Thermo Dynamics Solar Boiler SB32-9PV User manual

Solar Boiler™ Installation Manual (OG-300), page 1 of 14IN.410.06.DEC/99
domestic hot
water supply
cold water
supply
1
4
5
7
8
3
AAA
AAA
AAA
AAA
AAA
9
2
10
11
12
6
Solar BoilerSBy Thermo Dynamics Ltd.
Installation Manual for SB32-9PV, SB64-9PV, Systems
CERTIFICATION
The solar energy system described by this manual, when properly installed and maintained,
meets the minimum standards established by the SRCC, (Solar Rating & Certification
Corporation). This certification does not imply endorsement or warranty of this product by
SRCC.
WARNING:
- Installation shall be in accordance with the National Fire Code, and all local
codes.
-The approved heat transfer fluid is a mixture of 40% Propylene Glycol USP and
60% distilled water. The substitution of any other heat transfer fluid can cause
irreparable damage and create a health and safety hazard.
-The Solar Boiler™ module contains 3.75 litres, (1 USgallon), of heat transfer
fluid when full.
-The installation of the Solar Boiler™ should be inspected by a qualified
technician prior to start-up.
1. Micro-Flo® solar collectors
2. Solar storage tank
3. Temperature gauge (optional)
4. Solar Boiler™ Module
5. 3/4" Hard Copper Tube
6. Photovoltaic Module
7. LifeLine® tubing
8. Solar isolation and bypass valves
9. Temperature - pressure relief valve
10. Mixing valve
11. Heat traps
12. Auxiliary water heater
U
S
N
So is the
Fuel Prices are
always rising ...
Congratulations on the purchase of your new Solar Boiler™ by Thermo
Dynamics Ltd. The Solar Boiler™ is the newest and most advanced concept in
residential solar water heating systems.
This manual outlines all the steps for a quick, easy, trouble-free installation.
Read the entire manual carefully before any installation attempt is made.

Solar Boiler™ Installation Manual (OG-300), page 2 of 14IN.410.06.DEC/99
S32 A
Solar Collector
S32B
Solar Collector
[Optional]
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
South
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
Solar Collector Installation
Micro-Flo® solar collectors are designed 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 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
recommended collector slope for a home located 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 figure. 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.
How the Solar Boiler™ works
•Solar collectors absorb sunlight and convert it to heat.
•When there is sufficient sunlight, the photovoltaic module produces
electricity and turns the pump.
•The pump circulates heat transfer fluid, (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 water 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 significantly less when
water is preheated by the solar water heater.
• In this manner, the solar water heater saves electrical energy.
NOTE: The Solar Boiler™ is designed to shut off when a temperature
of 180°F is attained in the solar storage tank.
The HTF is a 40/60 % by volume mixture of Propylene Glycol
USP and distilled water, and will provide freeze protection to -
10°F (-24°C)

Solar Boiler™ Installation Manual (OG-300), page 3 of 14IN.410.06.DEC/99
usually 16" or 24"
rafter
roof small nails
rafter
roof
acceptable
not acceptable
lock
washer
bolt track
3/8" bolt
aluminum
channel, (6")
3/8" nut
A
B
IN
IN
OUT
OUT
silicon
IN
OUT
lag bolt
3/8" nut and
lock washer
3/8" bolt
"A" Collector
bolt track
1
2
3
Locating Roof Rafters
✍
❏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 find the center of the rafters, lift the shingle and
use small nails to find the two edges of the rafter.
❏Drill a 1/4" pilot hole in the rafter for each of the
front mounting clips.
Flush Mounting Micro-Flo® Solar Collectors
✍
❏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 bottom 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 collector 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.
Optional Second Solar Collector
✍
❏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 collector B to
A as shown in the figure.
❏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.

Solar Boiler™ Installation Manual (OG-300), page 4 of 14IN.410.06.DEC/99
4
5
6
Preparing the photovoltaic module
✍
❏Attach the two large aluminum brackets to the
photovoltaic module using the 3/8" bolts, nuts, and
lock washers supplied.
❏Make sure both aluminum angle brackets are securely
fastened to the photovoltaic module.
❏The location of the PV module should be as shown
in the diagram. It is recommended that it be located
towards the top of the collectors so that snow will
easily fall off.
Wiring the photovoltaic module
✍
❏The photovoltaic module comes with an electrical junction box located on the back of the
module. Open the box, and note the positive terminal marked "+" and the negative
terminal marked "-". (Follow the diagram on the back of the PV module)
❏16/2 wire is supplied with your Solar Boiler™. Drill a small 1/4" hole in the junction
box and slip the wire through. Tie a knot in the wire so that it can not be pulled out of
the box. Connect the black wire to the "+" terminal, and the white wire to the "-"
terminal.
❏Seal the hole in the junction box wire hole with silicon. Close the junction box securely.
CAUTION: The photovoltaic module produces electricity when exposed to sunlight. To
avoid any chance of shock, cover the photovoltaic module with a towel during installa-
tion. The photovoltaic module is rated for 1.2 amps, 17.0 volts, and 20 watts.
Locating the photovoltaic module
✍
❏Locate the photovoltaic module as shown in the
diagram. Using the 3/8" bolts, washer, and nuts,
attach the photovoltaic module to the "B"
collector bolt track as shown in the diagram.
Tighten the nuts securely. The location should be
as close to the top of the "B" collector as possible.
It can be on either the left hand side or the right
hand side.
white wire
black wire
knot
seal with silicon
Junction box
16/2 wire
3/8" nut and
lock washer
3/8"
bolt
Photovoltaicmodule
junction box
A
BPV
Photovoltaicmodule
"B"
Collector
bolt
3/8" bolt,washer,
nut

Solar Boiler™ Installation Manual (OG-300), page 5 of 14IN.410.06.DEC/99
7
9
IN
OUT IN
OUT
LifeLine® connection between collector A and B
✍
❏Remove the orange caps from the fittings on the
collectors. Turn the 3/8" compression nuts on
the fitting body until finger tight.
❏Insert the two 3/8" copper tubes into the ports as
shown.
❏Using a 11/16" and a 5/8" wrench, tighten the
nuts one full turn.
IMPORTANT: The 11/16" wrench is required to
prevent the fitting body from rotating while
turning the nut with the 5/8" wrench.
8
LifeLine® tubing
A
B
AA
AA
AA
AA
AA
AA
AA
LifeLine® and CopperTube Kit Installation (For ease, the term "LifeLIne®" will be used
in the manual to refer to both.)
✍
•LifeLine® is used to connect the Solar Boiler™ module to the solar collectors.
•Locate the solar collectors as close as possible to the Solar Boiler™ module without compromising
collector orientation. This will minimize the length of LifeLine® required to connect the Solar Boiler™
to the solar collectors.
•Run the LifeLine® to the solar collectors via an unused space or closet. Note: All LifeLine® installed
in the horizontal position must slope down 1/4" for every horizontal foot.
•Secure the LifeLine® at intervals of 6 feet with the clamps. Do not kink the tube.
•Do not cut the LifeLine® until you are absolutely sure there is adequate length available.
•Insulate the entire length of LifeLine® with insulation provided.
3/8" copper
tube
3/8" copper tube
(marked with
tape)
IN
OUT
White wire (–)
Black wire (+) Wire from Photovoltaic
module
LifeLine® roof penetration
✍
❏Make a roof penetration at a position 6" - 8" horizontally
away from the bottom “A” collector ports.
❏Pass the LifeLine® through the roof penetration from below.
Clamp the LifeLine® to the truss. Do not crimp the
LifeLine®. Mark one of the copper tubes with tape on both
ends to identify it as the supply line. It will be connected to
the "IN" port of the "A" collector and to the pump or
"OUT" port of the Solar Boiler module.
❏Use a 3/8" tube bender to bend the copper tubes so that they
may be inserted to the bottom ports of the "A" collector.

Solar Boiler™ Installation Manual (OG-300), page 6 of 14IN.410.06.DEC/99
10
11
12
IN
OUT
Note:
Be sure to note which wire to the Solar Boiler™ is POSITIVE
LifeLine® connection to collector "A"
✍
❏Insert the marked 3/8" copper tube into the "IN" (blue) port of
the "A" collector. Use a 5/8" wrench to tighten the compression
nut one full turn. Be sure to hold the bulkhead union from
moving during this process with a 11/16" wrench. DO NOT
OVER TIGHTEN !
❏Insert the other 3/8" copper tube into the "OUT" (red) port of
the "A" collector. Use a 5/8" wrench to tighten the compression
nut one full turn. Be sure to hold the bulkhead union from
moving during this process with a 11/16" wrench. DO NOT
OVER TIGHTEN !
❏Insulate the copper tubing using the 3/8" ID insulation provided
with the Solar Boiler™. Seal the roof penetration with silicon
sealant.
AAA
AAA
solar storage tank
AAAA
Solar Boiler™
A
A
bottom tank
tee
drain bib
Flexhose™(15") long nipple
tank drain port ball valve
A
A
AA
AA
90°union
Flexhose™(15")
A
A
A
union nut
AA
AA
Setting up the Solar Boiler™ module,bottom connections
✍
❏Place the Solar Boiler™ module and solar storage
tank next to your auxiliary water heater.
❏Attach a 90°3/4" elbow to the bottom of the Solar
Boiler™ module and position it in the direction of
the solar storage tank.
❏Remove the drain valve from the solar storage tank.
Install the bottom tank assembly. Position the tee such that one end points toward the Solar Boiler™.
❏Apply teflon tape to the hose bib and attach it to the end of the tee that is pointing away from the Solar Boiler™.
❏Connect the bottom of the Solar Boiler module to the tee at the bottom of the solar storage tank using 3/4" hard copper
tubing. In the diagram, the copper tubing is referred to as Flexhose™. Flexhose™ is no longer used.
bulkhead union
flare gasket
flareadapter
3/8"
compression nut
3/8" copper tube
use teflon tape or pipe thread sealer here
"A" solar collector
LifeLine® 3/8" adapter (SKIP THIS STEP IF
YOUR COLLECTOR HAS 3/8" PORTS)
✍
❏In order to connect 3/8" tube(s) to the 1/4" bulkhead unions
on the solar collector, adapters are included with installation
hardware. The adapters consist of several brass and copper
fittings. A top view of the lower right hand corner of the
“A” solar collector is shown here and illustrates the proper
arrangement of the fittings.
❏Before attaching the flare adapter, remove the 1/4" compres-
sion nut from the solar collector.
❏Connect fittings in the order shown.
❏Use two wrenches to tighten all connections. Use a 9/16"
wrench to prevent the bulkhead union from turning.

Solar Boiler™ Installation Manual (OG-300), page 7 of 14IN.410.06.DEC/99
cold water
supply
AA
AA
AA
AAA
domestic
hot water
supply
close main water
supply valve
Tee connector Ball valve #1
Tee connector
solar storage tank auxiliary
DHW tank
Solar Boiler™
cold inlet hot outlet cold inlet hot outlet
Ball valve #2 Ball valve #3
heat trap heat trap
For normal solar operation:
• Ball valve #1 - close
• Ball valve #2 - open
• Ball valve #3 - open
mixing valve
13
14
15
cold water
supply
AAA
AAA
AAA
AAA
AAA
domestic
hot water
supply
close main water
supply valve
Tee connector Ball valve #1
Tee connector
solar storage tank auxiliary
DHW tank
Solar Boiler™
cold inlet hot outlet cold inlet hot outlet
Setting up the Solar Boiler™ module,top connections
✍
❏Using 3/4" copper tube,attach the top port of the Solar
Boiler module to the copper elbow fitting at the top of
the tank. In the diagram, the 3/4" coper tube replaces the
Flexhose™ which is no longer available.
❏Wrap teflon 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 temperature - pressure relief valve to a drain.
(We recommend a plumber integrate the Solar Boiler™
and solar storage tank with your existing water heater.)
AA
AA
AA
solar storagetank
AAA
AAA
AA
56"
Flexhose™
rear view
AA
AA
AA
AA
Flexhose™(56")
A
A
AA
AA
tank port
3/4" short
nipple
top tank tee
pressure/temperature
relief valve
hot outlet
Isolation Bypass preparation
✍
❏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.
Isolation Bypass connection
✍
❏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.

Solar Boiler™ Installation Manual (OG-300), page 8 of 14IN.410.06.DEC/99
Switch openswhen
set point isreached
Set point control.
Set at 80°C (180°F)
Important: Disconnect ALL wires from
thermostat before connecting the wire from
the Solar Boiler™.
+ PV module
– PV module
Solar storagetank
top thermostat
Limit Control
Reset button
Solar Boiler™
terminal block
LCB (red)
LCB (white)
16
17
IN (RED)
OUT (BLUE)
on pump
Rear view of the Solar Boiler™
vent tube
pressure relief
valve
Solar Boiler™ cover
3/8" copper
tube
3/8" copper tube
(marked with
tape)
insulation
Connect to terminal block
•The Solar Boiler™ module is precharged with the heat transfer fluid.
✍
❏Remove the plugs from the brass fittings and retain. Replace with the nuts provided. Turn the nuts on
until finger tight.
❏Insert the marked copper tube in the fitting located on the pump until it bottoms. Using two wrenches,
one on the fitting body and one on the nut, tighten the nut exactly one full turn.
❏Repeat the above procedure for the other copper tube, which connects to the "IN"
(red) port under the pump.
Important: Do not over tighten the nuts. Failure to follow this procedure could
result in a leaky connection and/or cracked nut.
❏Connect the photovoltaic module (PV) and solar storage tank thermostat to the
Solar Boiler™ terminal block as shown in the diagram. Note: Not all tanks
have the same thermostat as shown in the diagram. Please refer to your tank
owners manual for a schematic of the thermostat.
❏Set the top thermostat of the solar storage tank at 80°C
(180°F). Note: Some thermostats have a high limit which
is less than 80°C. If so, set the thermostat to its maximum.
Do not set the thermostat higher than 80°C.
CAUTION: NEVER CONNECT ANY OTHER WIRES
OR SOURCES OF ELECTRICITY TO THE SOLAR
STORAGE TANK THERMOSTATS!!! NO A/C POWER
IS TO BE CONNECTED TO THIS THERMOSTAT
Solar Boiler™ Start up
✍
❏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 fills 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 indicated in step 15.
❏Remove the pressure relief valve and brass cap from the
Solar Boiler. Some fluid may be visible.
❏Connect the wires from the photovoltaic module to the
proper screws as shown in step 16. Ensure there is suffi-
cient sunlight. The pump will begin operation, and air
bubbling wwill be heard.
❏When the pump has been running for a few minutes, you
will not hear any bubbling noise from the Solar Boiler.
Place a small container under the vent tube. Slowly, fill the
Solar Boiler with fluid until it comes out of the vent tube.
❏Reinstall the pressure relief valve and brass cap. Pressurize
the system using a small pump. Pressurize to approximately
5 psi. (use a tire gauge to check the pressure).
❏Check for leaks at all LifeLine® connections. If a leak is
observed, tighten the nut 1/4 turn. Remember to use two
wrenches, one on the fitting body and one on the nut.
vent tube
pressure relief valve
1/4" compression
nut
brass cap
air valve
fill tube

Solar Boiler™ Installation Manual (OG-300), page 9 of 14IN.410.06.DEC/99
Congratulations
You are now ready to enjoy of your new Solar Boiler™. It can provide a large fraction of your hot water requirements. If you have any
questions or comments regarding its operation or installation, contact your dealer, installer, or Thermo Dynamics Ltd.
Operating Restrictions
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 antifreeze, ethylene glycol, or other poisonous fluids. Thermo Dynamics recommends a mixture of 40%
Propylene Glycol USP and 60% distilled water for use as the heat transfer fluid.
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.
-pH and Freeze Protection:
The pH and freeze protection capability of the propylene glycol USP/water solution should be checked annually.
-Back Flushing the Heat Exchanger:
The Solar Boiler™ heat exchanger should be flushed with clean water ever 6 months. First, close the valve at the bottom of the solar
storage tank near the Flexhose™ 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 flow for a few minutes. This will remove residue
from the heat exchanger and hoses.
-Reservoir Fluid Level:
The fluid level in the Solar Boiler™ reservoir should be checked every year. Instructions for this procedure are part of the refilling
instructions.
Repairs
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 fro 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 qualified 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 notified before you attempt disconnection.
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 flow 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-
fied technician.
* Available by mail order from Thermo Dynamics Ltd.

Solar Boiler™ Installation Manual (OG-300), page 10 of 14IN.410.06.DEC/99
SYMPTOM
Solar Boiler Stays
OFF
Fluid Leaks
Antifreeze not Hot
on Bright Sunny
Day
No Heat Transfer
to Water on Bright
Sunny Day
Pump/Motor
Unusually Noisy
COMPONENT
Photovoltaic Module
Linear Current Booster (LCB)
Pump
Motor
Storage tank thermostat
Solar Collectors
Solar Boiler
Solar Storage Tank
Motor not turning pump
Pump
Flexhose™
Solar Boiler Cover
Dip Tube
PROBLEM
snow covered
module is in the shade
loose wire connections
defective LCB
pump is seized
defective motor
loose wire connections
defective storage tank thermostat
LifeLine® connections
copper tube connections
absorber or internal connections
LifeLine® connections
pump housing
heat exchanger
hose fitting
hose
fittings
loose or defective wire connections
pump is seized
defective motor
pump very hot and fluid cool (turning
but not circulating)
air trapped near top of tank
connection
kink in hose
valve closed at bottom of solar storage
tank (near hose connection)
cover of Solar Boiler is resting against
the motor or pump
low fluid level in reservoir
SOLUTION
-remove snow or allow to melt
-check to see if there are any removable obstructions shading the module
-check all wire connections
-measure resistance to make sure that there is not an infinite resistance
-measure voltage of module on a bright sunny day (approx. 17 VDC)
-contact dealer or Thermo Dynamics to replace LCB
-turn pump shaft by hand to check that it is turning freely
-have pump repaired or replaced
-measure resistance of motor (ohms)
-replace with new motor
-check wire connections
-reset thermostat
-check thermostat relay
-replace thermostat
-use two wrenches to tighten the nut 1/4 turn
-use two wrenches to tighten the nut 1/4 turn
-disconnect photovoltaic module and contact dealer or Thermo Dynamics for
assistance
-use two wrenches to tighten the nut 1/4 turn
-replace pump
-contact dealer or Thermo Dynamics for assistance
-tighten hose 1/8 turn
-isolate tank from pressure, depressurize, remove hose, replace gasket on swivel
end and reseal threads on solid end
-isolate tank from city supply, depressurize and replace hose
-repair or replace
-tank may require replacement, contact dealer or Thermo Dynamics
-have a technician repair or replace as required
-remove pump to verify that motor is turning freely
-turn pump shaft by hand to check that it is turning freely
-have pump repaired or replaced
-replace with new motor and reattach pump
-check fluid level and add fluid as required (see technical note attached to
installation manual)
-disconnect photovoltaic module and contact dealer or Thermo Dynamics
-open cap at top of tank connection about 1/2 turn to allow air to escape (DO
NOT REMOVE CAP)
-undo kink
-open valve
-adjust cover
-disconnect photovoltaic module and check fluid level in reservoir (see technical
note attached to installation manual)
TROUBLESHOOTING PROCEDURES AND INSTRUCTIONS
IMPORTANT: If any of the above persist and you are unable to correct the problem, contact your dealer or Thermo Dynamics Ltd. immediately. The safest action to take in any case is to
disconnect the Solar Boiler module from the photovoltaic module.
Thermo Dynamics Ltd. reserves the right to modify their products without notice as deemed necessary for product improvement and development.

Solar Boiler™ Installation Manual (OG-300), page 11 of 14IN.410.06.DEC/99
Refilling Cap
Terminal Strip
IN (RED)
OUT (BLUE)
on pump
Rear view of the Solar Boiler™
vent tube
pressure relief
valve
Solar Boiler™ cover
3/8" copper
tube
3/8" copper tube
(marked with
tape)
insulation
Connect to terminal block
Solar Boiler HTF (heat transfer fluid) Draining/Refilling Instructions
Your Solar Boiler™ is precharged with HFT (heat transfer fluid) which is a mixture of Propylene Glycol USP and distilled water
(40/60 by volume). In the event that you should have to drain and/or refill the Solar Boiler™, follow these instructions to
ensure proper system operation.
Draining the HTF (heat transfer fluid)
The HTF should never be drained during system operation. HTF should only be drained in
the morning before system start up, or at least one hour after system shut down in the evening.
This is to ensure that the HFT is not excessivily hot.
✍
❏Remove the cover from the Solar Boiler. Turn the Solar Boiler off using the switch,
(ON = green; OFF = black), located under the cover. (Switch only available on some
models. If no switch, disconnect the wires)
❏Disconnect the 3/8" copper lines from the Solar Boiler™. Allow any fluid from
the lines to drain into a container. Leave lines disconnected.
❏To drain the fluid in the Solar Boiler™ module, you will have to wait until
their is enough sunlight for the system to operate. With a container under the
outlet of the pump, turn the Solar Boiler™ ON. Keep the unit on until no
liquid comes out of the pump. Turn the Solar Boiler™ OFF. Do not turn
the system on again until Solar Boiler™ is refilled.
❏The system is now drained. Connect the 3/8" copper lines to the Solar Boiler™ unit. To refill the Solar Boiler™, follow
the instructions listed below.
Refilling the Solar Boiler™ with HTF (heat transfer fluid)
✍
❏Remove the cover from the Solar Boiler. Turn the Solar Boiler off using the switch, (ON = green; OFF = black), located
under the cover. (Switch only available on some models. If no switch, disconnect the wires)
❏Locate and remove the pressure relief valve attached to the vent tube at the back of the unit.
❏Locate the fill tube at the side of the unit and remove the brass cap from the fill tube. Using the wooden dowel provided
check the fluid level in the reservoir. This level should be about 8 - 12” on the dowel while the system is operating. If the
level is low contact your dealer or Thermo Dynamics Ltd. before continuing.
❏If the fluid level is low inspect the system for signs of leakage. Inspect all visible fittings on the Solar Boiler and the connec-
tions at the solar collector on the roof. Also inspect under the Solar Boiler case for signs of HTF on the floor. Propylene
glycol USP dries very slowly and will remain on surfaces for an extended period of time.
❏The recommended heat transfer fluid is a 40/60 mixture by volume of Propylene Glycol USP and distilled water. Fluid
should be added to the Solar Boiler with a funnel to prevent spillage. When adding fluid, follow the step 17 on page 8.
❏Replace the brass cap on the fill tube and hand tighten. Replace the
pressure relief valve on the vent tube at the back of the Solar Boiler.
Turn the Solar Boiler ON using the switch or by connecting the PV
wires, replace the cover on the Solar Boiler.
Back Front
pump
motor
vent tube

Solar Boiler™ Installation Manual (OG-300), page 12 of 14IN.410.06.DEC/99
Solar Boiler™ Service Log
To ensure optimum
performance from
your Solar Boiler™,
Thermo Dynamics
Ltd. recommends
that the system is
back flushed at least
every 6 months. This
service log must be
kept up to date.
Failure to do so will
render the warranty
null and void.
Back Flushing Procedure.
• Close the valve at the bottom of thesolar storage tank near the
Flexhose™ that connects the tank to the Solar Boiler™, shown
in the diagram in the diagram.
• Connect a hose to the drain bib at the bottom of the solar
storage tank, and place the free end in a drain.
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
Date:____________ Technician__________ Back Flush_________
Comments____________________________________________________
For more system maintenance procedures, please refer to your
installation manual, or contact your local dealer, or Thermo
Dynamics Ltd. at [phone]
solarstoragetank
AA
AA
™
bottom tank
tee
drain bib
Flexhose™(15") long nipple
tank drain port ball valve
A
A
AA
AA
Operating and Emergency Procedures
Once you have installed and connected your Solar Boiler™ to
the photovoltaic module, you are ready to enjoy free solar
energy.
To determine if your Solar Boiler™ is operating properly,
perform the following simple tests:
• On a bright sunny day, draw some water from your hot
water tap. Feel the cold water inlet pipe to your solar storage
tank. This pipe should be cold. Carefully feel the pipe exiting
your solar storage tank. It should feel significantly warmer.
CAUTION: THE SOLAR BOILER™ IS CAPABLE OF
PRODUCING VERY HOT WATER. DO NOT HOLD
ON TO THE PIPE EXITING YOU SOLAR STORAGE
TANK.
• Another method for checking the operation of your Solar
Boiler™ is to read the temperature gauge located on the front.
At the end of a bright Sunny day, open a hot water faucet and
observe the thermometer. The temperature of the water
leaving the solar tank should be higher than the temperature of
the city supply water going into the tank.
In the event that the there is an emergency such as a leaky tank,
turn off the Solar Boiler™ using the switch or disconnecting
the wires from the photovoltaic module. Close all valves as
shown in the diagram:
Ball Valve #1 - Close
Ball Valve #2 - Close
Ball Valve #3 - Close
If you are planning to be away for extended periods of
time, turn the system off using the switch located under
the cover of the Solar Boiler™.
cold water
supply
AA
AA
AA
AAA
domestic
hot water
supply
close main water
supply valve
Tee connector Ball valve #1
Tee connector
solar storage tank auxiliary
DHW tank
Solar Boiler™
cold inlet hot outlet cold inlet hot outlet
Ball valve #2 Ball valve #3
heat trap heat trap
For normal solar operation:
• Ball valve #1 - close
• Ball valve #2 - open
• Ball valve #3 - open
mixing valve
If there is only a problem with the solar tank, you can
open Ball Valve #1 to bepass the solar and continue to
have hot water until the system is serviced.

Solar Boiler™ Installation Manual (OG-300), page 13 of 14IN.410.06.DEC/99
System Configurations and Specifications
System Collectors Surface Area Boiler Module DHW Load
SB32-9 PV 1 S32B 2.91 m2 (32 ft2) SBM-9DC < 250 L/day
SB 64-9 PV 1 S32A 5.82 m2 (64 ft2) SBM-9DC 250 - 400 L/day
1 S32B
SB32-9PV SB64-9PV
Life Expectency of major components. Please note that these are only projected values of when a component may need to be
replaced.
• Solar Collectors 35 years
• Photovoltaic Module 25 years
• LifeLine® Tubing 50+ years
• Solar Boiler™ Module c/w
DC Motor 15 years
Pump 15 years
Heat Exchanger 50+ years
Linear Current Booster 50+ years
Solar Boiler™ Module,
SBM-9DC
Solar Boiler™ Module,
SBM-9DC
S32A Solar Collector S32A Solar Collector
S32B Solar Collector
Photovoltaic Module
Photovoltaic Module
Thermo Dynamics Ltd.
44 Borden Avenue
Dartmouth, Nova Scotia
Canada, B3B 1C8
Tel: (902) 468 - 1001
Fax: (902) 468 - 1002
www.thermo-dynamics.com
[email protected]
your authorized dealer:

Solar Boiler™ Installation Manual (OG-300), page 14 of 14IN.410.06.DEC/99
Material Safety Data Sheet for PROPYLENE GLYCOL, USP [HEAT TRANSFER FLUID]
The HTF (heat transfer fluid) used in this Solar Boiler™ system is a mixture of Propylene Glycol, USP and distilled water
(40/60)% by volume.
The following is a brief outline of the Material Safety Data Sheet for Propylene Glycol, USP. For more information, contact Van
Waters & Rogers, reference MSDS: L1173.
Product code: VW&R Code: L1173
CAS Registration #: 57-55-6
Product Name: Propylene Glycol
Product Supplier: Van Waters & Rogers
9800 Van Horne Way
Richmond
British Columbia
V6X-1W5
1. INGREDIENTS:
(% w/w, unless otherwise noted)
Propylene glycol CAS# 000057-55-6 99%
2. ENVIRONMENTAL AND DISPOSAL INFORMATION:
Action to take for Spills/Leaks: Cover with absorbent material, soak up and sweep into bag.
Disposal method: Incinerate or bury away from water supplies in accordance with local regulations.
3. HEALTH HAZARD DATA:
EYE: May cause slight transient eye irritation. Corneal injury is unlikely.
SKIN CONTACT: Essentially nonirritating to skin on prolonged contact Repeated exposure may cause slight flaking,
tenderness, and softening of skin.
SKIN ABSORPTION: A single prolonged skin exposure is not likely to result in absorption of harmful amounts.
INGESTION: Single dose oral toxicity is extremely low. No hazards anticipated from ingestion incidental to industrial
exposure.
INHALATION: A single prolonged (hours) inhalation exposure is not likely to cause adverse effects. Mists are not
likely to be hazardous.
CHRONIC EFFECTS OF EXPOSURE: Repeated excessive ingestion may cause central nervous system effects.
4. FIRST AID:
EYES: Irrigate immediately with water for at least 5 minutes.
SKIN: Wash off in flowing water or shower.
INGESTION: No adverse effects anticipated by this route of exposure.
INHALATION: No adverse effects anticipated by this route of exposure.
NOTE TO PHYSICIAN:
No specific antidote. Supportive care. Treatment based on judgement of the physician in response to reactions of the patient.