SunRay 1000 Solar Water Pasteurizer Installation Instructions Safe Water Systems, Inc. 1600 Kapiolani Blvd., Suite 721 Honolulu, Hawaii 96814 Phone: 808-949-3123 Fax: 808-949-3103 E-mail: info@safewatersystems.com Internet: www.safewatersystems.com
1. INTRODUCTION The SunRay 1000 Solar Water Pasteurizer uses the heat of the sun to disinfect microbiologically contaminated water and makes it safe to drink. The SunRay 1000 sets a new standard for quality, efficiency, reliability and ease of use. Installing a SunRay 1000 is straightforward and requires only a few common hand tools. Anyone with basic mechanical skills and the ability to read and follow written instructions can install a SunRay 1000. Experience with plumbing pipe and fittings is recommended but not required. ADVANTAGES * No electricity required. The SunRay 1000 operates exclusively on heat provided by the sun. Electricity is not required. The SunRay 1000 is designed for areas where electrical power is not available. * Low Maintenance. Manufactured from impact-resistant glass vacuum tubes and corrosion-resistant stainless steel, the SunRay 1000 system is extremely durable and will operate for many years with a minimum of maintenance. With only one moving part, the SunRay 1000 can be serviced quickly and easily with common hand tools. * Automatic Operation. SunRay 1000 functions automatically and does not require a technician to operate it. * Effective. As proven in several university tests and confirmed by government agencies, SunRay 1000 is 99.999% effective in killing disease-causing bacteria, viruses and other harmful microbes found in contaminated water. This is accomplished through pasteurization, the process of disinfection by the application of heat. Water is heated to a minimum temperature of 80 o C (170 0 F) which is sufficient to kill all harmful organisms. * High Efficiency. SunRay 1000 will disinfect up to 1,000 liters (264 gallons) of water per day, depending on sunlight conditions. On very sunny days, even more water will be disinfected. On cloudy day, less water will be disinfected. 2
2. BEFORE YOU START For best performance, the SunRay 1000 solar collector should be located where it will be exposed to the sun from 9:00 am to 4:00 pm every day of the year. Make certain that the area is free from shading throughout the entire day. Do not place it under or near trees, or close to a building that will shade the solar collector. Any shading during the day will significantly reduce the quantity of safe drinking water produced. When the installation site is north of the equator, position the SunRay 1000 collector facing south. If the location chosen for the installation has shade in the east or is usually cloudy in the morning, position the collector facing to the southwest to take advantage of the afternoon sun. If there is shading in the west or it is usually cloudy in the afternoon, position the collector facing to the southeast for better performance in the morning sun. When the installation site is south of the equator, position the SunRay 1000 collector facing north. If the location chosen for the installation has shade in the west or is usually cloudy in the morning, position the collector facing to the northeast to take advantage of the afternoon sun. If there is shading in the east or it is usually cloudy in the afternoon, position the collector facing to the northwest for better performance in the morning sun. The main components of the system are a vacuum tube solar water heating collector, a high-efficiency heat exchanger, stainless steel frame, and thermal control valve. Tools Required For Installation One large and one very large flat faced adjustable ( crescent ) wrenches One large and one very large grooved, square jaw ( water pump ) pliers 10 mm combination wrench 10 mm socket and ratchet with 3 extension Screwdrivers, both straight and Phillips type Teflon (plumber s) tape for sealing pipe threads Copper tubing cutter (if copper pipe is used) Hole saw to drill holes in water tanks for bulkhead fittings If mounting to concrete foundation: drill with masonry drill bit Liquid dish soap, water and small bucket Tarp, opaque heavy duty plastic sheet or other suitable material to cover solar collector, 5 meters X 4 meters or larger Additional Parts Required For Installation Mounting hardware for solar collector Water filter housing and mounting bracket Water filter cartridge 3
Safe water storage tank Shut-off valves for water source, solar collector and safe water storage tank Pipe and pipe fittings to connect water source and tanks to SunRay 1000 Pipe insulation for collector outlet pipe and heat exchanger-to-collector pipe Aluminum foil tape to wrap pipe insulation NOTE: Safe Water Systems provides installation kits for various types of installations that include all these parts. They may be ordered at the time of purchase and included with the SunRay 1000. Mounting Foundation The SunRay 1000 is designed to be installed on the ground, a raised foundation or on a flat concrete roof. It is not designed to be installed on an angled roof. The solar collector frame must be fastened to a solid and secure foundation. Because the collector is a large surface area, precautions must be taken to prevent SunRay 1000 from being blown over and damaged during heavy storms. When mounting the SunRay 1000 on the ground, a concrete foundation or raised pillars of concrete or concrete blocks is recommended. The SunRay 1000 may be anchored directly to a flat concrete roof. See the Mounting Configuration diagram for details on foundation alternatives. NOTE: to assure proper performance, the foundation must be level. Mounting Hardware Appropriate hardware must be used to attach the SunRay 1000 to the concrete foundation or a concrete roof. If mounting to concrete, special concrete anchors are required. If mounting to wood, lag screws or machine bolts are recommended. Refer to the Mounting Configuration diagram for details. Water Filter Housing and Filter Cartridge Unless the water is very clean, a particulate filter is required to prevent dirt and debris from clogging the solar collector, pipes and the thermal control valve. The recommended type of filter cartridge is a very fine stainless steel mesh. The advantage of this type of filter is that it does not require replacement. Instead, when the filter is dirty, it can simply be removed, washed and reinstalled. Where the water source is relatively clean, a 100-micron cartridge is recommended. Where the water may be dirty, a 5 or 10 micron cartridge is recommended. The filter must be cleaned frequently as needed. When the system is first used, the filter cartridge should be inspected every day to see if it needs to be cleaned. 4
A stainless steel filter cartridge does not remove bad taste, odor, minerals, salt or chemical pollutants. An activated carbon filter may be used in addition to the stainless steel filter cartridge to remove bad taste and odor as well as some other pollutants. Carbon filters do require periodic replacement. NOTE: It is critically important that the filter is cleaned on a regular basis. If the filter becomes plugged up it will block the flow of water and cause the solar collector to overheat and boil the water inside the collector. Boiling water and steam is very dangerous and can easily injure people. Inlet Shut-Off Valve A shut-off valve should be installed on the water supply source so that the water can be turned off while the system is being maintained or repaired. The shut-off valve should be located at the source on the inlet pipe before the filter. Ball valves or gate valves are commonly available. Ball valves are recommended as they last longer and are not as likely to leak as gate valves. Inlet and Outlet Shut-Off Valves To facilitate the servicing of the SunRay 1000, shut-off valves can be installed on the supply inlet and the discharge outlet connections on the heat exchanger. NOTE: these valves must be open when the solar collector is uncovered. If the inlet or outlet valves are closed while the collector is heating, the collector may rapidly overheat, build up pressure and cause the release of dangerously hot steam. TO PREVENT OVERHEATING AND THE ACCIDENTAL RELEASE OF DANGEROUSLY HOT STEAM, DO NOT CLOSE THE INLET OR OUTLET VALVES DURING NORMAL OPERATION. If the solar collector must be taken out of operation for any reason, the solar collector MUST be covered to prevent overheating. A heavy tarp or opaque plastic sheet must be available for this purpose. Safe Water Storage Tank and Shut-Off Valve Once the disinfected water exits the SunRay 1000, it must be stored in a sanitary storage tank. The safe water storage tank must be covered and tightly sealed to prevent any possibility of recontamination from contact with insects, rodents, dirty hands, dirty water containers, etc. The safe water storage tank must have a shut-off valve on its outlet so that the clean water delivery can be turned on and off. A locking-type valve can be installed to prevent unauthorized access, or a simple ball valve may be used. 5
The tank should be cleaned every 30 to 60 days with a mild solution of chlorine (bleach) and water to insure that it remains sanitary, clean and free from bacteria. NOTE: do not use contaminated water to clean the tank. Use only pasteurized water. NOTE: If possible, the safe water storage tank should be positioned so that the inlet to the tank (at the top of the tank) is lower than the outlet of the solar collector (48 from the base of the SunRay 1000) so that water can flow without resistance from the outlet into the tank. If the tank inlet point is higher than the collector outlet the water in the pipe creates a back pressure on the thermal control valve. If the safe water holding tank inlet is higher than the thermal control outlet, a check valve MUST be installed to prevent the stored water in the tank from causing backpressure on the thermal control valve. See the Check Valve section below for more information. Pipe and Fittings for Water Source and Tanks Since they will have very hot water inside them, the pipes and fittings within 5 meters of SunRay 1000 must be capable of withstanding high temperatures. Copper, special high temperature plastic pipe (CPVC), or galvanized metal pipe and fittings must be used. Regular plastic pipe such as PVC and polyethylene and other plastic pipes designed for cold water use are not acceptable for use near the SunRay 1000 and must not be used. If they are used, they will easily melt. NOTE: Galvanized steel fittings may be connected to the brass fittings on the heat exchanger but they must not be connected to copper fittings. When galvanized and copper fittings contact each other, corrosion will occur and the fittings will eventually disintegrate. NOTE: If special high temperature plastic pipe (CPVC) is used, it must be covered to prevent deterioration from the harmful ultra-violet rays of the sun. If it is not protected, the pipe will become brittle and eventually fail Additional Parts That May Be Required For Installation, Check Valve Inlet Supply Tank with Float Valve Hand Pump, Solar Pump or Electric Pump Check Valve If the safe water storage tank inlet (at the top of the tank) is higher than the thermal control valve outlet (48 from the base of the SunRay 1000), a check valve must be installed to prevent the stored water in the tank from causing backpressure on the thermal control valve. 6
The check valve must be the swing type, not the spring type. An ordinary spring type check valve has too much resistance and will not open. Spring check valves should not be used unless they are specially designed to open at very low pressure (2 pounds or less). It is critical that the check valve must be installed in a horizontal section of the pipe between the heat exchanger outlet and the safe water storage tank. If the check valve is not level (and is angled in the wrong direction) it will allow water to flow in the reverse direction and therefore not prevent backpressure on the thermal control valve. Water will only flow in one direction though the check valve. A marking on the body of the valve indicates the direction the water flows. Be sure to install the check valve in the proper direction so that the water flows from the solar collector to the tank and does not flow from the tank back to the solar collector. Inlet Supply Tank and Float Valve An inlet supply tank may be required under the following circumstances: 1) If the water source is pressurized 2) If the water source is below the level of the SunRay 1000 (river, lake, shallow well, etc.) Water Source is Pressurized The thermal control valve is not designed to operate with a pressurized water system with greater than 15 pounds of pressure. With a pressure of more than 15 pounds, the vacuum tube seals (that seal the tubes to the header box) may leak. If the water source pressure is greater than 15 pounds, the easiest solution is to install a water tank with float valve a minimum of 3 meters (9 feet) above the base of the solar collector. The float valve automatically keeps the tank full of water by turning the pressurized water source on and off while the water in the tank flows by gravity into the SunRay 1000 system. The size of tank required for the inlet water supply is dependent on the water source. If the water source is always available and is reliable, then a very small tank can be used. If the water source is intermittent or unreliable, then a tank with a larger capacity will be required. In either case, a larger tank is never a problem. A float valve must be installed in the elevated supply tank to turn off the flow of water when the tank is full. When the water level in the tank goes down, the float valve opens and allows water to fill the tank again. When the tank is full, the float valve shuts off the water supply. Float valves are available at hardware stores, plumbing supply stores or where water tanks are sold. 7
Although the type of float valve that is commonly used in toilets is satisfactory, a high quality, commercial-type float valve is highly recommended as it will be more reliable. Always purchase the best quality float valve that is available. Water Source is at Lower Level If the source of water is below the level of the SunRay 1000, such as a river, lake or shallow well, an elevated supply tank must be installed to provide a gravity flow of water to the SunRay 1000. The tank must be elevated a minimum of 3 meters above the base of the solar collector. The tank must be filled with enough water every day to supply the SunRay 1000. On a sunny day up to 1,000 liters will be needed. There are several ways the supply tank can be filled: 1) By hand. Carry water from water source and pour it into the supply tank. 2) By a hand operated pump (hand pump) 3) By a solar electric powered pump (solar pump) 4) By an electric pump (if electricity is always available) A float valve is required if a solar or electric pump is installed. A float valve is not necessary if the supply tank is filled by hand or with a hand pump. Carrying water by hand is the least expensive option, but requires manual labor. Using a hand pump allows the tank to be filled with a minimum amount of labor. Hand pumps may be purchased locally or from Safe Water Systems. If purchased locally, be sure the pump is capable of pushing water to a higher elevation. Many hand pumps only pull water from a lower level to bring it to ground level. A solar electric powered pump kit can automatically supply water to the SunRay 1000. A solar electric panel generates electricity from sunlight and powers a 12-volt pump. The pump can either fill an elevated supply tank, or it can be used to provide pressurized water directly to the SunRay 1000 inlet, without the need for an elevated tank. If an elevated tank is used, the solar pump automatically fills the tank whenever the sun is shining. When the tank is full, a float valve shuts off the flow of water, causing a pressure switch to shut the pump off. When the water level drops, the pressure switch will turn the pump on again. If an elevated tank is not used, the pump turns on and off automatically as needed to pressurize the water supply to the SunRay 1000. 8
Solar electric powered pump kits are considerably more expensive than hand pump kits, and they will require more maintenance and repair. Their primary advantage of solar pumps is that they operate automatically Where electricity is available, a conventional electric pump can be used to pump water into the supply tank. The tank must have a float valve to shut the flow of water off when the tank is full. INSTALLING THE SUNRAY 1000 SYSTEM Introduction Before beginning to assemble the SunRay 1000 make sure that you have all the necessary tools, materials and supplies. NOTE: All threaded pipe fittings must be wrapped with Teflon (plumber s) tape before assembly to prevent leaking. Although it is highly recommended, if Teflon tape is not available, plumber s thread paste may be used. NOTE: the SunRay 1000 frame is held together with stainless steel bolts and nuts. The hardware kit which is shipped from the factory does not contain lock washers for the bolt sets. If a hardware kit was supplied from Safe Water Systems, lock washers were provided in this kit. In any case, stainless steel lock washers or thread locking compound should be used to prevent the bolts and nuts from loosening. CAUTION: The vacuum tubes are glass. They can easily be broken if they are not handled carefully. After they are installed, they are strong and not easily broken. The most vulnerable parts of the tubes are the ends. One end has a pointed nipple. If this nipple is broken, the vacuum will be lost and the tube cannot be used. Handle the tube carefully at all times. Do not take the tubes out of the box until they are ready to be installed in the solar collector. If the SunRay 1000 is being installed in an area where it might be damaged by children, animals or flying debris, a wire mesh screen should be suspended above the top of the solar collector to prevent the tubes from breaking. Contact Safe Water Systems for more information. Installing the Inlet Supply Tank and Float Valve (If one is required and does not already exist) The bottom of the supply tank must be located at least 3 meters higher than the bottom of the solar collector frame. The supply tank can be placed on a roof or mounted on a tower or frame. It is necessary to install pipe from the water source to the supply tank and from the supply tank to the SunRay 1000 inlet connection. 9
If the flow of water into the supply tank is continuous then a float valve is required to stop and start the flow of water. The float valve mounts on the inside of the supply tank. Follow the manufacturer s instructions INSTALLATION PROCEDURE Carefully open the shipping crate. Remove all the boxes. Handle the long boxes that contain the vacuum tubes with great care. Do not allow them to be dropped. Open the vacuum tube boxes and inspect the tubes without removing them to see if any of them have been broken. A minimum of 50 tubes are required for the solar collector. 60 tubes are provided. 10 tubes are spares and should be stored in a safe and secure location The solar collector frame is made of two halves (left and right) that are joined together. Each half is assembled separately and then connected to the other half with the header tank in the middle. 25 vacuum tubes are installed on each side of the header tank. The heat exchanger is mounted under the solar collector. NOTE: The Front of the solar collector is the part that is close to the ground. The Back of the solar collector is the part that is raised off the ground by the vertical legs of the frame. The Left and Right sides are from the perspective of standing at the Back, looking at the back of the collector. Outside is the side facing away from the side of the solar collector. Inside is the side facing the middle of the solar collector. 10
1. The frame is built from four triangular Sections (Left Outer, Left Inner, Right Outer, Right Inner). Two Sections are joined together to make a Half Frame (Left Half, Right Half). The two Half Frames are joined together with the Header Tank and Heat Exchanger in the middle. Assemble the Left Outer Section from pieces #1, #2, #3, #4 and #5 as shown in the picture above. Assemble the other three Sections from the pieces as shown in the chart below. Note: in the left and right inner sections, the support piece is vertical, not angled as shown in the picture above. 11
Section Vertical Horizontal Support Diagonal Left Outer 1 2 3 4 Right Outer 15 16 3 18 Left Inner 10 16 9 8 Right Inner 37 2 23 19 2. Assemble the Sections to make a Half. Left Outer and Left Inner Sections connect together to make the Left Frame Half. The Right Outer and Right Inner Sections connect together to make the Right Frame Half. The pieces that connect the sections together are shown in the chart below. Frame Half Top Middle Bottom Left 6 21 7 Right 20 7 21 Note that on pieces #21 and #7 there is an extra hole on one end. This extra hole must go on the outside of each half. Note that the bottom piece of both Half Frames is opposite orientation to the middle pieces. 3. Install diagonal braces. The four #13 pieces are installed diagonally between the vertical legs and the horizontal top pieces of each half. 4. Attach pieces #11 and 24. Attach piece #11 to the outside of the Right Half section. Attach piece #24 to the outside of the Left Half section. Note that there is an extra hole at one end of pieces #11 and 24. This end goes to the top of the frame. Leave the nuts loose at they will need to be removed to install additional pieces later. 12
5. Install the Reflectors, piece #12. 6. Join the Left Half and Right Half. Using the two pieces #27 and the three pieces #25, connect the two Frame Halves together. 7. Install pieces #26 and the Vacuum Tube Socket Frame #32. Since the same bolts hold both pieces, they must be installed at the same time. Do not tighten the bolts until after the Vacuum Tubes have been installed. 13
8. Mount the Frame. When mounting the SunRay 1000 frame to either a concrete footing on the ground or a concrete roof, it must be firmly anchored to prevent it from being blown over by strong winds. See the Mounting Configuration diagram for suggestions on mounting methods. NOTE: It is critically important that all of the foundation points are level with each other so that the frame sits perfectly level. If the frame is not level, there may be air pockets in the tubes which will cause areas of the tube to over heat. 9. Install the Header Tank. Lay the Header Tank onto pieces #27 and tighten the nuts. 10. Install the Vacuum Tubes. Remember to always handle the tubes with great care to prevent them from breaking. Two people are needed to install the tubes. Person #1 holds the open end of the tube, lubricates it and inserts it into the Header Tank. Person #2 holds the closed end of the tube and puts it into the Tube Socket Frame. 10.1 Person #1 slips a green cover ring over the open end of the tube. 10.2 Person #1 lubricates the open end of the tube by dipping it in a bucket that contains a mixture of liquid dish soap and water. Person #2 holds the closed end of the tube. 10.3 Person #1 inserts the open end of the tube carefully into the Header Tank. Both people may carefully twist the tube to force it through the sealing ring inside the Header Tank. Person #2 must be careful not to let the nipple to hit the Socket Frame during this process. The tube should be inserted only far enough so that the hard green plastic fitting be put on the closed end of the tube. 14
10.4 After the open end of the tube goes through the seal in the Header Box Person #2 puts the hard green plastic fitting on the closed end of the tube. The plastic fitting is then lowered into the Tube Socket Frame. Now the tube can be carefully pulled back so that the fitting rests loosely in the Socket Frame. Be certain that that the silicon sealing ring inside the Header Tank is not accidentally pushed into the tank. This will cause a leak. 10.5 To fit the tubes into the frame, it is necessary to push the tube into the Header Tank and then pull it back into the Tube Socket Frame. When installing the tubes in the first side of the frame, this is not a problem. When the second side is installed it is critically important that the tubes are not inserted into the Header Tank so far that they hit the tube on the opposite side. If the tubes hit each other, they can easily break. 10.6 Person #1 must hold the tube and prevent it from going in too fast. If the tube slips in too fast, it can go in too far and cause the tube to break. If a tube does break, it is necessary to remove all of the broken glass from the inside of the header tank. This is difficult to do. Be very careful when inserting the tubes on the second half of the frame so that the tubes do not break. After all the tubes are installed, tighten the Tube Socket Frame mounting bolts, adjust all the tubes to the same length and adjust the socket connectors so the tubes are held snugly in the frame. 15
11. Install the Socket Protection Panel. Using the small sheet metal screws, install the rounded cover piece # 36 over the outside end of the tubes. 12. Install the Heat Exchanger. Put The Heat Exchanger on to the horizontal frame pieces in the middle of the frame. The Heat Exchanger is held in place with pieces #30. The pieces must be wrapped around the Heat Exchanger and the ends must be bent to shape. The long pieces of threaded rod inserts into the holes near the heat exchanger. Leave the nuts loose until after the pipe connections are made on the heat exchanger. 12. Install the Header Tank Fittings. These parts include the thermal control valve, air vent and fittings that go on the top end of the Header Tank as shown 16
NOTE: IT IS CRITICALLY IMPORTANT TO HOLD THE PIPE ON THE HEADER TANK SECURE WHILE ATTACHING FITTINGS TO IT. IF THE PIPE ON THE HEADER TANK IS TWISTED IT CAN BREAK OFF INSIDE THE HEADER TANK. HAVE ONE PERSON HOLD THE PIPE WITH A PIPE WRENCH TO PREVENT IT FROM TWISTING WHILE ANOTHER PERSON TIGHTENS THE BRASS TEE ONTO THE PIPE. WHEN INSTALLING OTHER PARTS ON TO THE TEE, ALWAYS HOLD THE HEADER TANK PIPE TO PREVENT IT FROM TWISTING. NOTE: some of the threaded connections of the fittings of the assembly on the header tank outlet are quite loose and are not a good fit of the threads. Wrap the threads many times with Teflon tape to prevent leaking. If the two pieces bottom out and cannot be turned any further and it is not in the correct position, remove the piece that is being inserted and put on additional Teflon tape to take up the extra gap. Install the Header Tank outlet parts in the following order: 1. Brass tee onto Header Tank outlet pipe. Final position must be perfectly horizontal 2. Elbow onto tee. Final position must be with opening perfectly vertical 3. Large reducer busing into elbow. 4. Small reducer bushing into large reducer bushing 5. Air vent into small reducer bushing. Final position must be perfectly vertical. 6. Thermal control valve into tee. Final position must be with outlet perfectly vertical 7. Compression fitting. Leave loose until collector outlet pipe is installed. 13. Install the Heat Exchanger pipes. The short copper pipe connects the compression fitting on the outlet of the Thermal Control Valve to the compression fitting on the left/back side of the Heat Exchanger. The long copper pipe connects the compression fitting on the right/front of the Heat Exchanger to the compression fitting and elbow on the bottom of the Header Tank. (Remember to hold the pipe exiting the bottom of the Header Tank while attaching the fittings). Pasteurized cold water outlet to storage tank Preheated hot water to bottom of solar collector Pasteurized hot water from top of solar collector Contaminated water inlet from supply source 17
14. Insulate Pipes. The Header Tank outlet fittings, Thermal Control Valve, pipe from the Thermal Control Valve to Heat Exchanger, and pipe from Heat Exchanger to Solar Collector Inlet must all be insulated. Most pipe insulation will not withstand exposure to sunlight and must be covered. The insulation can be covered with aluminum tape (commonly used in the heating and air conditioning industry) or other suitable material. If an installation kit was supplied by Safe Water Systems pipe insulation and a roll of aluminum foil tape was provided. 15. Install the Filter Housing. The filter must be installed in the pipe from the water source that goes to the inlet connection on the heat exchanger. If the installation requires an inlet supply tank, the filter may be placed before this tank to prevent the accumulation of dirt and particles in the tank. If an inlet supply tank is not required, the filter can be mounted anywhere between the water source and the inlet connection on the heat exchanger. The filter housing must be mounted firmly to prevent damage to the pipes while removing the filter cartridge. NOTE: there is only one correct direction in which the filter housing can be installed. When connecting it to the pipes, be certain that opening marked In is connected to the water source, and the opening marked Out is connected to the heat exchanger inlet fitting. A shut-off valve must be installed between the water source and the filter so the water supply can be turned off while cleaning the filter cartridge. The valve can be located next to the filter or strainer, at the source, or at another convenient place. 15. Pipes and Fittings. Pipes and fittings within 5 meters of the heat exchanger must be capable of withstanding hot water. Copper, galvanized, or special high temperature plastic pipe (CPVC) and fittings must be used. PVC, polyethylene and other plastic pipes that are designed for cold water are not acceptable for use near the heat exchanger as they will not withstand the high temperature. If used, they will melt. NOTE: If high temperature plastic pipe and fittings are used they must be covered and protected from sunlight. These pipes are not resistant to the ultra-violet rays of the sun, and they will become brittle when exposed to sunlight. The pipes connecting the heat exchanger to the header tank inlet, and the pipe connecting the header tank outlet to the heat exchanger should also be insulated. Cover these pipes with pipe insulation and aluminum foil tape. Other exposed pipes can be simply covered with aluminum foil tape. 18
START-UP PROCEDURE CAUTION: DO NOT ALLOW WATER TO GO INTO THE VACUUM TUBES WHEN THE TUBES ARE HOT OR WHEN THEY ARE EXPOSED TO SUNLIGHT. IF COLD WATER CONTACTS THE TUBES WHEN THEY ARE HOT, THE TUBES MAY SHATTER. THE TUBES MUST BE COLD WHEN WATER GOES INTO THE TUBES. To prevent the tubes from becoming hot, or to allow them to cool down if they are already hot, cover them with a heavy tarp, opaque plastic sheet or other suitable material that will completely block sunlight from striking the tubes. When filling the solar collector for the first time, leave the air vent off of the thermal control valve assembly until the collector is full of water. When water is flowing freely, install the air vent. After the collector is full of water and the sun is striking the tubes, the water in the tubes will begin to heat up. After several hours, the water will become hot enough to open the thermal control valve. When the brass ring on the end of the thermal control valve is almost too hot to touch it is almost ready to open. When the thermal control valve opens, water will flow out of the solar collector, through the heat exchanger and into the storage tank. When cold water contacts the thermal control valve, the valve will close and wait for the water to be heated again. After several cycles the thermal control valve will stay open for longer periods of time. NOTE: It is important that the solar collector is always full of water. If it runs dry, the solar collector will overheat and boil the remaining water inside it. If water is not available for any reason, the solar collector should be covered to prevent damage. MAINTENANCE The filter cartridge must be cleaned frequently to remove accumulated dirt and debris. How often it needs to be cleaned depends on how dirty the water is. If the water is very dirty, check the filter every day. If it does not need cleaning every day, check after one week, or progressively longer periods of time. NOTE: It is critically important that the filter is checked and cleaned on a regular basis. If the filter becomes clogged, it will prevent water from entering the solar collector, which will cause it to overheat and boil the water inside the tubes. DO NOT ALLOW COLD WATER TO GO INTO THE SOLAR COLLECTOR IF THE TUBES ARE HOT! No regular maintenance is required for the solar collector. 19
SERVICING THE THERMAL CONTROL VALVE The thermal control valve should operate for many years before it needs new internal parts, unless it becomes damaged. All the internal parts that might wear out can be replaced if necessary. There are four replaceable parts: two O-rings, a return spring and the thermal actuator. O-Ring Replacement The thermal control valve may drip a small quantity of water from the open vent end of the valve when it is operating during the day. If dripping occurs at night, then the O- rings are worn out and should be replaced. CAUTION: The thermal control valve may be very hot when the sun is shining. Dangerously hot water may come out of the valve that could burn your skin. Do not service the thermal control valve when it is hot. Service the thermal control valve after the sun has gone down or in the early morning before the sun comes up. To replace the thermal control valve O-Rings: 1. Turn off the inlet shut-off valve 2. Remove the brass cap on the end of the thermal control valve 3. Remove the main shaft by simply pulling it out by hand. 4. Remove the O-rings by carefully lifting them out of their groove and pulling them off the shaft. 5. Clean any dirt or debris out of the grooves. 6. Carefully re-install the new O-rings onto the shaft 7. Put the shaft assembly back into the valve body and insert the spring. 8. Screw the brass nut onto the valve all the way until it is tight. The brass nut will automatically compress the spring the proper amount. Thermal Actuator Replacement The thermal actuator, which is attached to the thermal control valve inside the solar collector, is designed for very long life, but it may eventually need replacing. The thermal actuator is engineered so that when it fails, it will fail closed, preventing the thermal control valve from operating, and preventing contaminated water from passing through the system. If the thermal control valve stops operating and will not open, it means that the thermal actuator may have failed and needs to be replaced. Before attempting to replace the thermal actuator, see the troubleshooting guide for other possible causes of failure. Follow the instructions above to remove the main shaft. Remove the thermal actuator by unscrewing it from the shaft. Install a new actuator and reassemble the thermal control valve. - End- 20