Your Solar Home SolarSheat Installation Manual

The Your Solar Home SolarSheat is an integrated solar thermal heating system designed for residential use, featuring high-efficiency solar collectors, a heat transfer fluid loop, a storage tank, a control unit with digital display, and compatibility with existing hydronic heating systems. It is engineered to reduce conventional heating fuel consumption. Below are key sections for safety, system overview, installation, commissioning, operation, maintenance, and troubleshooting.

1. System Overview & Components 2. Safety Precautions 3. Pre-Installation Planning 4. Installation Procedure 5. System Commissioning 6. Control Unit Operation 7. Maintenance Schedule 8. Specifications 9. Troubleshooting 10. Warranty & Support

System Overview & Components

Key components: Solar Collector Array, Heat Transfer Unit (HTU) with pump and expansion vessel, Insulated Storage Tank, Control Unit with sensors, Piping & Insulation, Mounting Hardware.

Component	Description
Solar Collector	High-vacuum tube or flat-plate collector for capturing solar energy
Heat Transfer Unit (HTU)	Contains circulation pump, expansion vessel, safety valves, and heat exchanger
Storage Tank	Insulated tank for storing heated water/fluid
Control Unit	Digital controller for system monitoring and pump operation
Temperature Sensors	Collector, tank, and return line sensors
Piping & Insulation	Copper or PEX piping with foam insulation for heat loss prevention
Mounting Hardware	Roof brackets, rails, and fasteners for collector array
Fill/Drain Valves	For filling the system with heat transfer fluid and draining for maintenance
Pressure Gauge	Indicates system pressure in the closed loop
Air Vent	Automatic or manual valve to remove air from the system

Safety Precautions

Read all instructions before installation. Use proper personal protective equipment (PPE).

Electrical Safety: Ensure power is disconnected before wiring the control unit and pump.
Thermal Safety: System components become extremely hot during operation. Allow to cool before servicing.
Fluid Safety: Heat transfer fluid may be hot and under pressure. Release pressure and cool before opening valves.
Roof Safety: Use fall arrest systems when installing collectors on roofs.
Lifting Safety: Collectors and tanks are heavy; use appropriate lifting equipment and techniques.

WARNING! Failure to follow safety instructions can result in serious injury, property damage, or system failure. Installation should be performed by qualified personnel.

Pre-Installation Planning

Assess site suitability and gather necessary tools and materials.

Site Survey: Determine optimal roof orientation (South-facing in Northern Hemisphere) and tilt angle. Ensure no shading from trees or structures.
Structural Check: Verify roof integrity can support collector weight, including snow and wind loads.
Path Planning: Plan the route for piping between collectors, HTU, and storage tank to minimize length and heat loss.
Tool Gathering: Required tools may include drill, wrench set, pipe cutter, soldering torch (for copper), pressure tester, multimeter, and level.
Permit Check: Contact local authorities to determine if a building or plumbing permit is required.

CAUTION! Incorrect planning can lead to poor system performance, leaks, or structural damage.

Installation Procedure

Follow steps in sequence. Do not skip steps.

Mount Collectors: Install roof brackets securely into rafters. Attach mounting rails and secure collectors to rails according to layout diagram.
Install Storage Tank: Place tank in a dry, protected location (e.g., basement, utility room) near existing water heater if used for pre-heating.
Install Heat Transfer Unit (HTU): Mount HTU on wall near tank. Ensure it is level and accessible.
Run Piping: Connect collectors in series or parallel as per design. Run insulated pipes from collectors to HTU and from HTU to storage tank heat exchanger.
Electrical Connections: Wire the circulation pump to the control unit. Connect temperature sensor probes to collectors, tank, and return line. Connect control unit to mains power (120V AC).
Fill System: Connect fill hose to fill valve. Slowly fill the closed loop with recommended heat transfer fluid (propylene glycol mix). Use a pump to achieve initial pressure (typically 12-15 psi cold). Open air vents to bleed air until fluid runs clear.
Pressure Test: Pressurize system to 1.5 times operating pressure (check specifications) and hold for one hour to check for leaks.

Tip: Double-check all connections for tightness. Label all pipes for future reference.

System Commissioning

Power on and initiate first operation.

Power Up: Turn on power to the control unit. The display should illuminate.
Set Parameters: Navigate control unit menu to set language, time, temperature differential for pump activation (default often 10°F), and high-limit safety temperature.
Initiate Pump: The pump should start automatically when the collector temperature exceeds the tank temperature by the set differential.
Verify Flow: Check that pipes near the pump vibrate slightly and that temperature readings on the controller change, indicating fluid circulation.
Check for Leaks: Inspect all connections, valves, and the pressure gauge over the first 24-48 hours of operation.
Integration Test: If connected to a domestic hot water or space heating system, verify that heat is being transferred to the storage tank and subsequently to the load.

WARNING! Do not leave the system unattended during initial operation until you have confirmed there are no leaks or abnormal noises.

Control Unit Operation

The digital control unit manages system operation and provides status information.

Front Panel: LCD Display, POWER Button, MENU/Select Button, Up/Down Arrow Buttons.

Display Screens: Home screen shows collector temperature, tank temperature, and pump status (On/Off). Menu access allows adjustment of: Temperature Differential, High-Limit Setpoint, Pump Speed (if variable), Manual Pump Override, System Time, Fault Log Viewing, and Reset Function.

Normal Operation: The pump runs when T_collector > T_tank + Differential. Pump stops when T_collector < T_tank + Differential or if T_tank reaches the high-limit setpoint.

Maintenance Schedule

Regular maintenance ensures longevity and efficiency.

Weekly: Visually inspect collectors for debris (snow, leaves). Check control unit for error codes.
Monthly: Check system pressure gauge. Pressure should remain stable. A significant drop indicates a potential leak.
Annually (Before Heating Season):
1. Inspect fluid quality and concentration (test with refractometer). Top up or replace fluid as needed.
2. Check and tighten all electrical connections.
3. Inspect pipe insulation for damage and repair.
4. Clean collector glass or tubes with water and a soft cloth to remove dirt and dust.
5. Exercise all manual valves to prevent seizing.
6. Verify operation of safety relief valves.
Every 3-5 Years: Have a qualified technician perform a full system check, including pump performance and heat exchanger inspection.

CAUTION! Always depressurize and cool the system before performing any maintenance that involves opening fluid lines.

Specifications

Collector Type: High-Vacuum Tube or Selective Surface Flat Plate.
Collector Area: Varies by model (e.g., 40 sq ft).
Storage Tank Capacity: 80-gallon (standard), insulated with polyurethane foam.
Heat Transfer Fluid: Food-grade propylene glycol/water mix (typically 50%).
Maximum System Pressure: 87 psi (6 bar).
Maximum Fluid Temperature: 350°F (177°C).
Pump: Low-power, glandless circulation pump.
Control Voltage: 24V AC or 120V AC.
Operating Environment: Collectors rated for all weather conditions.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No heat production	Pump not running, low fluid, air in system, sensor fault	Check pump power and fuse. Verify fluid level/pressure. Bleed air from high points. Check sensor connections and readings.
Low system pressure	Fluid leak, underfilled during installation	Inspect all joints, valves, and collectors for leaks. Top up fluid to correct pressure.
Pump runs continuously	Stuck relay, faulty temperature sensor, differential set too low	Check control unit for error codes. Test sensors with multimeter. Adjust temperature differential setting.
Fluid leaking from collector	Damaged seal or broken tube (vacuum tube type)	Identify leaking tube. Replace seal or entire tube following manufacturer's procedure.
Control unit display blank	No power, blown fuse, faulty unit	Check circuit breaker and power outlet. Inspect fuse in control unit. Contact support if power is present.
High-pressure warning	Overheated fluid, expansion vessel pre-charge lost	Check that pump is running and heat is being drained. Check and adjust pre-charge pressure in expansion vessel.

Reset: Control Unit Menu > System > Reset (if applicable).

Warranty & Support

Your Solar Home SolarSheat is backed by a 10-year limited warranty on collectors and a 5-year warranty on other components (tank, pump, controller). Warranty is valid only if installed by a certified installer according to this manual. Registration may be required.

For technical support, troubleshooting assistance, or to locate a certified installer:

Visit: www.yoursolarhome.com/support
Call: 1-800-SOLAR-HEAT (1-800-765-2743)
Email: [email protected]

Retain your purchase receipt and installation documentation for warranty claims.