Inaa PVT Installation Manual

The Inaa PVT (Photovoltaic Thermal) system is an integrated solar solution that combines photovoltaic electricity generation with solar thermal heating. This manual provides comprehensive instructions for the safe installation, configuration, operation, and maintenance of the Inaa PVT system. It is intended for qualified installers and technicians. Below are key sections covering system overview, safety, installation procedures, commissioning, operation, and troubleshooting.

System Overview & Components

The Inaa PVT system consists of hybrid PV/T collectors, a mounting structure, a dual-circuit heat exchanger, a circulation pump, a storage tank, a system controller, and necessary electrical and hydraulic components.

Component	Description
PV/T Collector	Hybrid panel generating DC electricity and capturing thermal energy.
Mounting Structure	Aluminum rails and brackets for roof or ground mounting.
Heat Exchanger Unit	Transfers thermal energy from collector loop to domestic hot water or space heating loop.
Circulation Pump	Moves heat transfer fluid through the collector loop.
Storage Tank	Insulated tank for storing heated water.
System Controller	Monitors temperatures, controls pump, and manages energy flow.
DC Isolator	Safety disconnect for the PV electrical circuit.
Inverter	Converts DC power from PV to AC for grid connection or local use.
Expansion Vessel	Compensates for thermal expansion in the hydraulic loop.
Pressure Relief Valve	Safety device to prevent over-pressurization.

Safety Precautions

Installation involves electrical, mechanical, and hydraulic work at height. Strict adherence to safety standards is mandatory.

1. Electrical Safety: Disconnect all power sources before working. Use appropriate PPE (insulated gloves, safety glasses).
2. Working at Height: Use certified fall protection equipment when installing on roofs.
3. Lifting: PVT panels are heavy; use mechanical aids or multiple personnel.
4. Thermal Fluid: Use recommended heat transfer fluid. Avoid skin contact.
5. Tool Safety: Use tools rated for the task. Inspect tools before use.

WARNING! Only qualified personnel certified in electrical and plumbing systems should perform this installation. Failure to follow codes may result in injury, fire, or system damage.

Pre-Installation Planning

Proper planning ensures optimal performance and safety.

1. Site Assessment: Verify roof integrity, orientation (south-facing optimal), shading, and local building codes.
2. Component Check: Unpack and verify all parts against packing list. Inspect for shipping damage.
3. Layout Design: Plan array layout, conduit runs, and piping routes to minimize losses.
4. Permits: Secure all necessary electrical, plumbing, and building permits.
5. Utility Notification: Notify utility company if connecting to the grid.

CAUTION! Do not proceed with installation if any component is damaged. Contact supplier immediately.

Mounting & Mechanical Installation

Install the mounting structure and PVT collectors securely.

1. Install Mounting Rails: Secure rails to roof rafters or ground mounts using provided hardware. Ensure level and proper spacing.
2. Attach Collector Brackets: Fix brackets to the rails at designated points.
3. Lift and Secure Collectors: Carefully lift each PVT panel onto the brackets. Secure with clamps and bolts. Torque to specification (typically 20-25 Nm).
4. Grounding: Establish a continuous equipment grounding conductor (EGC) path for the array frame.

Tip: Use a template or layout string to ensure perfect alignment of collectors.

Electrical Wiring & Connections

Connect the PV electrical output and controller wiring.

• PV Circuit: Connect collectors in series/parallel as per design. Use UV-resistant, conduit-rated PV wire (e.g., USE-2).
• DC Disconnect: Install and wire the DC isolator near the array.
• Conduit: Run conduit from array to inverter location. Secure and weatherproof all entries.
• Inverter Connection: Connect PV output to inverter DC input. Connect inverter AC output to load center/grid per local code.
• Controller Power: Provide a dedicated 120V/240V AC circuit for the system controller and pump.

WARNING! All electrical work must comply with NEC (National Electrical Code) or local equivalent. Polarity must be correct.

Hydraulic/Piping Connections

Connect the thermal fluid loop between collectors, heat exchanger, pump, and tank.

1. Pipe Routing: Use insulated copper or PEX piping for hot fluid lines. Maintain slope to avoid air pockets.
2. Collector Loop: Connect supply and return headers to the collector array. Use high-temperature seals.
3. Pump & Valves: Install circulation pump, isolation valves, air vent, and pressure gauge in the primary loop.
4. Heat Exchanger: Connect primary (collector) loop and secondary (domestic) loop to the heat exchanger.
5. Filling & Pressurization: Fill system with recommended heat transfer fluid (propylene glycol mix). Pressurize to 1.5 bar static pressure.

CAUTION! Check for leaks thoroughly before final insulation. Do not use standard water in freezing climates.

System Commissioning

Power up and test all system functions.

1. Final Inspection: Verify all mechanical, electrical, and hydraulic connections are secure and correct.
2. Electrical Test: With DC isolator OFF, measure open-circuit voltage (Voc) of PV array. Ensure it matches design and is within inverter limits.
3. Hydraulic Test: Power pump briefly to bleed air from the loop using manual air vents. Top up fluid as needed.
4. Controller Startup: Power the controller. Navigate menus to set parameters: pump differential temperatures, maximum collector temperature, etc.
5. Functional Test: Monitor system for one full sun cycle. Verify pump activates when collectors are hotter than tank, electricity is being generated, and no alarms are present.

Note: Record all commissioning data (voltages, pressures, temperatures) in the logbook.

Controller Setup & Operation

The system controller is the brain of the PVT system.

Default Access: Password 0000 for installer menu.

Key Settings:

• Pump Start Delta-T: Typically 5-8°C (collector vs. tank).
• Pump Stop Delta-T: Typically 2-3°C.
• Max Collector Temp: Set to 95°C for safety.
• Language: ENGLISH (default).
• Time/Date: Set for accurate logging.

Operation: The controller runs automatically. The display shows real-time data: collector temp, tank temp, pump status, PV power, and daily energy yield.

Maintenance Schedule

Regular maintenance ensures longevity and performance.

Interval	Task
Monthly	Visually inspect collectors for debris, shading, or damage. Check controller for error codes.
Bi-Annually	Check hydraulic system pressure. Inspect for fluid leaks. Clean collector surface with water and soft cloth.
Annually	Test pressure relief valve. Check fluid pH and freeze point; replace if degraded. Tighten electrical connections. Verify mounting hardware torque.
5 Years	Consider replacing heat transfer fluid. Inspect and service circulation pump.

CAUTION! Always shut down electrical and isolate hydraulic pressure before performing maintenance.

Technical Specifications

• PVT Collector: 250Wp electrical output, 600W thermal output (approx. under standard conditions).
• Electrical Ratings: Voc: 40V, Isc: 8.5A per panel. Grid-tie inverter efficiency: >96%.
• Thermal Fluid: Propylene Glycol/Water mix (50/50 recommended for freeze protection to -35°C).
• Maximum System Pressure: 6 bar.
• Maximum Fluid Temperature: 120°C.
• Controller Power Supply: 120V AC, 60Hz, 50W.
• Operating Environment: -40°C to +50°C ambient.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
No PV Power Output	Tripped breaker, blown fuse, shading, inverter fault.	Check DC isolator and AC breaker. Reset inverter. Ensure no shading on panels.
Pump Not Running	No power, controller setting, stuck impeller, air lock.	Check pump power supply. Verify Delta-T settings in controller. Bleed air from loop.
Low Thermal Output	Low sun, air in system, degraded fluid, scaling in heat exchanger.	Bleed system. Check fluid quality and replace if necessary. Descale heat exchanger.
High-Pressure Alarm	Over-pressurized expansion vessel, blocked pipe.	Check and adjust pre-charge pressure in expansion vessel. Inspect for flow restrictions.
Fluid Leak	Loose fitting, failed seal, pipe corrosion.	Tighten connections. Replace seals or damaged piping section.
Controller Display Blank	Loss of AC power, faulty controller.	Check 120V AC supply to controller. Reset power. Contact support if persistent.

Reset Procedure: Controller Menu > System > Factory Reset (requires password).

Technical Support: 1-800-INAA-PVT (1-800-462-2788); www.inaapvt.com/support