SunEarth SolarStation HX User manual

July 2020
INSTALLATION MANUAL
SolarStation HX
Model 100005-6 (Indirect Glycol)
The SolarStaon HX is SunEarth’s soluon to external heat exchange solar thermal systems up
to 160 2 of collector area. Designed with mul speed pumps to ensure compability with a
wide range of system conguraons.

2 July 2020
TABLE OF CONTENTS
1. SYSTEM COMPONENTS AND PRINCIPLES
1.1 SAFETY
1.2 COMPONENTS
1.2 PRINCIPLES
2. INSTALLATION
2.1 SOLARSTATION HX MOUNTING
2.2 SOLARSTATION HX PLUMBING CONNECTIONS
2.3 SOLARSTATION HX ELECTRICAL CONNECTIONS
3. SYSTEM COMMISSIONING
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
4.1 SYSTEM IDLING
5. OPERATIONS AND MAINTENANCE
5.1 EMERGENCY SHUT OFF
5.2 FREEZE PROTECTION
5.3 DESCALING THE HEAT EXCHANGER

3 July 2020
1.1 SAFETY
Electrical Shock, Fire, Explosion and Burn Hazards
This system must be installed, adjusted, and put into operation only by a trained,
qualified professional or service agency in accordance with the National Electric
Code ANSI/NFPA 70 (Canada CSA C22.1), state and local codes, and authorities
having jurisdiction.
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 July 2020
1.2 COMPONENTS
1. SYSTEM COMPONENTS AND PRINCIPLES
Figure 1.2.1: SolarStation HX Components
Item Description
1Differential Temperature Controller
2Solar Circuit Dial Pressure Gauge
3Solar Circuit Pressure Relief
4Solar Circuit Drain Valve
5Solar Circuit Fill Valve
6Solar Pump w/ Check Valve
7Potable Pump w/ Check Valve
83/4 FIP Expansion Tank Piping Connection
9Mounting Bracket
10 Plate Heat Exchanger
11 Pump Service Valves
7
6
10
9
11
4
*Pressure relief and **air separator on model 100005-6 only
**
*
S2
P2
P1 S1
1
9
8
5

5 July 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. the potable pump 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 pumps
should be on when the sun is shining and there
is an adequate temperature differential. The
pumps 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 T3 can be checked to
ensure your system has hot water ready for
use.
1. SYSTEM COMPONENTS AND PRINCIPLES
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 HX Installation Diagram
*Piping connections for electric water heater shown
3
2
1
2
3
HOT TO FIXTURES
DRAIN TEE
COLD PORT TEE
SOLAR RETURN
SOLAR FEED
COLD INLET
3

6 July 2020
2.1. TANK MOUNTING
When tank mounting the SolarStation HX,
place the bracket over the SolarStation HX and
place the assembly on the side of the tank.
The side of the SolarStation HX should be 1” to
the left of the top electric cover. The bracket
should lie flat on the top of the tank. Scribe
the tank to match the bracket location
(Figure 2.1.1).
Using two #10 X 3/4” self drilling screws,
screw the top of the bracket to the top of the
hot water tank. Ensure the vertical section of
the bracket above the heat exchanger is flush
with the side of the tank before seating the
screws.
While holding the bracket and the SolarStation
HX firmly against the tank, drive two #10 X
3/4” self-drilling screws into the lower section
of the bracket just below the heat exchanger
(Figure 2.1.2) and two screws just above the
heat exchanger (Figure 2.1.3).
2.1. WALL MOUNTING
Please consult authority having jurisdiction
(AHJ) for fasteners sizes and mounting
requirements if connecting to a wall.
2. INSTALLATION
Figure 2.1.1: Strut Dimensions
Figure 2.2.1: Connection Details
WALL
Figure 2.1.1: SolarStation HX Top Mount
Figure 2.1.3: SolarStation HX Above HX Mount
Figure 2.1.2: SolarStation HX Below HX Mount

7 July 2020
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
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 HX has four plumbing
connections detailed in Figure 2.2.1. The two
plumbing connections located on the left are
associated with the solar circuit. The two
plumbing connections on the right are
associated with the potable circuit.
The (S2) solar feed/out should be plumbed to
the feed pipe for the solar thermal array. The
(S1) solar return/in should be plumbed to the
return pipe for the solar thermal array. The
(P2) potable feed/out should be plumbed into
the solar storage tank on an upper port with a
dip tube. The (P1) potable return/in should be
plumbed into the solar storage tank on a lower
port or a port with a dip tube as shown in
Figure 2.2.2.
Using the flexible stainless steel or copper tubing,
attach the expansion tank to the expansion
tank port at the lowest point on the left,
below the collector loop pump. Mount the
expansion tank to the wall or to the storage
tank.
All collectors and horizontal pipe runs plumbing
should be supported to allow complete
drainage of the system if necessary, the
2. INSTALLATION
”
”
S2
S1
P2
P1
SOLAR IN
SOLAR FEED
POTABLE IN
POTABLE OUT
S2 S1 P2
P1
Figure 2.2.1: SolarStation HX Connections
Figure 2.2.2: SolarStation HX Potable Connections

8 July 2020
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 line cord is supplied from the
SolarStation HX. An electrical supply outlet
installed per approved methods per electrical
code for a 120VAC 1ph connection.
The temperature sensor installed on the array
outlet should be connected into the T1 terminal
block . The temperature sensor installed near
the bottom of the solar storage tank should be
connected into the T2 terminal block. The
upper tank temperature sensor should be
connection into the T3 terminal block.
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.
The T3 upper tank sensor should be installed in
a dry thermowell located at the hot outlet of
the solar storage tank.
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 HX 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.
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(#5).
2. Open the fill valve.
3. Open the drain valve. Connect the drain
valve to a bucket(#4).
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
3. SYSTEM COMMISIONING
Figure 2.3.1: T1 Array Temperature Sensor Installation
*Seal Temperature Sensor into thermowell with light coat of sealant

9 July 2020
ten minutes.
7. Discharge any air caught in the air trap
using the Schrader valve located below the
collector pump
8. Repeat previous steps until no air is
discharged.
9. Close drain valve.
10.Continue charging until it reaches the
necessary pressure for the system’s
configuration.
11.Close the fill valve.
12. Turn off and disconnect charging pump.
Note: It is recommended to install commissioning
automatic 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 verified and
increased if needed with the automatic air vent
isolation valves being closed and plugged with
the commissioning air vents being removed .
3.4. CONTROLLER SETUP
Once 120VAC powered select AUTO via the
ON/OFF/AUTO switch on the side of the
controller will illuminate. 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 0301U 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 0301U
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 ON/OFF/AUTO 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
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

10 July 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 ON/OFF/AUTO 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.
5.2 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.
5.3 DESCALING THE HEAT EXCHANGER
1. Turn off your solar water system with the
switch on the side of the solar differential
control and disconnect the power to the
SolarStation HX by unplugging it from the
wall outlet.
2. Close the two shut-off valves on the right
side of the SolarStation HX. See Figure
2.2.1, ports P2 & P1.
3. Unscrew the plugs to open the descaling
and clean out ports .
4. Remove any sediment buildup from the
clean out port.
5. Flush the heat exchanger with a weak
solution of white vinegar and water.
6. Close and tighten descaling and clean out
ports.
7. Return shut-off flanges to the open position
and reconnect the power to the
SolarStation HX.
5. OPERATIONS AND MAINTENANCE