installationmanual - butlermaxxkit
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Assembly Instructions OutlineNOT COMPREHENSIVE. USE IN CONJUNCTION WITH COMPLETE
INSTRUCTIONS.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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WARNING!
For your safety, please read through this manual carefully before installation to
minimize the risk of fire, property damage, and personal injury! For complete safety
instructions, refer to the complete installation manual (included).
SAFETY PRECATIONS
Only Butler Solar System as intended and described in the Installation Manual
and the Technical Manual; use other described will void warrant and may led fire,
property damage, and personal injury.
Wear leather gloves to protect your hands and Safety glasses or a face shield to
protect your face when opening the Hot Water Tank Drain Valve and removing tank
inlet or outlet fittings.
BEFORE LOOSENING ANY PIPE CONNECTIONS NEAR THE HOT WATER TANK
ALWAYS TURN OFF THE POWER AND/OR GAS TO THE HOT WATER TANK TO ALLOW
THE WATER TO COOL DOWN AND TO RELIEVE THE TANKS INTERNAL PRESSURE.
ADDITIONALLY BE SURE TO ALWAYS ATTACH A HOSE TO THE DRAIN VALVE BEFORE
OPENING IT.
Butler Solar system must be properly installed in accordance with Installation
and Technical Manual before it is used.
Do not drill into the roof or walls until you have looked or verified using a stud,
wire & pipe finder that no pipes or electric lines are in your drill path.
Wear protective gloves and safety glasses during installation.
Keep system and components away from children and animals.
Be sure that any ladders used are properly stable on the ground.
USE PROPER SAFETY PROCEDURES WHEN WORKING ON THE ROOF! Harnesses,
rubber soled shoes, are recommended.
Store solar modules in dark or shaded places until the installation of mounting
hardware.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
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Work under dry conditions
If water or heat exchanger fluid begins leaking from the top of the heat
exchanger wand, it means corrosion has breached a heat exchanger wall. Even though
one wall is still intact, the heat exchanger should be removed.
BEFORE YOU START
Make sure that you have obtained the proper sized fastening hardware. A
collection of screws and bolts is recommended.
Best to install on cool and cloudy day.
Make sure that all of the components in the component list are present before
beginning assembly. Contact us if anything is missing.
Acquire the necessary local permits that may be required for you to complete
this installation.
Things You May Need
One gallon of propylene glycol antifreeze (Peak Sierra carried by NAPA Auto
Stores), Not shippable, so you must provide
-inch OD plastic tubing to go from flush valve to filling pump or fill/drain valve to bucket
(provided with system)
New flexible hot water tank inlet and or outlet lines of appropriate length
Teflon pipe tape for threaded fittings
2 ABS/PVC black drainpipe and fittings including elbows and angles; alternatively, standard
plastic or metal down spouts including elbows and angles to hide the umbilical in outside wall
installations
Black electrical tape
Assorted nails and screws
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
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Roof patching mesh
Electrical solder or wire nuts
Plumbers Lead-Free solder and flux for copper tubing
Sandpaper to clean copper surfaces
Standard roof jack flashing for 2 roof penetration
Collector supporting and elevating hardware if needed
-20 Hollow Wall Anchors to hold collector down on roof (Stainless Steel or corrosion resistant
fasteners)
Flange and pipe mounting hardware
Caulking
Henrys Roofing Tar in caulking tubes for roof penetration and fastener seals
GE Clear Silicone II or equivalent for caulking split pipe and fittings
Compass or GPS receiver to act as a compass and to obtain the site Latitude, Longitude and
direction of true South.
Level or level/inclinometer combination to measure the collector tilt angle
Thin stick or measuring tape
Milwaukee M-SpectorTM or equivalent video probe system to inspect the sacrificial anode and
look into walls for wires and pipes.
Battery Operated Filling Pump System with battery output to run pump to check system circulation
A flushing hose to connect the clean source of water hose female on one end inch compression on
the other.
A inch compression draining hose about 6 feet long
One 15/16 inch drill bit
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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One 3./4 NPT pipe tap
A good Digital Volt Meter With a Thermocouple to measure Temperature
One rat tail file
Oil to lubricate compression fittings
Pipe solder and sweating supplies, including a self igniting torch
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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Page | 6Figure 1: Typical Butler System Schematic
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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Page | 7 1) Roof Mountings
a) Assemble the SunMaxx 10, 25, or 30 tube collector. You have the option of
either flat mounting or angle mounting. It is recommended that you do not install the
evacuated tubes themselves until the rest of the components have been assembled and
firmly mounted.
To determine proper mounting orientation, use the procedure outlined in thecomplete instruction manual.
Figure 2: SunMaxx Evacuated Tube Collector
b) Mount the collector to the roof. Be sure that you are utilizing the proper bolting
procedure for your roof and installation.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
Angled Mount Flat Mount
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c) Mount the self-pressurizing unit above the manifold of the collector. It is
important that the self pressurizing unit is the component at the highest elevation.
Refer to figure 3.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
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d) Mount the PV panel, again making sure that you are utilizing the proper bolting
procedure for your roof installation. It is essential that the panel be oriented such that
it receives the maximum sunlight exposure.
Figure 3: Basic Roof Arrangement
e) Use the Pipe Roof Jack Flashing kit to create an entrance for the Split ABS Pipe
Covering. The Flashing should be the component with the least elevation.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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2) Solar Wand and Tank Components Assembly
CAUTION: TURN OFF THE SOURCE OF FUEL OR POWER BEFORE BEGINNING TO WORK ON THE HOT
WATER TANK. DOUBLE-CHECK, IF NECESSARY, TO BE CERTAIN THAT THE FUEL OR POWER HAS
BEEN SHUT OFF!!!
a) Insert the Solar Wand into the hot water outlet of the water tank.
Be sure that the tank has been depressurized
Refer to the complete assembly instructions for more information regarding installation
and safety!
b) Connect the solar wand to the pump station using the flex tubes, making sure that each
nozzle on the solar wand is connected to the proper inlet/outlet in the pump (see figures 5 and
6).
c) Install the subsequent cold in/hot out valves using the configuration shown in figure 4.
Be sure the anti-scald valve is oriented properly and a heat trap is present between it and the
solar wand.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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Figure 4: Water Tank Assembly
Figure 5: Pump Schematic
3) Piping/Wiring
a) Using 3/8 copper piping and
standard plumbing fastening
techniques connect the inlet and outlet
of the collector to the top of the pump box
through the flashing. Use the included
ABS split tube covering to protect the
piping from the elements (see figure 3). Also
make sure that the hot outlet branches off
Silicon Solar Inc, Solar Park, Bainbridge, NY 13733 USA Ph: 607-563-7865 Fax: (866) 746-5508
www.siliconsolar.com
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to the self pressurizing unit.
b) Wire the PV panel to the pump box as shown in figure 6 below. Fit the wire into
the same ABS covering on the pipes. Refer to complete manual for wiring instructions
c) Install the tank top high limiter switch. Make sure that it is in contact with the
top of the tank under the insulation. Refer to the complete manual for wiring
instructions.
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
www.siliconsolar.com
http://www.siliconsolar.com/http://www.siliconsolar.com/ -
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Figure 6: Basic Wiring Diagram
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329
http://www.siliconsolar.com/