SunEarth SolarStation XXL Operating instructions

Description / Applications
System Overview
The SunEarth SolarStation XXL solar thermal glycol system. The
SolarStation XXL allows for easy installation of large solar water
heating systems.
SunEarth
™
SolarStation XXL
Installation/ Owner’s Manual

Page 1
SunEarth Glycol Instructions © SunEarth Inc
Contents
Features....................................................................................................................2
SunEarth SolarStation XXL Features ........................................................................................................... 2
Safety ............................................................................................................................................................ 2
Glycol System Specications ..................................................................................4
Installation ...............................................................................................................3
Installing the Collectors ................................................................................................................................. 4
Installing the Temperature Sensor ................................................................................................................ 5
Pipe Runs...................................................................................................................................................... 5
Installing the Tempering Valve....................................................................................................................... 5
Installing the Differential Control ................................................................................................................... 5
Check Collector Loop for Leaks .................................................................................................................... 5
Charging the System..................................................................................................................................... 5
Operation ...............................................................................................................6
Starting the System....................................................................................................................................... 6
Emergency Shut Off...................................................................................................................................... 6
Maintenance.............................................................................................................6
Freeze Protection.......................................................................................................................................... 6
Clear Sediment from Strainer........................................................................................................................ 6
Descaling the Heat Exchanger ..................................................................................................................... 6
Change Heat Transfer Fluid .......................................................................................................................... 7
Pumps ........................................................................................................................................................... 7
Service .......................................................................................................................................................... 7
Warranty Information ..............................................................................................9

SunEarth Glycol Instructions © SunEarth Inc Page 2
Electrical Shock, Fire, Explosion and Burn Hazards
This system must be installed, adjusted, and put into operation only by a trained, qualied 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.
The installer must carefully read and follow the installation and service instructions contained in this manual. Also make
these instructions available to the equipment owner, so they can be kept for future reference.
Features
SunEarth SolarStation XXL Features
SunEarth has uniquely created the SolarStation XXL package which allow for the easy installation
of a large scale industrial solar water heating system using an atmospheric solar storage tanks.
• Heat exchangers, circulators and state of the art digital controls in one space saving package
• Patent pending heat exchange process means the pumps run less, increasing savings
• Extra layer of protection with 2 heat exchangers between potable water and glycol loop
• Decreased installation time
• Reduces labor and engineering costs
• Easy maintenance
• Scalability allows for a wide variety of applications
• 1.5 inch potable piping connections for easy tie in to back up tanks
Electrical Shock and Fall Injury Hazard.
Use extreme caution when mounting collectors on a roof or when connecting any wiring or electrical hookups.
Safety
○Secure all ladders on level ground
○Locate all possible hazards, overhead wires, loose shingles, etc.
○Make sure power is turned off before adding water to the system
○NEVER connect power to the water heater or storage tank until it has been lled.
○Use a tempering valve or mixing valve to prevent scalding
○Consult proper authorities 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 penetrating structural members and re-rate assemblies.

Page 3
SunEarth Glycol Instructions © SunEarth Inc
Section: Installation
Notes:
◦The pipe size will be determined by the size of the collector array.
◦To Backup heat source DO NOT USE PLASTIC PIPES!
◦ An expansion tank should be installed on the potable water side for systems that do not allow backow.
◦Refer to manufacturer’s instructions regarding installation of the tempering valve.
Installation
Refer to Figure 1 for the relative location of the pipes, collectors, and SSXXL pump package.
Figure 1 - Installation Diagram

Page 4
SunEarth Glycol Instructions © SunEarth Inc
LOWER MOUNT
SEE DETAIL A
UPPER MOUNT SEE DETAIL B
UPPER TELESCOPING LEG
SWING MOUNT
SEE DETAIL C
UPPER TELESCOPING
LEG - 38" LENGTH
LOWER TELESCOPING
LEG - 36" LENGTH
DETAIL A
DETAIL B
45°
3/8" x 3" LAG SCREWS
3/8" FLAT WASHER
5/16" x 2-1/2" BOLT
5/16" FLAT WASHER
5/16" NUT
5/16" LOCK WASHER
5/16" FLAT WASHER
8" ALUMINUM FOOT
LOWER ALUMINUM TELESCOPING LEG
ALUMINUM STRUT
5/16" x 2-1/2" BOLTS
5/16" FLAT WASHER
5/16" NUT
5/16" LOCK WASHER
5/16" FLAT WASHER
2 - #10 SELF TAPPING SCREWS
STRAIGHT ALUMINUM
SWING MOUNT
COLLECTOR
LOCK
3/8" BOLT
3/8" LOCK WASHER
3/8" FLAT WASHER
S-NUT
LOCKSTRAP
UPPER ALUMINUM TELESCOPING LEG
DETAIL C
3 - #10 SELF TAPPING SCREWS
ANGLED ALUMINUM
SWING MOUNT
5/16" NUT
5/16" LOCK WASHER
5/16" FLAT WASHER
5/16" FLAT WASHER
3/8" x 3" LAG SCREWS
5/16 x 2-1/2" BOLT
3/8" FLAT WASHER
8" ALUMINUM FOOT
Section: Installation
Collector Adjustable Mount
LOWER MOUNT
SEE DETAIL A
UPPER MOUNT SEE DETAIL B
UPPER TELESCOPING LEG
SWING MOUNT
SEE DETAIL C
UPPER TELESCOPING
LEG - 38" LENGTH
LOWER TELESCOPING
LEG - 36" LENGTH
DETAIL A
DETAIL B
45°
3/8" x 3" LAG SCREWS
3/8" FLAT WASHER
5/16" x 2-1/2" BOLT
5/16" FLAT WASHER
5/16" NUT
5/16" LOCK WASHER
5/16" FLAT WASHER
8" ALUMINUM FOOT
LOWER ALUMINUM TELESCOPING LEG
ALUMINUM STRUT
5/16" x 2-1/2" BOLTS
5/16" FLAT WASHER
5/16" NUT
5/16" LOCK WASHER
5/16" FLAT WASHER
2 - #10 SELF TAPPING SCREWS
STRAIGHT ALUMINUM
SWING MOUNT
COLLECTOR
LOCK
3/8" BOLT
3/8" LOCK WASHER
3/8" FLAT WASHER
S-NUT
LOCKSTRAP
UPPER ALUMINUM TELESCOPING LEG
DETAIL C
3 - #10 SELF TAPPING SCREWS
ANGLED ALUMINUM
SWING MOUNT
5/16" NUT
5/16" LOCK WASHER
5/16" FLAT WASHER
5/16" FLAT WASHER
3/8" x 3" LAG SCREWS
5/16 x 2-1/2" BOLT
3/8" FLAT WASHER
8" ALUMINUM FOOT

SunEarth Glycol Instructions © SunEarth Inc
Section: Installation
Installing the Temperature Sensor
1. Strap the PT1000 probe sensor to the
copper pipe at the collector outlet using
a stainless steel screw clamp or use a
SunEarth thermal well.
2. For sensor to operate correctly it must be
isolated from exterior conditions. All of the
exposed copper, as well as the sensor
itself, needs to be completely covered with
insulation and UV jacketing.
Pipe Runs
Use copper or stainless steel tubing sized for
the array size and run lenghts. All pipes should
be wrapped with insulation. We recommend
Elastomeric insulation. Outdoor pipes should
also be jacketed with UV protection material or
some other means to protect it from moisture
and ultraviolet deterioration. All pipes must be
well supported or they will sag. Sagging pipes
may trap water. The hanger should spread the
load so that the insulation is not compressed.
Installing the Tempering Valve
Refer to manufacturer’s instructions for
information on installing the tempering valve.
Installing the Differential Control
Your SSXXL system is automated by the
differential controls located in the control box.
Place sensors as shown in Figure 1. The control
for the solar loop uses a sensor installed at
the outlet of the collector array and a sensor
at the coldest part of the the atmospheric tank.
The potable loop uses a sensor placed on the
cold in line between 2 closely positioned tees
leading to 2 of the ball valves at the top of
the SSXXL. Install the other sensor at the
top of the atmospheric tank. Ensure that the
tank volume does not drop below the position
of the tank sensor.
Page 5
Check Collector Loop for Leaks
1. Before the system has been charged, open
all shut-off valves on the collector loop.
2. Apply 100 psi 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.
Charging the System
1. Flush the system with water to clean out
any debris or sediment from the pipes and
collectors.
2. Connect the outlet of a transfer pump via a
hose to the ll valve.
3. Open the ll valve.
4. Open the drain valve. Connect the drain
valve to a bucket.
5. Fill the bucket with the appropriate mixture
of propylene glycol and water.
6. Run the pump. Continue running the pump
until you do not see air bubbles in the
coolant.
7. Turn off the pump. Let the system sit for ten
minutes.
8. Discharge any air caught in the air trap.
9. Repeat previous steps until no air is
discharged.
10. Close drain valve.
11. Continue charging until it reaches
the necessary pressure for the system’s
conguration.
12. Close the ll valve.
13. Turn off and disconnect charging pump.
Do not use plastic piping
PEX, PVC and other forms of non-metal pipes will burst
at solar temperatures. Only use correctly sized copper
or stainless steel pipes in solar heating system on both
the solar and potable water loops. All connections to and
from the S SXXL must be copper or stainless steel.

S SunEarth Glycol Instructions © SunEarth Inc Page 6
Section: Installation
Operation
Starting the System
1. Conrm that all shut-off valves are fully
open.
2. Turn on the system and let it run.
3. Double-check every component and all pipe
runs and ttings for leaks.
Emergency Shut Off
1. If there is a leak or other issue requiring the
collector loop to be drained, turn the system
off by setting the switch on the left side of
the differential control to the “OFF” position.
2. Attach a hose to the drain valve.
3. Open the drain valve.
Warning! DO NOT dispose of the heat transfer
uid 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.
Maintenance
The solar water system requires very little by
way of maintenance, but a few regular system
checks can extend the life of your system well
beyond 20 years.
Freeze Protection
This system is designed to protect itself from
freeze damage to temperatures as low as -30°F
as long as the heat transfer uid in the collectors
is at least 40% GRAS propylene glycol. Freeze
tolerance limits are based upon an assumed
set of environmental conditions. In the event
of extreme or prolonged cold weather, protect
Burn and Scald Hazard
Excessive water temperatures could cause explosion,
burns, scalding, pressure relief ooding and tting
leaks. Carefully follow the outlined procedures for
temperature sensor installation to ensure accurate
water temperature sensing and effective control
operation.
your system by shutting it down and draining
the collector loop as described in the “Vacation
Settings” and “Emergency Shut- Off” sections.
Clear Sediment from Strainer
1. Turn off your solar water system with the
switch on the side of the differential control
and disconnect the power to the SSXXL
by unplugging it from the wall outlet.
2. Close the two shut-off flanges. Open
the clean out port.
3. Remove any sediment buildup from the
clean out port.
4. Close and tighten clean out port.
5. Return shut-off flanges to the open position
and reconnect the power to the SSXXL
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
SSXXL by unplugging it from the wall
outlet.
2. Close the shut-off valves. Open the
descaling 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 tighten descaling and clean out
ports.
5. Return shut-off flanges to the open position
and reconnect the power to the SSXXL.

Page 7
SunEarth Glycol Instructions © SunEarth Inc
Service
To obtain service for your SSXXL, notify the
dealer who installed or sold the SSXXL. In
notifying your dealer, provide identification of your
SSXXL, date of purchase (with proof), and the
nature of the defect. To obtain the location of
the nearest authorized SunEarth service and/or
distribution facility, call [phone] or email
[e-mail]
Change Heat Transfer Fluid
The heat exchange uid contains buffers which keep
the pH of the solution neutral. Heat and time will
degrade these buffers, so it is important that you drain
the uid and recharge the system every 3-5 years.
To drain the system:
1. Turn the system off by setting the switch on the left
side of the differential control to the “OFF” position.
2. Attach a hose to the drain valve on the lower left
side of the SSXXL.
3. Open the drain valve. Dispose of used heat transfer
fluid according to manufacturer’s directions.
Pumps
The circulation pumps have a life expectancy of
5-10 years. If a pump should require servicing or
replacement:
1. Turn off the system with the switch on the side of
the differential control.
2. Close all the ball valves at the top of the SSXXL.
Leave the system off for several hours until the
pumps are completely cooled to room temperature.
3. Solar pumps are flanged so they can be easily
removed by loosening the flange’s nuts and
bolts. Potable loop pumps use bolts and must be
unscrewed.
Section: Installation
Burn Hazard
Exercise extreme caution when draining, as the heat
transfer uid may be dangerously hot.

SunEarth Glycol Instructions © SunEarth Inc Page 8
Section: Installation

Page 9
SunEarth Glycol Instructions © SunEarth Inc
Warranty Information
Section: Warranty
Effective 05/3/18 Protecting Our Environment –Since 1978
www.sunearthinc.com
TWO-YEAR LIMITED PRODUCT WARRANTY
This warranty only applies to the following SunEarth products (hereinafter SunEarth Products):
Pump Stations: SRS Series, 100005-2 Series, 100005-5 Series, 100005-6 Series, 100005-7 Series
Under conditions of normal use and service the above SunEarth Products are warranted to the original, or
subsequent users, for a period of 2 year from the date of sale to be free of defects in material and
workmanship pursuant to the exclusions detailed in this written warranty statement. SunEarth's liability for
these products shall be limited to repairing or replacing at SunEarth's option, without charge, F.O.B.
SunEarth's factory or an authorized SunEarth distributor or service center. SunEarth will not be liable for
any costs of transportation, inspection, removal, reinstallation, or any other labor or freight charges that
may arise in connection with a warranty claim, except as expressly set forth in this warranty.
SunEarth pump station Series SRS and 100005-6 are exclusively designed for use in residential domestic
solar water heating systems. No other use or application of these products is covered under this statement of
limited warranty.
FREIGHT AND SHIPPING EXPENSES
In the event of a valid warranty claim approved by SunEarth, SunEarth will pay for freight and shipping
expenses as follows:
Year 1 of Warranty: SunEarth will pay the freight and shipping costs for the new or repaired SunEarth
Product between SunEarth and the nearest local distributor, dealer, authorized service center, city, or
shipping terminal. THIS WARRANTY DOES NOT APPLY
This warranty does not apply to the following: (1) conditions resulting from a failed component or part
that is not part of the above listed SunEarth Products; (2) to damage caused by freezing conditions; (3) to
conditions resulting from misuse, abuse, neglect, accident, or alteration; (4) to conditions resulting from the
introduction of harmful chemicals, caustic fluids, or deleterious fluids, including improperly applied or
maintained heat transfer fluids; (5) to SunEarth Products in which heat transfer fluids other than potable
water or propylene glycol (DowFrost HD recommended) are used; (6)to propylene glycol pH levels above
10 or below 8; (7)to periods of stagnation in excess of 30 days; (8)to excessive pressure; (9) to conditions
resulting from floods, earthquakes, winds, fire, lightning, or circumstances beyond SunEarth's control; (10)
to damage caused by installation methods, that do not conform to relevant national, state or local codes and
ordinances, good industry practices, or to current applicable SunEarth manuals, diagrams, technical
bulletins, or written installation instructions; (11) or to applications other than medium temperature (110 -
160F) domestic water heating.
If one of the above SunEarth Products is purchased outside the United States certain conditions of this
warranty may NOT apply. Please contact your local SunEarth distributor or dealer for details.
LIMITED WARRANTY
EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY, THE ABOVE SUNEARTH
PRODUCTS ARE PROVIDED WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR

Page 10
Section: Warranty
Effective 05/3/18 Protecting Our Environment –Since 1978
www.sunearthinc.com
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTY
OR NON-INFRINGEMENT. SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED
WARRANTIES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
LIMITATIONS OF REMEDIES
IN NO EVENT SHALL SUNEARTH BE LIABLE FOR ANY DAMAGES FOR LOST PROFITS,
LOST SAVINGS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES, ARISING OUT
OF THE USE OR INABILITY TO USE THE ABOVE SUNEARTH PRODUCTS, OR FOR ANY
CLAIM BY A THIRD PARTY. SOME STATES DO NOT ALLOW THE LIMITATION OR
EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU.
EXCLUSIVE AGREEMENT
THIS WARRANTY CONSTITUTES THE ENTIRE, COMPLETE, FINAL, AND EXCLUSIVE
AGREEMENT FOR THE SUNEARTH PRODUCTS LISTED ABOVE. THIS WARRANTY
SUPERSEDES ANY PROPOSAL, AGREEMENT, OR REPSRESENTATION, OR ANY OTHER
COMMUNICATION, EITHER WRITTEN OR ORAL, MADE BETWEEN SUNEARTH AND
SUNEARTH’S DISTRIBUTORS OR DEALERS, OR BETWEEN SUNEARTH AND THE END
CONSUMER.
RETURNED GOODS
No material shall be returned without authorization or beyond the warranty period. When credit is issued it will be at the
price charged, or prevailing price if lower, less handling charges based on costs of reconditioning, packaging, etc. Products
which are obsolete or made to special order are not returnable.
TO MAKE A CLAIM
To obtain service under this warranty, the product in question must be returned to the distributor or dealer
of SunEarth products nearest you, or an authorized SunEarth service center. Each claim must be
accompanied by documentation providing the following:
1) Owner’s name, address, email address, and phone number
2) Installation contractor’s name, email address, and phone number
3) Original sales receipt
4) Product model and serial number(s)
5) Date of installation
6) Date of failure
7) Reason for failure
8) Pictures of the suspected manufacturing defect –digital pictures of the suspected manufacturing defect
also need to be submitted
If you have any warranty questions, contact your installation contractor or SunEarth at [phone].

SolarStation XXL SyStem
SunEarth Inc.
8425 Almeria Ave · Fontana, CA 92335 · Phone: [phone] Email:
[e-mail]
www.sunearthinc.com