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  5. Installation Operation & Maintenance

Velux CLI U12 SD0F1110 NG B/U Installation Operation & Maintenance

Summary of CLI U12 SD0F1110 NG B/U

  • Page 1

    Solar water heating systems installation • operation • maintenance the solar energy system described in this manual, when properly installed and maintained, meets the minimum standards established by the srcc. This certification does not imply endorsement or warranty of this product by srcc. Cli u12...

  • Page 2

    2 – contents contents part 1: product and safety information page – 3 − definitions page – 3 − local installation regulation page – 3 − water temperature adjustment page – 3 part 2: general information page – 4 − preface page – 4 − introduction page – 4 − system description page – 4 − specifications...

  • Page 3: Special Attention Boxes

    Part 1: product and safety information – 3 2 – contents be sure to read and understand this entire manual before attempting to install and operate your velux solar water heating system. Pay particular attention to the special attention boxes located throughout this manual which will alert the user o...

  • Page 4

    4 – part 2: general information preface the velux solar water heating system uses the sun’s energy as a source of heat to produce hot water for domestic household use. Designed to meet the certification requirements of srcc 0g-300, velux solar water heating systems are reliable, and can typically ge...

  • Page 5

    4 – part 2: general information part 2: general information – 5 cli u12 sk0f 319, cli u12 sdof 1110, cli u12 sk0f 2110, cli u12 sdof 1111, cli u12 sk0f 2111, cli u12 sdof 1112, cli u12 sk0f 2112, cli u12 sdof 1113, and cli u12 sk0f 2113, are systems that include rack systems for installation on flat...

  • Page 6

    6 – part 3: solar water heater system installation the contractor shall obtain all required permits and approvals for installing the solar system. The installation shall conform to all federal, state and local regulations governing solar water heating system installations. The contractor shall adher...

  • Page 7

    6 – part 3: solar water heater system installation part 3: solar water heater system installation – 7 cooled glycol heated glycol velux solar water heating system with electric or gas back-up system models: cli u12 sd0(w/l/f/p) 118 el b/u cli u12 sd0(w/l/f/p) 1110 ng b/u cli u12 sd0(w/l/f/p) 1111 lp...

  • Page 8

    8 – part 3: solar water heater system installation velux solar water heating system with boiler back-up system models: cli u12 sd0(w/l/f/p) 119 hx b/u cli u12 sk0(w/l/f/p) 219 hx b/u cli u12 sk0(w/l/f/p) 319 hx b/u notes: 1. This drawing is meant to show a system piping concept only. The installer i...

  • Page 9

    8 – part 3: solar water heater system installation part 3: solar water heater system installation – 9 velux water heating system with tankless back-up system models: cli u12 sd0(w/l/f/p)118 aux tlg cli u12 sk0(w/l/f/p)218 aux tlg cli u12 sko(w/l/f/p)318 aux tlg notes: 1. This drawing is meant to sho...

  • Page 10

    10 – part 3: solar water heater system installation velux solar pre-heat water heating system system models: cli u12 sd0(w/l/f/p)118 aux el cli u12 sd0(w/l/f/p)118 aux gas cli u12 sk0(w/l/f/p)218 aux el cli u12 sk0(w/l/f/p)218 aux gas cli u12 sk0(w/l/f/p)318 aux el cli u12 sk0(w/l/f/p)318 aux gas no...

  • Page 11

    Velux solar system components listed below are the components included in the velux water heating systems. 1. Velux solar collector: absorbs the sun’s energy and transfers this energy into the heat exchanger located on the bottom of the solar storage tank. 2. Velux collector flashings/racking: flash...

  • Page 12

    4. Pump station controller: operational control center for velux solar systems. All solar loop system safety devices, temperature gauges, pressure gauges, fill valves and drain valves are housed within or attached to the pump station controller. Consists of the following components: a. Solar control...

  • Page 13

    5. Other system components: a. Anti-scald mixing valve: automatically blends the hot water and the cold water feed line to control the discharge temperature to an acceptable and safe temperature. This will also increase the amount of hot water that is drawn from the solar storage tank by not allowin...

  • Page 14

    14 – part 3: solar water heater system installation solar collector orientation operating your velux solar water heater for optimal efficiency is based on the correct orientation, pitch, and location of the solar collectors. In north america, collectors should be oriented due south, however they may...

  • Page 15

    14 – part 3: solar water heater system installation part 3: solar water heater system installation – 15 cli u12 4000 • 2 collector layout • 16” o.C. Rafters cli u12 4000 • 3 collector layout • 16” o.C. Rafters collector location on 16” o.C. Rafters.

  • Page 16

    16 – part 3: solar water heater system installation cli u12 4000 • 2 collector layout • 24” o.C. Rafters cli u12 4000 • 3 collector layout • 24” o.C. Rafters collector location on 24” o.C. Rafters.

  • Page 17

    16 – part 3: solar water heater system installation part 3: solar water heater system installation – 17 3. Mark off the location for the flexible piping penetration locations. Verify that there are no roof joists or obstructions prior to drilling, then drill, or cut openings for piping penetrations....

  • Page 18

    18 – part 3: solar water heater system installation 6. Open the packaging for the zfr flexible pipes (used for interconnection between two collectors). The zfr pipes are a fixed length and are not to be cut -- the cone shaped end connections on these pipes are designed specifically for use with velu...

  • Page 19

    18 – part 3: solar water heater system installation part 3: solar water heater system installation – 19 9. Locate the collector temperature sensor, couplant tube, and extension cable. Locate the collector temperature sensor well in the top left corner of the collector bank (last collector in the col...

  • Page 20

    20 – part 3: solar water heater system installation flashing installation install the velux flashings ensuring that the collectors are properly flashed and sealed in accordance with standard roofing practices and the velux flashing instructions. Reference your velux collector installation manual for...

  • Page 21: Warning

    20 – part 3: solar water heater system installation part 3: solar water heater system installation – 21 solar storage tank and pump station controller location choose a location for your solar storage tank and pump station controller centralized to the domestic hot water piping system. You must also...

  • Page 22

    22 – part 3: solar water heater system installation inspection of solar storage tank prior to installation, inspect the solar storage tank for possible damage. Check markings on the rating plate to be certain the power supply corresponds to that for which the water heater is equipped (electric and p...

  • Page 23

    22 – part 3: solar water heater system installation part 3: solar water heater system installation – 23 expansion tank installation 1. Locate the expansion tank wall bracket to the right of the pump station controller and secure to wall. The wall bracket screws should screw directly into a wall stud...

  • Page 24

    24 – part 3: solar water heater system installation air separator and fittings to tank 1. Connect the air separator to the solar heat exchanger at the upper port marked “from solar collector” using the brass nipple provided. Install the flextube connection fittings provided to the air separator and ...

  • Page 25

    24 – part 3: solar water heater system installation part 3: solar water heater system installation – 25 solar loop piping to solar heat exchanger 1. Install the zfm-002 flexible pipes between pump station and solar storage tank heat exchanger. Connect the gasket end of one of the zfm-002 flexible pi...

  • Page 26

    26 – part 3: solar water heater system installation 1. Connect the thermostatic mixing valve provided to the solar storage tank “hot” water connection using pipe tape. Connect the mixing valve hot port “h” to the solar storage tank, as shown. Connect the brass tee fitting provided to the solar stora...

  • Page 27

    26 – part 3: solar water heater system installation part 3: solar water heater system installation – 27 3. Connect the 3/4” hot and cold water service pipes to the hot water quick connect fitting and cold water quick connect fitting, respectively, as shown. Insure that the service piping connections...

  • Page 28

    28 – part 3: solar water heater system installation tank and collector temperature sensor connection to pump station controller 1. Route the solar collector sensor, storage tank bottom sensor, and storage tank top sensor wires to the solar pump station controller and remove the solar system control ...

  • Page 29: Warning

    28 – part 3: solar water heater system installation part 3: solar water heater system installation – 29 electrical connection (velux solar water heating system with electric back-up only) refer to the installation/operation manual provided with your solar storage tank, and keep it with this manual a...

  • Page 30: Danger

    30 – part 3: solar water heater system installation gas connection (velux solar water heating system with gas back-up only) for installation and operation instructions, refer to the installation/operation manual provided with your solar storage tank. The installation/operation manual for your water ...

  • Page 31: Warning

    30 – part 3: solar water heater system installation part 3: solar water heater system installation – 31 venting connection (velux solar water heating system with gas back-up only) ! Warning the venting system must be installed properly following all local codes or in the absence of local codes, the ...

  • Page 32

    32 – part 3: solar water heater system installation boiler back-up heat exchanger connection (velux solar water heating system with boiler back-up only) for installation and operation instructions, refer to the installation/operation manual provided with your solar storage tank. The installation/ope...

  • Page 33

    32 – part 3: solar water heater system installation part 3: solar water heater system installation – 33 commissioning the solar system prior to filling the solar collectors with heat transfer fluid, ensure that the collectors have been covered for a minimum of 1 hour. The solar loop piping should be...

  • Page 34: Important

    34 – part 3: solar water heater system installation programming system controller ! Important the factory default settings on the solar system controller operation menu is off -- this prevents system pumps from operating until the system has been commissioned. To turn on the system, change the setti...

  • Page 35: Caution

    34 – part 3: solar water heater system installation part 4: maintenance – 35 maintenance check list a properly maintained solar water heating system can provide years of dependable trouble free service. It is suggested that a routine preventive maintenance program be established and followed by the ...

  • Page 36: Warning

    36 – part 4: maintenance estimated life of components proper care and maintenance of your solar system will determine the life expectancy of the individual components of the system. Refer to the manufacturers’ warranty of the individual components for warranty coverage. To obtain warranty service, c...

  • Page 37

    36 – part 4: maintenance part 5: specifications – 37 part 5: specifications velux solar collector velux collectors feature: • copper absorber plate coated with highly selective coating having emissivity 0.95 • absorber coating applied by cathode sputtering process • collector flow tubes laser welded...

  • Page 38

    38 – part 5: specifications velux flextubes and connections velux flexible pipe specifications max operating pressure 145 psi external diameter, pipe 7/8” internal diameter, pipe 5/8” wall thickness, insulation 5/8” liquid volume 0.02 gal./ft. Material, pipe stainless steel / aisi 316 ti material, i...

  • Page 39

    38 – part 5: specifications part 5: specifications – 39 velux glass lined solar storage tank (with electric back-up) velux solar storage tank dimensions model # gal dimensions a b c d e tff 060 0205us 60 22” 59 1 ⁄ 4 ” 53” 7 3 ⁄ 8 ” 29 1 ⁄ 2 ” tff 080 0205us 75 24” 59 1 ⁄ 4 ” 53” 7 3 ⁄ 8 ” 29 1 ⁄ 2 ...

  • Page 40

    40 – part 5: specifications velux glass lined solar storage tank (with back-up heat exchanger) velux solar storage tank dimensions model # gal dimensions a b c d e f g tff 060 1205us 55 22” 59 1 ⁄ 4 ” 53” 5 3 ⁄ 8 ” 27 1 ⁄ 2 ” 37 1 ⁄ 2 ” 56” tff 080 1205us 70 24” 59 1 ⁄ 4 ” 53” 5 3 ⁄ 8 ” 27 1 ⁄ 2 ” 3...

  • Page 41

    40 – part 5: specifications part 5: specifications – 41 velux glass lined solar storage tank (with atmospheric gas backup) • glass lined steel tank • two protective aluminum anode rods • r-value of r-17 • internal double wall glass coated steel solar heat exchanger • honeywell self diagnostic gas co...

  • Page 42

    42 – part 5: specifications velux glass lined solar storage tank (with power vent gas backup) • glass lined steel tank • two protective aluminum anode rods • r-value of r-17 • internal double wall glass coated steel solar heat exchanger • honeywell self diagnostic gas control (120 v.A.C.) • flammabl...

  • Page 43

    42 – part 5: specifications part 5: specifications – 43 velux solar pump station dimensions height (a) 12” width (b) 10” center distance supply - return 4 3 ⁄ 4 ” supply - return connections 3/4” npt velux solar pump station technical data power supply 120 volt, 2 amp maximum design pressure 145 psi...

  • Page 44

    44 – part 5: specifications velux heat transfer fluid – inhibited propylene glycol-based heat transfer fluid typical concentrations of dowfrost fluid required to provide freeze and burst protection at various temperatures note: these figures are examples only and may not be appropriate to your situa...

  • Page 45

    44 – part 5: specifications part 5: specifications – 45 propylene glycol emergency overview exposed to potential health effects first aid eye may cause slight transient (temporary) eye irritation. Corneal injury is unlikely. Mists may cause eye irritation. Flush eyes with plenty of water. Skin conta...

  • Page 46

    46 – part 6: component lists part 6: component lists system models system component part number quantity cli u12 sd0l 118 el b/u cli u12 sd0l 118 aux el cli u12 sd0l 118 aux gas cli u12 sdol 118 aux tlg collector cli u12 4000 1 flashing system edl u12 0000 1 storage tank tff 060 0205us 1 pump statio...

  • Page 47

    46 – part 6: component lists part 6: component lists – 47 velux solar system kits parts breakdown system models system component part number quantity cli u12 sd0w 118 el b/u cli u12 sd0w 118 aux el cli u12 sd0w 118 aux gas cli u12 sdow 118 aux tlg collector cli u12 4000 1 flashing system edl u12 000...

  • Page 48

    48 – part 6: component lists velux solar system kits parts breakdown system models system component part number quantity cli u12 sd0f 118 el b/u cli u12 sd0f 118 aux el cli u12 sd0f 118 aux gas cli u12 sdof 118 aux tlg collector cli u12 4000 1 rack system zft 101 1 storage tank tff 060 0205us 1 pump...

  • Page 49

    48 – part 6: component lists part 6: component lists – 49 velux solar system kits parts breakdown system models system component part number quantity cli u12 sd0p 118 el b/u cli u12 sd0p 118 aux el cli u12 sd0p 118 aux gas cli u12 sdop 118 aux tlg collector cli u12 4000 1 rack system zft 100 1 stora...

  • Page 50: Caution

    50 – part 7: troubleshooting part 7: troubleshooting nature of trouble possible cause service no hot water. Improper wiring. Check controller and tank wiring. No power – blown fuse or circuit breaker tripped. A. Shorted wiring. Replace or repair. B. Circuit overloaded. Provide adequate circuit or re...

  • Page 51

    50 – part 7: troubleshooting part 7: troubleshooting – 51 nature of trouble possible cause service pump does not operate (even though there is solar radiation and the tank is cold). No power to pump. Check controller and pump wiring. Controller improperly set. Check program - refer to pump station m...

  • Page 52

    52 – velux solar srcc og-300 label set instructions the following labels must be attached to the relevant valves in the system in order for it to be considered og-300 compliant. This page should be laminated, each label cut from it, punched in the margin at the right hand side and affixed to the app...

  • Page 53

    52 – velux solar srcc og-300 label set maintenance notes – 53 notes maintenance notes.

  • Page 54

    54 – service information installer information installers name: company: address 1: address 2: city: state: zip: phone number: fax number: e-mail: installation information collectors: model number: serial number: 1. 2. 3. 4. Tank: gallons: aux: orientation: pitch: installed date: service information.

  • Page 55

    54 – service information srcc og-300 system certification – 55 solar c er tificatio n this product certified by: solar rating and certification corporation 1679 clearlake road cocoa, fl 32922 (321)638-1537 www.Solar-rating.Org velux america, inc. 104 ben casey drive fort mill, sc 29708 srcc document...

  • Page 56

    Xus 20142-0311 ©2011 velux group ® velux, velux logo are registered trademarks velux america inc. 450 old brickyard road • po box 5001 • greenwood, sc 29648-5001 tel 1-866-99-velux • fax 1-864-943-2631 • www.Veluxusa.Com/solar.