SunEarth SolarStation XL User manual

May 2020
INSTALLATION MANUAL
SolarStation XL
The SolarStaon XL is SunEarth’s soluon to medium sized solar thermal systems up to 720 2
of collector area. Designed with mul speed pumps to ensure compability with a wide range
of system conguraons.

2 May 2020
TABLE OF CONTENTS
1. SYSTEM COMPONENTS AND PRINCIPLES
1.1 SAFETY
1.2 COMPONENTS
1.2 PRINCIPLES
2. INSTALLATION
2.1 SOLARSTATION XL WALL MOUNTING
2.2 SOLARSTATION XL PLUMBING CONNECTIONS
2.3 SOLARSTATION XL ELECTRICAL CONNECTIONS
3. SYSTEM COMMISIONING
3.1 CHECK THE ARRAY LOOP FOR LEAKS
3.2 FLUSHING THE SYSTEM
3.3 CHARGING THE SOLAR CIRCUIT
3.4 CONTROLLER SETUP
4. EXTENDED NON-USE PROCEDURES
5. OPERATIONS AND MAINTENANCE

3 May 2020
1.1 SAFETY
Electrical Shock, Fire, Explosion and Burn Hazards
This system must be installed, adjusted, and put into operaon only by a
trained, qualied professional or service agency in accordance with the
Naonal Electric Code ANSI/NFPA 70 (Canada CSA C22.1), state and local
codes, and authories having jurisdicon.
1. SYSTEM COMPONENTS AND PRINCIPLES
!DANGER!
!SAFETY PRECAUTIONS
• Secure all ladders on level ground
• Locate all possible hazards, overhead wires, loose shingles, etc.
• Make sure power is turned o before adding water to the system
• NEVER connect power to the water heater or storage tank unl it has been
lled.
• Use a tempering valve or mixing valve to prevent scalding
• Consult proper authories and check with your local building inspector for
permit requirements and local building codes before project
commencement. The system must meet local code requirements for
penetrang structural members and re-rate assemblies.
• Burns from Hot Water and Steam-Use extreme care when opening relief
valves, and lling storage tanks.
• Use this appliance only for its intended purpose as described in this
installaon, operaons and Maintenance Manual.
!WARNING!
For your safety, the information in this manual must be followed to minimize risk of fire
or explosion, electric shock, or to prevent property damage, personal injury, or loss of
life.
Be sure to read and understand the entire installation, Operation and Maintenance
manual before attempting to install or operate a water heating system. It may save you
time and cost. Pay particular attention to the Safety instructions. Failure to follow
these warnings could result in serious bodily injury or death. Should you have problems
understanding the instructions in this manual, or have any questions, STOP, and con-
tact SunEarth.

4 May 2020
1.2 COMPONENTS
SOLAR RETURN SOLAR SUPPLY
6
4
2
5
7
1
14
12
1. SYSTEM COMPONENTS AND PRINCIPLES
3
10
11
Figure 1.2.1: SolarStation XL Components
Item Description
1Master Service Switch
2Differential Temperature Controller
3Solar Pump Service Switch
4Digital Flow Meter
5Potable Circuit Dial Pressure Gauge
6Solar Circuit Dial Pressure Gauge
7Solar Circuit Pressure Relief
8Solar Circuit Pressure Sensor
9Solar Pump w/ Check Valve
10 Potable Pump w/ Check Valve
11 3/4 FIP Expansion Tank Connection
12 Heat Exchanger Digital Temperature Sensor
13 Mounting Bracket
14 Plate Heat Exchanger
15 6’ ELECTRICAL SOURCE CONDUIT
16 PUMP SERVICE VALVES
8
9
13
16
15

5 May 2020
1.3 SYSTEM PRINCIPLES
When the differential temperature controller
detects an adequate temperature difference
between the collector temperature sensor “T1”
and the bottom tank temperature sensor “T2”
the pump begins circulating the propylene
glycol heat transfer fluid (HTF) through the
system with the solar pump. HTF moves
through the collector and absorbs energy from
the sun, increasing the HTF temperature. The
heated HTF then moves through the heat
exchanger. When the heat exchanger
temperature sensor “T3” is higher than the
storage temperature, the potable pump turns
on. This moves the heat from the heat
exchanger to the storage tank. Hot water is
then available for delivery.
This system’s solar loop contains pressurized
HTF which can protect your system at
temperatures up to –60 degrees Fahrenheit.
This system should not be installed in any area
that has experienced ambient air temperatures
below -60°F. Use Table 3.3.1 in section 4 to
determine the required concentration of
propylene glycol and distilled water to provide
adequate freeze protection in your specific
climate. HTF shall be used in this system as
the primary freeze protection agent.
Unauthorized fluid substitutions can result in a
threat to health, welfare and safety and may
cause the system piping to freeze.
When the system is operating, the pump
should be on when the sun is shining and there
is an adequate temperature differential. The
pump should be not be running at night or
when the solar tank has reached its default
maximum set point temperature T2 of 140
degrees Fahrenheit. The top of tank
temperature sensor T5 can be checked to
ensure your system has hot water ready for
use.
1. SYSTEM COMPONENTS AND PRINCIPLES
COLLECTOR BANK(S)
TS
Notes:
• Array piping sizes to be determined by the array size
• The solar expansion tank size to be determined by the array size
• A potable water expansion tank should be sized per the solar storage volume and installed
on the cold water supply.
1
Figure 1.3.1: SolarStation XL Installation Diagram
3
2
1
2
3

6 May 2020
2.1. WALL MOUNTING
When wall mounting the SolarStation XL,
1-5/8 by 13/16 (min) inches Solar strut
must be used. The strut must have a
minimum depth of 13/16 inches for
proper clearance from the wall. Using at
least 2, 3/8 inch strut nuts and bolts, affix
the 5052-H32 aluminum mounting
bracket to the strut. Please consult
authority having jurisdiction (AHJ) for
fasteners sizes and mounting
requirements when connecting strut to
the wall.
2.2. PLUMBING CONNECTIONS
The collector loop must be plumbed using
copper or stainless steel piping and copper,
brass, bronze or stainless steel fittings. Lead-
free solder shall be used. Use of galvanized
steel, PEX, CPVC or PVC is prohibited. PEX may
be used only in systems that meet the
following conditions:
• Only Solder Fluxes meeting the criteria of
ASTM B 813 should be utilized for joining by
soldering any copper and copper alloy tube
and fittings in the entire solar system.
It may be necessary to increase the pipe size
for longer pipe runs or reduce the pipe size for
shorter runs or higher efficiency pumps. The
pipe must be large enough that the velocity of
the water in the pipe does not exceed 4 ft/s.
Hot water flowing at over 4 ft/s in a pipe will
erode the pipe and reduce system life.
Allowance should be made for expansion and
contraction of piping due to changes in
temperature of the fluid and piping. Use
flexible pipe supports and avoid long straight
piping runs. Include bends and elbows to allow
for expansion such as swing joints at the
collector inlet & outlet.
The collector loop piping, plus any
interconnecting hot water piping shall be well
insulated with high quality flexible closed cell
insulation to minimize heat loss. The insulation
shall have a maximum operating temperature
of 220°F or higher. When it comes to pipe
S2
S1
P2
P1
SOLAR IN
SOLAR OUT
POTABLE IN
POTABLE OUT
S1
S2
P2
P1
FRONT
BACK
2. INSTALLATION
Figure 2.1.1: Strut Dimensions
13/16” MIN
1-5/8”
Figure 2.2.1: Connection Details
WALL

7 May 2020
insulation the rule is simple: thicker is better.
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 jacketed, wrapped
with aluminum foil tape, or painted with two
coats of high quality water-based acrylic resin
coating as supplied by the insulation
manufacturer.
The SolarStation XL has four plumbing
connections detailed in Figure 2.2.1. The two
plumbing connections located in the front are
associated with the solar circuit. The two
plumbing connections at the rear are
associated with the potable circuit.
The (1) solar feed should be plumbed to the
feed pipe for the solar thermal array. The (2)
solar return should be plumbed to the return
pipe for the solar thermal array. The (3)
potable feed should be plumbed into the solar
storage tank on an upper port. The (4) potable
return should be plumbed into the solar
storage tank on a lower port.
All collectors and horizontal pipe runs plumbing
should be supported to allow complete
drainage of the system if necessary, the
recommended slope is 1/4 inch per foot,
sloped to drain.
It is recommended that an appropriately sized
Tempering Valve be installed on the solar tank
potable outlet connection per the
manufacturers instructions.
2.3. ELECTRICAL CONNECTIONS
A 6 foot electrical lead is supplied from the
SolarStation XL . An electrical supply junction
box must installed using approved methods
per electrical code for a 120VAC 1ph
connection.
The 0503 controller front cover should be
removed along with the controller electrical
cover plate. The temperature sensor installed
on the array should be connected into the T1
port in of the differential controller. The
temperature sensor installed near the bottom
of the solar storage tank should be connected
into the T2 port of the differential controller.
Ports T3 and T4 are occupied by the prewired
heat exchanger temperature sensor and the
potable feed temperature sensor. An optional
upper tank temperature sensor can be installed
in port T5.
The T1 array temperature sensor should be
installed in a dry thermowell on the array
outlet header connection as shown in Figure
2.3.1
The T2 tank sensor should be installed in a dry
thermowell on the lower 1/6th of the solar
storage tank.
2. INSTALLATION
Figure 2.3.1: T1 Array Temperature Sensor Installation

8 May 2020
3.1. CHECK THE ARRAY LOOP FOR LEAKS
1. Before the system has been charged, open
all shut-off valves on the collector loop.
2. Apply 20 psi less than the pressure relief
valve rating of pressure for 15 minutes.
Any drop in pressure during that time
indicates a leak.
3. Find the source of the leak and repair it.
Repeat this procedure until the loop holds
pressure.
3.2. FLUSHING THE SYSTEM
After installing the SolarStation XL the system
should be flushed. Piping in new solar
installations can be covered with dirt, grease,
solder flux or other impurities that over time
affect the quality of the propylene glycol HTF.
A thorough cleaning is required before
charging the system with propylene glycol
water mixture.
Step 1 – Fill solar tank with water and ensure
there are no leaks on the potable side of the
system. Open the nearest hot water fixture
and run to flush out any flux from the
installation.
Step 2 -Keeping the two potable isolation/flush
valves closed during potable circuit flush.
Open a flush/drain port allowing water to flush
circuit to this point then close flush/drain port.
Open other flush/drain port allowing water to
flush circuit to this point then close flush drain
port.
Alternate flush/drain sequence stated above
until all air is removed from the potable circuit.
Step 3—Keeping the two solar isolation/flush
valves closed. Flush array loop with water to
clean out any debris or sediment from the
pipes and collectors.
3.3. CHARGING THE SOLAR CIRCUIT
Once the system is flushed you are ready to fill
the solar storage tank with water and to
charge the collector loop with a mixture of heat
transfer fluid (HTF) and water. Due to
variations in municipal water quality
throughout the country, distilled or deionized
water shall be used to mix with the propylene
glycol HTF. Refer to Table 3.3.1 for percent
concentrations.
1. Connect the outlet of a transfer pump via a
hose to the fill valve.
2. Open the fill valve.
3. Open the drain valve. Connect the drain
valve to a bucket.
4. Fill the bucket with the appropriate mixture
of propylene glycol and water.
5. Run the pump. Continue running the pump
until you do not see air bubbles in the
coolant.
6. Turn off the pump. Let the system sit for
ten minutes.
7. Repeat previous steps until no air is
discharged.
8. Close drain valve.
9. Continue charging until it reaches the
necessary pressure for the system’s
configuration.
10.Close the fill valve.
11. Turn off and disconnect charging pump.
Note: It is recommended to install commissioning
automac air vents as provided in SunEarth Add-a-
row and systems kits on each collector bank. Two
weeks following system commissioning the solar
circuit pressure should be veried and increased if
needed with the automac air vent isolaon valves
being closed and plugged with the commissioning air
vents being removed .
3. SYSTEM COMMISIONING
Percent By Volume - Dow Frost HD
Temperature (°F) Freeze Protection
20 18%
10 29%
036%
-142%
-20 46%
-30 50%
-40 54%
-50 57%
-60 60%
Table 3.3.1: HTF Concentration

9 May 2020
3.4. CONTROLLER SETUP
Once 120VAC powered via the master power
switch the controller screen will illuminate and
the time functions should be input per the
SETR A 503 TTR instruction manual. No other
setup of the controller is necessary for the
system to function in automatic mode. Tuning
of the system controller is possible referencing
the SETR A 503 TTR instruction manual.
4.1. SYSTEM IDLING
Solar water heating systems can reach very
high temperatures when there is no daily hot
water usage on the system. If a short summer
vacation is planned, the SETR A 503 TTR
differential temperature controller has a
vacation function which, when activated, will
dissipate heat at night. See the control manual
to activate this function. Remember to
deactivate this function upon returning system
to operation!
During extended idling 6 weeks or more it is
advisable to either cover the solar collectors
with an opaque material or to manually drain
the collector loop HTF. SunEarth recommends
that you cover the collectors if practical.
If you choose to drain the HTF in the solar
array loop follow these steps:
1. Turn the system MASTER POWER SWITCH
to the “OFF” position.
2. Attach a hose to the solar array loop drain
valve. Secure the other end to a suitable
storage container with volume capacity
larger than the solar array loop volume.
WARNING! Solar heat transfer fluid may
be under high temperature and pressurized
extreme care should be taken as HTF may
turn to steam when exposed to atmospheric
pressure.
3. Carefully open the drain valve.
Warning! DO NOT dispose of the heat transfer
fluid on the ground or in the water system.
Collect it in a container which can be sealed
and dispose of it according to the
manufacturer’s directions.
4. EXTENDED NON-USE PROCEDURES

10 May 2020
5.1. EMERGENCY SHUT OFF
1. If there is a leak or other issue requiring
the collector loop to be drained, turn the
system MASTER POWER SWITCH to the
“OFF” position.
2. Attach a hose to the solar array loop drain
valve. Secure the other end to a suitable
storage container with volume capacity
larger than the solar array loop volume.
WARNING! Solar heat transfer fluid may
be under high temperature and pressurized
extreme care should be taken as HTF may
turn to steam when exposed to atmospheric
pressure.
3. Carefully open the drain valve.
Warning! DO NOT dispose of the heat transfer
fluid on the ground or in the water system.
Collect it in a container which can be sealed
and dispose of it according to the
manufacturer’s directions.
5.1 FREEZE PROTECTION
It is extremely important to monitor the quality
of the heat transfer fluid (HTF) annually by
bleeding a few drops from the solar array loop
to verify pH is between 8-10 if outside this
range the HTF must be drained and replaced.
The chemical composition of the HTF may
change over time. A high quality propylene
glycol HTF capable of operating at high
temperatures should be used. The water used
to dilute the HTF is equally important, water
containing salts, acids, calcium or other
potential precipitates should not be used to
dilute the HTF initially or during subsequent re-
charges; de-ionized water is recommended.
The recommended propylene glycol HTF is Dow
Chemical “Dowfrost HD”. Technical and
engineering data for Dowfrost HD is available
at www.Dow.com.
A high quality HTF diluted with pure water and
properly maintained will prevent: appearance
of deposits on the piping; corrosion of compo-
nents; and loss of freeze protection. System
pH must be maintained between 8 and 10 to
avoid damage to the collector loop and
absorber plate piping.
5.2 DESCALING THE HEAT EXCHANGER
1. Turn off your solar water system with the
Master power switch.
2. Close the shut-off valves. Open the
domestic water service ports and remove
any sediment buildup from the clean out
port.
3. Flush the heat exchanger with a weak
solution of white vinegar and water.
4. Close and the service ports
5. Return shut-off flanges to the open
position.
5. OPERATIONS AND MAINTENANCE