Solar Thermal Collectors Technical Reference To maintain the standards used across the Solar Energy Industry, many of the calculations and measurements in this workbook are in metric units. However, we have included factors and equations to convert many of these units from metric to Imperial. If you need assistance, please ask your sales representative. SunMaxx Solar Inc, 15 Catherwood Rd. Suite C, Ithaca, NY 14850 USA Ph: (877)-786-6299 www.sunmaxxsolar.com Solar Thermal Collectors Technical Reference Table of Contents 1.0 What does SunMaxx offer? ............................................................................................................................... 1 2.0 How to Get the Most out of a SunMaxx System ............................................................................................... 2 2.1 Positioning the Collector: Azimuth and Inclination Angle ............................................................................ 3 3.0 How Does a SunMaxx System Work ........................................................................................................... 4 3.1 Vacuum Heat Pipe Collectors ........................................................................................................................ 5 3.1.1 The SunMaxx Tube .......................................................................................................................... 5 3.1.2 The SunMaxx Vacuum Tube Manifold ............................................................................................ 7 3.2 Flat Plate Collectors ....................................................................................................................................... 7 3.3 Flat Plate vs. Vacuum Heat Pipe .............................................................................................................. 9 3.4 Accessories ............................................................................................................................................ 10 3.4.1 Mounting Kits ................................................................................................................................ 10 3.4.2 Differential Temperature Controller ............................................................................................. 11 4.0 How does a SUNMAXX System Perform ................................................................................................... 11 4.1 Solar Fundamentals ............................................................................................................................... 11 4.2 Thermal Performance ........................................................................................................................... 12 5.0 How to Design a SUNMAXX System ......................................................................................................... 13 5.1 Determining Number of Collectors ....................................................................................................... 13 5.2 Determining Solar Storage. ......................................................................................................................... 15 5.2 Flow Rate ............................................................................................................................................... 15 5.3 Selecting Pipe Size ................................................................................................................................. 16 5.3.1 SunMaxx LineSet ........................................................................................................................... 16 5.4 The Circulator Pump .............................................................................................................................. 17 5.5 Sizing Expansion Vessel ......................................................................................................................... 19 5.6 Hydraulics .............................................................................................................................................. 21 5.6.1 Collector System ............................................................................................................................ 21 5.6.2 Overall System Design ................................................................................................................... 21 5.6.4 Common System Design Layouts .................................................................................................. 23 6.0 How to Install a SUNMAXX System ........................................................................................................... 30 6.1 General .................................................................................................................................................. 30 SunMaxx Solar Inc, 15 Catherwood Rd. Suite C, Ithaca, NY 14850 USA Ph: (877)-786-6299 www.sunmaxxsolar.com Solar Thermal Collectors Technical Reference 6.2 Manifold Connections ........................................................................................................................... 30 6.3 Flush Mounting System ......................................................................................................................... 31 7. System Commissioning Guidelines................................................................................................................ 32 7.1 Safety First ............................................................................................................................................. 32 7.2 Mounting collectors .............................................................................................................................. 32 7.3 Setting Pipe Runs ................................................................................................................................... 32 7.4 Tying Solar Tank to DHW Storage Tank ................................................................................................. 33 7.5 Pump Station Connection ..................................................................................................................... 33 7.6 Controller .............................................................................................................................................. 33 7.7 Pressurizing Line Set .............................................................................................................................. 34 7.8 Flooding and Purging ............................................................................................................................. 34 7.9 Inserting tubes- ..................................................................................................................................... 35 7.10 Performance assessment ...................................................................................................................... 36 8.0 How to Maintain a SUNMAXX System ...................................................................................................... 36 8.1 Periodic Checks ..................................................................................................................................... 36 8.2 Optional Checks..................................................................................................................................... 37 8.3 Five Year Checks .................................................................................................................................... 37 9.0 Troubleshooting ........................................................................................................................................ 38 9.0 Appendix ................................................................................................................................................... 40 9.1 Products ................................................................................................................................................ 40 9.2 System Sizing Tables .............................................................................................................................. 43 9.3 Checklist ................................................................................................................................................ 50 9.4 Commissioning Sheet ............................................................................................................................ 52 SunMaxx Solar Inc, 15 Catherwood Rd. Suite C, Ithaca, NY 14850 USA Ph: (877)-786-6299 www.sunmaxxsolar.com Solar Thermal Collectors Technical Reference 1.0 What does SunMaxx offer? Assured Quality through Independent Testing Solar Energy SunMaxx Solar Hot Water Collectors are SunMaxx is a leading solar energy company across independently tested and certified by the leading the United States, and around the world. With agencies in the United States, and around the three domestic offices, offshore manufacturing world. SunMaxx Vacuum Heat Pipe and Flat Plate facilities, and future expansions in the works, Solar Collectors are both Solar Keymark and SRCC SunMaxx Solar looks forward to an era of Certified to provide optimum performance and affordable solar energy products by offering the efficiency in a variety of conditions. This very best, most efficient solar products at the very independent testing proves that SunMaxx Solar best prices. provides a comparable, or better, product than the