InstallationManual - ButlerMaxxKit

8/6/2019 InstallationManual - ButlerMaxxKit

1/13

Page | 1

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/


2/13

Page | 2

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.




3/13

Page | 3

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




4/13

Page | 4

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




5/13

Page | 5

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




6/13

Page | 6Figure 1: Typical Butler System Schematic




7/13

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.



Angled Mount Flat Mount


8/13

Page | 8

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.




9/13

Page | 9

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.




10/13

Page | 10

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.




11/13

Page | 11

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



12/13

Page | 12

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.




13/13

Page | 13

Figure 6: Basic Wiring Diagram

http://www.siliconsolar.com/

Documents

InstallationManual - ButlerMaxxKit