Apricus Solar Water Heating System Installation and Operation ...

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Apricus Solar Collector Installation & Operation Manual - USA12. TroubleshootingWARNINGApart from those inspection items specifically outlined as “HOMEOWNER”, anymaintenance or repair must only be completed by Authorized Persons. The solar collectorwarranty may be void if non-Authorized Person attempt to maintain or repair the solarcollector or associated system components. The solar system operates at high pressureand high temperature and can result in damage to both property and personal injury if notcorrectly operated and maintained.CL = Specific to Closed Loop DF = Specific to Direct FlowDB = Specific to Drain-BackProblem Cause SolutionPump not ON duringgood solar radiationconditionsPump cycling ON andOFF during good solarconditionsPump always ON evenduring minimal solarradiation conditionsPump running at nightFluid dumping frompressure relief valve onpump stationFluid dumping frompressure relief valve ontankTemperature sensors not workingproperlyController settings incorrectController Max Temp setting hasbeen reachedPartial shading of collectorExcessive system flow rateController settings incorrectInsufficient flow rateAir lock in piping systemSensor location too lowController settings incorrectController settings incorrectPoor Sensor ReadingFaulty pressure relief valveFaulty expansion tankExcessive tank temperatureFaulty expansion tank· Check that sensor is installed correctly· Check that sensor wire is not damaged· Check sensor Ohm reading with Ohm to °F chart incontroller manual· Check controller is set to AUTO operation· Check maximum tank and collector settings· Check maximum tank and collector settings· Check collector location for shading· Adjust restrictor screw on flow meter· Reduce pump speed (select slower speed)· Check if differential (dT function) is correct, dTMin may° °be set too high, reduce to 2 C / 4 F· Check flow gauge for proper flow rate· Adjust restrictor screw on flow meter· Check that all isolation valves are open· (DF/CL) Release air from air vent on highest point· (CL) Purge system of air by following Fill andPressurize procedure described in section 7.9.· T2 sensor (bottom tank) should be slightly above thelevel of the solar flow port. If below the flow port, thepump may run continually even when there is no solarheat.°· dTMin may be set too low. Increase 2-3 especially ifclosed loop system.· (DF) Check that freeze protection setting is correct.Intermittent circulation is freezing conditions is normal.Ensure pipes are well insulated.· (DF) Tank S2 sensor not getting accurate reading· Replace pressure relief valve· (CL) Replace expansion tank on pump station· Check Maxtemp Tank1 setting of controller· Check tank sensor (T2) operation· Replace expansion tank on potable water sideCopyright 2011 – Apricus Inc Doc: A7-05.4.1.4-PB-1.9 Page 84 of 126
Apricus Solar Collector Installation & Operation Manual - USAProblem Cause SolutionPoor Solar HeatingContribution (Comparedto previous output atsame time of year)Poor Solar Contribution(Compared to expectedlevels)Not enough hot waterIntermittent shortbatches of cold waterwhen showeringIncreased hot water demandInsufficient flow ratePartial shading of collectorHeat loss from pipesDamage to evacuated tubesHeat pipes not operatingScale build up in brazed plate HE(if BPHE used)Thermo-siphoningInsufficient pump run timePump cycling too long anddissipating heatExcessive tank heat lossesIF ELECTRICElectric not heating waterIF BOILER or GAS TANKLESSBooster not heating waterFaulty tempering valveIncreased hot water demandFaulty tempering valveFaulty tankless gas boosteroperation (if post gas system)· Check if hot water demand has increased, which wouldreduce the % contribution from solar even with the samelevel of output· Check flow gauge for proper flow rate, check pumpoperation if flow rate insufficient· Adjust restrictor screw on flow meter· Check heat transfer fluid pH, color and viscosity, mayneed to be flushed and replaced.· Check collector location for shading or snow build up. Ifsnow buildup, ensure bottom of collector is raised off°roof, and angle of install is at least 45· Check that insulation is still in good condition with noexposed hot piping· Check that evacuated tubes are all intact and thebottom is still silver· Check that heat pipes are making good contact inheader, and are hot at the tip· Flush sediment from tank· Back flush BPHE with vinegar (or equivalent)· Install sieve and clean out valve before pump on BPHEloop.· System may be reverse thermo-siphoning at night.Ensure check valve after or in pump is working. Mayneed to install heat trap (downward U shaped pipe) onreturn line close to tank.· For normal ON/OFF pump operation (not variablespeed) ensure the pump is running long enough for theheat from the collector to return to tank - feel return linewith hand (careful) to check. Reduce dTMin valueslightly.· dTMin value set too low, especially if closed loopsystem (applies to ON/OFF or variable speed)· T2 sensor too low in tank, always reading cold water.Move to correct location.· Insulate both the hot and cold water pipes connected tothe storage tank. A check valve (spring not flap) on thecold and hot pipe close to the tank will help reduce heatmigration up the pipe.· Insulate any exposed fittings and valves on the storagetank. DO NOT impair the operation of the PTRV.· Check operation and power supply to element· Replace element if necessary· Check controller boost settings· Check gas/fuel supply· Check operation of boiler/heater· Check controller boost settings· Check operation of tempering valve· Install larger capacity boiler/booster· Revise boost settings of controller· Install larger storage tank· Check operation of tempering valve· Check operation of tankless gas boosterCopyright 2011 – Apricus Inc Doc: A7-05.4.1.4-PB-1.9 Page 85 of 126
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