SolarAttic PCS1 User manual

SolarAttic™

Pool Heater Manual

SOLAR Without PANELS

SolarAttic, Inc.

Elk River, Minnesota 55330

PCS1 Manual Page ii

Date of last Revision: 12/10/96

Manual Updates

Version Changes Made

6/15/93 Base date of manual. No changes in the period 6/15/93 - 1/3/94.

1/3/94 Updated Warranty information on Page S1-4. Changed all references

of Attic Technology, Inc to the new company name of SolarAttic, Inc.

2/15/94 Converted document to M.S. Word 5.1 file from M.S. Word 4.0 and

made minor format changes to this table. No other changes made.

5/9/94 Fixed some additional formatting problems that were discoveredÑa

direct result of the fileÕs conversion to MS Word 5.1. Several pages

were affected with mis-tabulation, mis-pagination and other minor

formatting issues. The technical and material content of the manual

was not affected by the conversion process.

Updated the service and weight caution paragraphs with minor

changes to pages S1-9 &10. Added Òlocation of temperature sensorsÓ

to page S1-11. Checked spelling and made some minor word

corrections. Updated the table of contents.

2/27/95 Fixed additional pagination & formatting problems on several pages

in four sections. Note: This is the second time and may be related to

either the system 7.5 upgrade; fixed vs true-type scalable font conflicts;

movements within the font folders; or, the page setup dialog settings.

Minor updates or corrections to the manual were made on the

following pages: S1-6, 10, 13; S3-5; S6-1. No substantive technical

changes were made to the manual at this time. Checked spelling.

5/1/95 Updated Troubleshooting Guide to include RelayÕs Wing Nut.

3/28/96 Inserted PCS1 Photo & Specifications into pages 2 & 3 of section 1.

Inserted BTU heat transfer graphs into page 7 of section 2. Inserted

Equipment Pad plumbing photos into pages 19 & 20 of section 3.

Inserted Attic Installation photos into pages 31 & 32 of section 3.

Inserted PCS1 Auto+ System layout graphic on page 53 of section 3.

Removed blank pages 54 & 55 of section 3. Added new page on bypass

valve winterization caution to service section 4 (new page 5).

7/17/96 Added Plumbing Caution concerning the use of drain-waste fittings.

12/10/96 Added cover page inside document for www.solarattic.com pdf file

Provided new web site address.

PCS1 Manual Page iii

Valuable Cou

The "SolarAtticª Pool Heater Manual" is supplied free of charge to all purchasers of

PCS1 Systems. If you purchased this manual separately, you can use this coupon to

deduct the complete cost of your manual from any PCS1 System purchased. There is no

time limit on this coupon. Record your manual purchase here.

Name: ___________________________________________________

Address:__________________________________________________

City, State, Zip:_____________________________________________

Purchased From:_____________ Date:________ Amount Paid: $ ________

SolarAttic, Inc.

Elk River, Minnesota 55330

PCS1 Manual Page iv

NOTICE

This manual is a PCS1 reference guide. It is not designed to answer all of the

technical questions that could arise. The manual illustrates one method of

installing the PCS1. Technical issues that are common to all installations are

discussed in length.

Each purchaser is solely responsible for the proper installation of the PCS1,

which must comply with local, state and national building codes. Where those

codes differ from the information contained herein, they supersede this

information and should be used.

If any doubt exists about complying with building codes, the services of a

competent and licensed building contractor, pool contractor, plumber or

electrician should be enlisted.

SolarAttic, Inc. welcomes any feedback on this manual. If you experienced any

difficulty in the installation of the PCS1, send photos and an explanation and we’ll

share the information and cover it in an updated version of this manual. If you

found this manual to be especially helpful, in any way, we’d like to hear about

that also. Send all comments or questions to:

SolarAttic, Inc.

15548 95th Circle NE

Elk River, MN 55330-7228

(763) 441-3440

(763) 441-7174 Fax

http://www.solarattic.com

Email: [email protected]

PCS1 Manual Page v

Table of Contents

DESCRIPTION PAGE

Manual Update Record................................................................................................... ii

Valuable Coupon.............................................................................................................iii

Notice .................................................................................................................................iv

Table of Contents ...........................................................................................................v-vi

SECTION 1: SYSTEM ARRIVAL S1-1

Specifications ...................................................................................................................2-3

LIMITED WARRANTY ..................................................................................................4

Dialog Manual...................................................................................................................5

CAUTION NOTICES.....................................................................................................6-10

Factory Shipment; Boxes Shipped; Shortage Claim.................................................11

Factory Shipment: Location of Temperature Sensors.............................................11

Factory Shipment: Damaged Equipment; Visible External Damage ....................12

PCS1 Shipping Crate: External Damage Inspection..................................................13

PCS1 Shipping Crate: Internal Damage Inspection ..................................................14

PCS1 Serial Number........................................................................................................15

SECTION 2: HEATING DATA S2-1

PCS1 Solar Theory ............................................................................................................2

PCS1 Solar Heating...........................................................................................................3

Empirical Tracking ...........................................................................................................4

PCS1 Operating Curves..................................................................................................5-6

Btus vs GPM Curve..........................................................................................................7

Btus vs DT Curve..............................................................................................................7

Pool Heaters .......................................................................................................................8

Backup heater use.............................................................................................................8

Solar Panel problems .......................................................................................................9

Gas Heater problems .......................................................................................................10

Heat Pump problems ......................................................................................................11

Ventilation........................................................................................................................12

SECTION 3: INSTALLATION S3-1

Installation Process [Basic]...............................................................................................2

Suggested Tool Lists .........................................................................................................3

Suggested Materials..........................................................................................................4

PCS1 Parts List....................................................................................................................5

Description of Valves.......................................................................................................6

STEP ONE: RETROFIT SUPPORT SYSTEM............................................................................7-8

New Layout........................................................................................................................8

Plumbing Process..............................................................................................................9

Plumbing Notes ............................................................................................................10-13

PCS1 Manual Page vi

Operating Modes..............................................................................................................14

Basic Plumbing Diagram [Without Flowreversal Valves] .....................................15

Plumbing Diagram [Flowreversal with Bypass Loop]..............................................16

Plumbing Diagram [Flowreversal Showing Normal Flow]...................................17

Plumbing Diagram [Flowreversal Showing Reverse Flow]...................................18

Equipment Pad Configuration...................................................................................19-20

Bypass Valve.....................................................................................................................21

STEP TWO: INSTALL PCS1 ...................................................................................................22

Attic Process ...................................................................................................................23-27

Attic Notes......................................................................................................................28-30

Attic Installation Photos..............................................................................................31-32

Enhancing Heat Transfer (A) ........................................................................................33

Electrical Wiring Notes ...............................................................................................34-36

Electrical Wiring Diagram .............................................................................................37

Internal Float Wiring......................................................................................................38

Polaris Pool Vac - Alternate Wiring Diagram (A)....................................................39

Description - Alternate Wiring Diagram A ...............................................................40

Pool Pump On Timer - Alternate Wiring Diagram B .............................................41

Description - Alternate Wiring Diagram B................................................................42

Pump + PCS1 On Timer - Alternate Wiring Diagram C.........................................43

Description - Alternate Wiring Diagram C................................................................44

STEP THREE: AUTOMATING THE PCS1 WITH THE LX220...................................................45

LX220 Installation Process...........................................................................................46-47

LX220 Operating Instructions........................................................................................48

LX220 Front Panel Lights................................................................................................49

LX220 Circuit Board Connections.................................................................................50

LX220 Internal Compartments & Relay Locations ...................................................51

Controller Notes ..............................................................................................................52

PCS1 Systems View .........................................................................................................53

LX220 Brochure .............................................................................................................54-55

SECTION 4: SERVICE S4-1

Service Notes.....................................................................................................................2

Spring Startup....................................................................................................................3

Winterization....................................................................................................................4

WinterizationÑBypass Valve.......................................................................................5

Freeze Warnings...............................................................................................................6

Unattended Pools..............................................................................................................7

Troubleshooting Guide ................................................................................................8-10

SECTION 5: REFERENCE S5-1

Common Questions......................................................................................................1-10

Dictionary of Terms........................................................................................................1-4

Site Survey Form............................................................................................................1-4

SECTION 1 - SYSTEM ARRIVAL Page S1-1

SECTION ONE

SYSTEM ARRIVAL

PCS1 Specifications

DESCRIPTION OF OPERATION: Solar radiation bombards the house’s roof

structure throughout the day. The roof functions as a “solar collector.” Solar

radiation reaches the attic through a process called “conduction.” The attic

functions as a storage and heat transfer area. The PCS1 is physically located inside

the attic and then transfers this solar radiation from the attic air into the swimming

pool’s water through a process called “forced air convection.”

FULL AUTOMATIC OPERATION: Is achieved with the optional LX220 control.

When the attic is eight degrees hotter than the pool and the pool needs heat, the

LX220 automatically routes water up to the PCS1 and turns it on. It can even

synchronize the pool’s pump by turning it on at the same time.

SECTION 1 - SYSTEM ARRIVAL Page S1-2

SECTION 1 - SYSTEM ARRIVAL Page S1-3

Temperature sensors sense the pool and attic temperatures. Maximum heat is then

extracted automatically. The pool owner simply sets the desired thermostat setting

on the LX220. Flowreversalª can substantially reduce the poolÕs heat demand by

allowing the heat to rise from the main drain. Flowreversalª is a trademark of

Mark Urban, Tustin, California. A pool blanket can be used when the pool is not in

use thereby minimizing heat losses caused by evaporation (60%). Specifications are

subject to change without notice.

Specifications

¥ Pool Sizes: Up to 1000 square feet or 35,000 gallons

¥ Up to 70,000 gallons with FlowReversalª valves

¥ Nominal BTU Rating: 60,000 BTUs/hour @ D 32°F

I.E. Pool water input 72°F & AtticÕs Peak @ 104°F

¥ BTU Transfer Range: 20-150,000 BTUs per hour

¥ Attic space required: 3 ft min height to peak; and,

square ft of attic equal to or greater than pool sq ft

¥ Attic access: Fits through standard 24" o.c. trusses

¥ Minimum access opening recommended: 21"x 31"

¥ Can be disassembled for smaller access openings

¥ PCS1 Size: 33"W x 30"H x 20"D

¥ PCS1 Weight: 135 pounds

¥ Shipping Crate Size: 42"W x 38"H x 24"D

¥ Shipping/Crated Weight: 246-253 pounds

¥ Power: 220 vac 1.8 amps @ Full Load

¥ Operating Cost: $5-11 per month @ 9¢ per KW/hour

¥ U.L. Listed: Coil, Motor & other components

¥ Plumbing: 1 1/2" or 2" PVC typical

¥ Pressure Drop: 4-6 PSI typical

¥ Air Flow Rate: 2500 SCFM

¥ Water Flow Rate: Range 15-80 GPM

¥ Optimal Water Flow Rate: 45-55 GPM

¥ Modes: Manual Off & On

¥ Optional Automatic Operation: LX220 control

U. S. Patent 5,014,770

SECTION 1 - SYSTEM ARRIVAL Page S1-4

Limited Warranty

All PCS1 convection units are warranted to be free from defects in material and

workmanship for a period of eighteen months from the date of shipment from the

factory. This warranty covers all parts and labor to correct manufacturing defects,

but does not cover incidental fin damage nor any corrosive damage to heat transfer

coils caused by improperly maintained chemical Ph levels in pools. Ph levels

outside of the 7.2 to 7.6 range void warranty. Use in salt water pools voids warranty.

Corrugated fins are used on the heat transfer coils for improved efficiency. They are

waffled in appearance and not straight. Fin bending that has been combed with a fin

tool does not affect performance and is not considered a manufacturing defect. Our

obligation under this warranty is limited to the repair or replacement, at our factory,

of any part or parts which, upon our examination, have proven to be defective.

Correction of such defects by repair or replacement (at our option) and return freight

via lowest common carrier, shall constitute fulfillment of SolarAttic, Inc.Õs

obligation to the purchaser.

This warranty does not apply to those products which, in our judgment, have been

altered or repaired outside our factory, or subjected to misuse, negligence, accident,

corrosive atmospheres, or operating beyond the limits of our design.

THIS WARRANTY CONSTITUTES THE BUYERS SOLE REMEDY. IT IS GIVEN IN LIEU OF ALL

OTHER WARRANTIES. THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR PURPOSE. WHERE CIRCUMSTANCES CAUSE REMEDY

EXPRESSED HEREIN TO FAIL OF ITS ESSENTIAL PURPOSE, SOLARATTIC, INC'S LIABILITY

SHALL NOT IN ANY EVENT EXCEED THE PURCHASE PRICE. IN NO EVENT, SHALL

SOLARATTIC, INC BE LIABLE FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, WHETHER

THE THEORY BE BREACH OF THIS OR ANY OTHER WARRANTY, NEGLIGENCE, OR STRICTLY

TORT. DISPUTES ARISING UNDER THIS AGREEMENT SHALL BE GOVERNED BY APPLICABLE

MINNESOTA LAW.

PCS1 SERIAL NUMBER: ______________________________________________

DATE SHIPPED FROM FACTORY: ______________________________________

SHIPPED TO: _______________________________________________________

_______________________________________________________

INSTALLED: _______________________________________________________

_______________________________________________________

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