shown
in the diagram.
13 – Isolation Bypass Preparation
cold water
supply
domestic
hot water
supply
close main water
supply valve
Tee connector Ball valve #1
Tee connector
solar storage tank auxiliary
DHW tank
olar oiler
cold inlet hot outlet cold inlet hot outlet
cold water
supply
domestic
hot water
supply
close main water
supply valve
Tee connector Ball valve #1
Tee connector
solar storage tank auxiliary
DHW tank
olar oiler
cold inlet hot outlet cold inlet hot outlet
Ball valve #2 Ball valve #3
heat trap heat trap
or ormal solar operatio
• Ball valve #1 - close
• Ball valve #2 - open
• Ball valve #3 - open
mixing valve
14 – Isolation Bypass connection
12

Solar Boiler™
15 – Solar Boiler™ Copper Tube Connections
The Solar Boiler ™ module is prelled with heat transfer uid.
Carefully remove the plugs from the brass ttings and retain.
Replace with the 3/8” compression nuts provided. Turn the
nuts on until nger tight.
Insert the marked copper tube in the tting located on the pump
until it bottoms. Using two wrenches, one on the tting body
and one on the nut, tighten the nut one full turn.
Repeat the above proceedure for the other copper tube.
IMPORTANT: Do not overtighten the nuts. Over-
tighten could cause a leaky connection and/or cracked
nuts.
Ensure that the household cold water main is
adequately electrically grounded
16 – Solar Boiler™ PV and Sensor connections
Locate the Delta-T Booster II. Ensure that the
power switch is in the “OFF” position.
Connect the “WHITE” and “GREEN” sensors
wires to the terminals marked “Tc”.
The “Ts” terminals are for the storage sensor
located in the Solar Boiler™ module and is
factory installed.
Feed the “RED and “BLACK” wires to the
“PV+” and “PV–” terminals. Connect the
“BLACK” wire to the “PV–” terminal. Connect
the “RED” wire to the “PV+” terminal.
13
Caution: Never connect any other sources of electricity to the Delta -T Booster. A 12 VDC power supply may be
connected directly to the motor wires, ORANGE = “+” and BLUE = “–”

Installation Manual for SB32-9PV and SB64-9PV
Pressurize the solar storage tank by opening the main cold water supply valve
and a hot water tap (near the Solar Boiler™ if possible).
As the solar storage tank lls with water, air will escape through the open hot
water tap. Check for leaks.
When the solar storage tank is full, close the hot water tap.
Ensure that the solar isolation bypass valves are in the correct positions as indi-
cated in step 14.
Ball Valve #1 - CLOSE
Ball Valve #2 - OPEN
Ball Valve #3 - OPEN
Carefully open the air vent at the top of the solar storage tank to
allow air to escape from the Solar Boiler™ module.
Remove the pressure relief valve and brass cap from the Solar Boiler module.
Some uid may be visible.
Remove the “Sensor Plug” from the Delta-T Booster II and replace it with the “Ser-
vice Plug”.
Turn the switch “ON” on the Delta-T
Booster II.
If there is sufcient sunlight, the
pump will begin operation. Initial
start up of the system should be done
with sufcient sunlight to ensure
proper operation.
17 – Filling Solar Storage Tank
18 – Solar Boiler Start Up
14
Pressure Relief Valve
Pressure Relief Valve
Location
Wooden Dowel for checking
uid level
cold water
supply
domestic
hot water
supply
close main
water
supply valve
Tee connector
Ball valve #1
T
ee connector
solar storage tank auxiliary
DHW tank
olar oiler
cold inlet hot outlet cold inlet hot outlet
Ball valve #2 Ball valve #3
heat trap heat trap
or ormal solar operatio
• Ball valve #1 - close
• Ball valve #2 - open
• Ball valve #3 - open
mixing valve
The Solar Boiler™ module contains 3.75 liters (1 USG) of HTF. An additional
3.75 liters (1 USG) is provided to top up the system. Once lled, an SB32-9PV
or SB64-9PV Solar Boiler™ system contains 4 – 6 liters (1.1 – 1.6 USG) of HFT
Brass Cap
Sensor Plug
Service Plug

Solar Boiler™
19 – Solar Boiler™ Start Up (continued)
20 – Solar Boiler Normal Operation
15
You will hear air bubbling in the Solar Boiler unit. This is normal. Place
a container under the vent tube. Using a funnel, SLOWLY pour the
supplied heat transfer uid into the Solar Boiler™ unit until uid comes
out of the vent tube. When the uid stops coming out of the vent tube,
replace the pressure relief valve and the brass cap, remove the “Ser-
vice Plug” and replace with the “Sensor Plug”.
Check for leaks at all copper tube connections. If a leak is observed,
tighten the nut 1/4 turn. Remember to use two wrenches,
one on the tting
body and one on
the nut.
• The Delta-T Booster II will turn ON when the Collector sensor measures 3°C
higher than the Storage sensor.
• The Delta-T Booster II will turn OFF when the Collector sensor drops in tem-
perature so that it measures 1 degree higher than the Storage sensor.
• The Storage High temperature set-point is factory set to 70°C (158°F).
• The Collector High temperature set-
point is 112°C (234°F).
• The Storage Low temperature set-point
is -3°C (27°F).
• There is 3°C (5.4°F) of hysteresis for all
setpoints, meaning that once a setpoint
has been reached, that temperature
must fall by 3°C before the controller
will turn ON again.
Caution: Never open the ll tube while the Solar Boiler is hot. Scalding uid
may spray. Always relieve the pressure in the Solar Boiler™ with the pressure
relief valve before opening the ll tube.
Pressure
Relief Valve /
vent tube
Fill Tube
Pressure
Gauge

Installation Manual for SB32-9PV and SB64-9PV
The following describes the conditions required to illuminate each particular LED:
(Delta T refers to the difference in temperature between the collector temperature and the storage
temperature.)
- RED: low delta T; Collector sensor open circuit.
- YELLOW: Storage temperature HIGH; Storage sensor short circuit.
- AMBER: Collector temperature HIGH; Collector sensor short circuit.
- GREEN (ON): the Collector temperature is sufciently greater than the Storage
sensor. System should be running. However, if there is insufcient sunlight,
the LED may be “ON” yet the pump will not be turning.
No LEDs will be illuminated when:
- The power switch is in the OFF position,
- There is no power from the PV panel (no sunshine),
- The Storage sensor is open circuited,
- The Storage sensor measures -3°C or less.
21 – Delta-T Booster II LED’s
16
The Delta T Booster II has two internal fuses, F1 and F2. Both fuses are fast
acting, size 3AG.
F1 is rated at 4 A, 250 VDC and is used to protect the controller circuit.
F2 is rated at 2 A, 250 VDC and is used to protect the motor from overheating.
Should either of these fuses need replacement, they must be replaced with an
equivalent rated fuse.
22 – Delta-T Booster II Fuses and Service Plug
Service Plug - The “Service Plug” provided is used to
override the Delta-T Booster II’s temperature controls.
The “Service Plug” should only be used for commissioning
and servicing the Solar Boiler™ System.
Fuse F1 - 4 amps Fuse F2 - 2 amps

Solar Boiler™
17
domestic hot
water supply
cold water
supply
1
4
5
7
8
3
9
2
10
11
12
6
System Components
1. S Series (Micro-Flo®) solar collector(s)
2. Solar Storage Tank
3. Delta-T Booster (inside the cover of the Solar Boiler)
4. Solar Boiler™ Module
5. 3/4” Hard Copper Tube
6. Photovoltaic Module, 20 Wp
7. Copper Tube Kit, 3/8” with insulation and 18/4 wire
8. Solar isolation and bypass valves
9. Temperature-pressure relief valves
10. Mixing Valve (recommended, not supplied)
11. Heat Traps
12. Auxiliary Water Heater

Installation Manual for SB32-9PV and SB64-9PV
Do not use the Solar Boiler™ system to heat any treated water system, such as
pools, directly.
Use the proper mixture and quantity of propylene glycol USP and distilled water for
freeze protection. DO NOT use automotive antifreeze, recreational vehicle anti-
freeze, ethylene glycol, or other poisonous uids. Thermo Dynamics recommends
a mixture of 40% Propylene Glycol USP and 60% distilled water for use as the heat
transfer uid.
The maximum safe working pressure of the Solar Boiler™ system is 60 psi (410
kPa)
System Maintenance
• Solar Collector Glass:
In some areas the glass plate of the collectors may require cleaning once a year
with an industrial cleaning product. In areas where air pollution is severe, more
frequent cleaning may be required.
• Back Flushing the Heat Exchanger: (see page 26)
The Solar Boiler™ heat exchanger should be ushed with clean water ever 6
months. First, close the valve at the bottom of the solar storage tank near the
1/2” brass tee that connects the tank to the Solar Boiler™. Second, connect a
hose to the drain bib at the bottom tank tee, and place the free end in a drain.
Open the drain bib and allow water to ow for a few minutes. This will remove
residue from the Solar Boiler™ heat exchanger.
• Reservoir Fluid Level:
The uid level in the Solar Boiler™ reservoir should be checked every year.
Instructions for this procedure are part of the relling instructions. (see page 22)
• Heat Transfer Fluid (HTF):
The HTF should checked annually. If the HTF is very dark in colour and has a
strong odour, it should be replaced. The extracted HTF should be disposed of at
your local Environmental Disposal Depot.
The pH and freeze protection capability of the HTF should be checked annually.
The pH should not be less than 6. Contact your installer or Thermo Dynamics
Ltd.
With proper system operation and maintenance, the HTF should last between 4
and 15 years without replacement.
Operating Restrictions and Maintenance
18

Solar Boiler™
Repairs and Energy Saving Tips
If any of the components of the Solar Boiler™ or Micro-Flo® solar collectors are
damaged, your local dealer or Thermo Dynamics Ltd. should be advised before any
repair is attempted.
In the case of broken glass, we recommend the use of an industrial vacuum cleaner
to remove all glass fragments from the collector and surrounding area. Cover the
collector with a sheet of plywood to protect the absorber plate until a replacement
glazing is obtained. Disconnect the wires from the photovoltaic module to the Solar
Boiler™ and contact your local dealer or Thermo Dynamics Ltd.
The Solar Boiler™ should be repaired by a qualied solar technician. In some
cases it may be necessary to disconnect the Solar Boiler™ for factory repair. Your
local solar dealer or Thermo Dynamics should be notied before you attempt dis-
connection.
Energy Saving Tips
There are several ways to increase the performance of your Solar Boiler™ and to
reduce hot water heating costs. Here are a few tips on getting the most from your
water heating system.
• Add an insulating blanket to your electric water heater.*
• Add an insulating blanket to your solar storage tank.*
• Install low ow shower heads.
• Use warm water instead of hot when washing clothes.
• Insulate exposed hot water pipe where possible.*
• Minimize hot water use on overcast days.
• Use solar heated water as it is collected. If possible, postpone consumption of
hot water to mid-morning or noon on a sunny day.
• Lower the thermostat setting of your electric water heater from 60°C (140°F) to
50°C (122°F). This should only be done by a qualied technician.
* Available from Thermo Dynamics Ltd.
Insulating tank blankets should be minimum 2” bre-glass with foil backing. Ex-
posed water pipes should be insulated with minimum 0.5” Elastomeric Expanded
Closed Cell insulation.
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