Checkout and Startu2.

Visual lnspection- Page 53

n . 7.0 CHECKOUTANDSTART-UP
Detailed checkouts (pipewalks) must be performed during installationto
v~rif),that the system is being installed in accordance withthe final
~proved drawings and specifications.

u~n completion of the installation, and before the system can be turned
oqer to the client or operating personnel, a final checkout must be
performed. This consists of:
. A visual inspection (pipewalk),

Fillingand pressurizing (liquidsystem), and

. A preoperational checkout.

UP<>n completionofthis checkout,the system willbe readyforopera-

tionaltesting.
.

7.1 VISUAL INSPECTION p~lorto fillingthe system and checking Its operation, a finalvisual
in~pectionmustbe performedto verifythat the installationofthe system
is comPlete, correct, and as specified. The Sample Installation Proce-
d re (Sections 1 and 2 of Appendix 4A of the Design Manual) can be
u,~ ed as a checklist for the visual inspection.

Ttjtephysical installation of the system must comply with:

. I.
Designand installationdrawings
Markup a copyofthe schematicduringthe pipewalkto
confirmthe installationand correctlocationof each compo:
nent.

Mark up copies of the collector layout, collector piping!

ducting, mechanical layout, and control schematics to verify
that the installationof each component was done in the
specified manner.

Use the applicable drawing review checklists (liquid:Nos. 3,

4, 6, and 8; air: nos. 3, 5, 7, and 8) to ensure that all items
. are checked.
. Construction specifications

Verifythat.the specifiedmaterialswere used and inthe

specifiedmanner.
Verifythat all the inspections and tests that must be per-
formed before acceptance of the system by the designer/
client are clearly described in the construction specifi-
cation. '

Installation Manual
 ---I

Checkout and Startuf I Filling and Pressurizing~

Component specifications

Verify that the specif,ed components and materials were

used and installed c<mectly.
. Good installation practice

Verify the use of sta~dard installation practices for any job

where such compon~nts and materials are used.

Use Section 6.4 to identify key aspects of component

location and installation applicable to the system. Verify that
these aspects are adequately addressed during installation.

Note and correct any deviations from system design and specifications.

The visual inspection must also determine that, at the time of accep-
tance, there is no damage to any,component or material, observable
component/material degradation,lor inexplicable system behavior.

Pay particular attention to damage to controls, sensors, wiring, flowme-

ters, thermometers, gauges and other instrumentation, collectors, and
insulation or jacketing; collector condensation or outgassing; and con-
densation in the pebble bed. I
Finally, the visual inspection must verify on-site availability of as-built
drawings and specifications, any installation checkout procedures pre-
pared by the designer, and an O&M manual, which includes all manufac-
turers' product literature and ope~atingand maintenance instructions for
all major components.

7.2 FILLING AND PRESSUR- For dralnback and recirculating systems, the system will tolerate a
IZING LIQUID SYSTEMS delay of a few days after filling and making the preoperational checkout
before proceeding to the operational testing and subsequent intercon-
nection of the solar system with t~e building load.

For closed-loop systems, the system must not be operated discon-

nected from the building load for any length of time due to the effects of'
stagnation on the glycol solution. Therefore, plan the preoperational
checkout (Section 7.3) and opera~ionaltesting (Section 8.0) schedule to
minimize any downtime between the tests. Make the subsequent inter-
connection of the solar system with the building load promptly after
operationaltestingis complete. -

Verify that the following proceduresI have been performed to the satisfac-
tion of the appropriate building officials and in accordance with the
specifications:

System pressure test.

. System cleaning and flushing.

Caution

Do not fill the collectors if they are

I sitting uncovered in direct sunlight!

Installation Manual
Checkout and Startup Preoperational Checkout- Page 55

Dralnback system Tolfillthe collector loop, open the manual air vent or hose bib at the top
of ~hedrainback tank to allow rapid purging of the air in the tank. Open
the two sight glass valves. Connect a hose to the hose bib at the bottom
of .he drainback tank and open any isolation valves in the collector
supply and return lines. Fillthe system with cold water untilthe water
letel reaches the specified level near the top of the drainback tank. Mark
thiF'level on the sight glass. Close the manual air vent or hose bib at the
top of the tank and disconnect the hose.
I
T9.fillthe remainder of the system, followthe procedures in Section
6.~.7.

Glycolsystem Td fillthe collector loop, followthe procedure in Section 6.4.7. Pressur-

iz~ the collector loop to the specified pressure.

To fillthe remainder of the system, followthe procedure in Section 6.4.7.

Ifthis part of the system is also a closed loop (as would be the case in a
s~stem providingonly space heating), pressurize itto the specified
pressure.

Recirculating system Fillthe entire system at once followingthe procedure in Section 6.4.7.
I

f Caution
For all systems, repeat the pipewalk from Section 7.1 to check all
I
piping and components for leaks.

7.3 PREOPERATIONAL Nbte:

CHECKOUT Alcopyofthis sectionis providedas AppendixE,whichcan be used to
makethe
I
systemcheckout.

7.3.1 After Filling System \{erify the following:

(before turning it ON) ~ No.

1'1 The system is isolated from line water pressure

and willnot deliver heat to the load during
I the checkout. --
I
I Procedure:
Close the isolation valve in any makeup water line.
. For service water heating systems:
Closethe bypass valves. (Ifthe system was
installedinan occupiedbuilding,be sure to
open the isolationvalveinthe linecarrying
cold makeupwaterdirectlyto the water heater.)

For space heating systems:

Turnoffthe building'sheatingsystem.

Installation Manual
Checkout and Startup IPreoperational Checkout- Page 56
~~
2. The collector loop has been fi,ledwith the
specified heat transfer fluid;the pressure in any
closed-loop part of the system is as specified. --
3. The drainback tank water levJI
I is as specified. --
4. The pH of the collector loop water or water/glycol
mixture is withinthe range recommended by the
collector manufacturer; ifa glycol solution has been
used, its concentration meets Ithe specifications. --
5. Allvalves/dampers,manualand automatic,are in
the properposition(openor closed)as necessary
forsystem operation. ' --
6. Specifiedreliefvalves have been installed. --
7. Thermometersare registering~ --
8. Collector glazings have been washed clean
of any dirt or debris. --

7.3.2 Turn ONthe System CAUTION

Do not turn the system ON ifthe collectors are stagnating.

Set the differential temperature cortroller (DTC) to "ON."

I
Verify the following:
~ tQ
1. Pumpimpellersor fan rotorsare rotatinginthe
correct direction. --
Procedure:
Visuallycheck shaft rotation o~the motor. Use
the pressure gauge(s) at each pump/fanto
verifythat the pressure increaseacross the pump
meets the designcriteriaand is inthe specified
flowdirection.

2. Allair has been ventedfromthe liquidsystem. --

Procedure: .

Check all manual and automatic air vents. --

3. Ducts,dampers,and other air system components
are free fromleaks.

4. Boththe flowmetersand electronicregisters

of any Btumeteringsystems are functioning. --

Installation Manual
Checkout and Startu/!.
5. I Record the following flow rates:
I
7.3.3 S4!tEach Flowrate as
SpeclflE!d
7.3.4 Balance the Flow
through Collector Banks
7.3.4.1 Using Flow Setters
7.3.4.2 Using Temperature
Port/Balancing Valve
. Siartwithallbalancingvalveswideopen. Measureand recordallbank
Preoperational Checkout- Page 57
I. Collector loop
I
. Forclosed loopsystems:
I Storage,tank to collector heat exchanger loop
I
I . Forspace heatingsystems:
Storagetank to deliveryheat exchangerloop.
w~ allcollectorbankbalancingdeviceswideopen, adjustany valves/
da/,~persor othercomponentsused to set loopflowto the specifiedrate.
M~rkthe settingsand set any memorystops.
I
sJt the flowthrougheach bank at the specifiedrate usingthe
m~nufacturer'srecommendedprocedure. This methodof balancingcan
b~ done day or night.
Balanceflowthroughallcollectorbanks by adjustingthe balancing
v~lvesuntilthe outlettemperaturefromeach bank is the same. Closing
th~valves increasesthe outlettemperature,whileopeningthe valve
d~creases it. Allowadequate timeforthe outlettemperatureto reach
equilibrium(see Figure11).
I
i
I Figure 11. Collector Bank Flow Balancing
I
oJtlet temperatures. Begin balancing by closing the valve in the coldest
b~nkuntilitsoutletis approximately5°F (3°C) belowthatofthewarmest
b~nk. Repeat withthe next coldest bank and continue until half of the
b~nks in that array have been adjusted. Measure and record all bank
o~tlet temperatures again, then continue bala nCinguntil all bank outlet
temperaturesare withina 5°F (3°C) spread. This
.
methodof balancing
flowcan only be done when the sun is out and there is a temperature
ri$e
I of at least 10°F (6°C)through the collectors.
~~
Markany adjustablecomponentsto show
the setpoint. Set any memorystops on
balancingvalvesor removehandlesfrom
conventionalvalves. --
Installation Manual

Checkout and Startup
7.3.5 Verify the Following
(after setting and balancing
flowrates)
Installation Manual
I
Preoperational Checkout- Page 58
~ tlQ
f required, adjust the overall collector loop
'Iowrate during/after balancing the flow
:hroughthe collector banks. --
1. The [currentdrawn by pumps/fans does not
eXCEfed the normal operating range specified
by t~e manufacturer for the voltage used. --
pr edure:
Use an ammeter to measure the amperage
~
at e ch pump/fan motor.
2. The~eis no sign of pump cavitation or other
imprpper operation. --
3. Fan bperation is quiet and smooth. --
I
4. If anlair handler unit is used, ~s operation meets
the manufacturer"s performance specifications. --
5. For drainback system, the 90llectors and
colle tor loop piping drain cornple~elyback
. to
the ~rainback tank. --
Pr edure:
Note the water level in the dralnback tank with
the ystem on. Mark it on the sight glass.
Turn the DTC to "OFF." Verify that draining
the ollectors and piping fills the drainback tank
to its original level. Note the amount of time it
take for the collector loop to drain completely.
CAUTION
If th~ system drainback does not fill the drainback tank to its original
"PUt¥1P OFF"level,wateris trappedsomewhereandthere is danger
of freeze damage. Find and correct the piping that is not draining.
If hose bibs have been installed on the collectors
or in ~hecollector supply line °ln the roof, open
them to verify that the collectors
I have drained.
TUrn he DTC to "ON." (Watch for collector stagnation.
If th system has only been s~ut off for a short
time, it may be possible to refil'. the collectors even
{
whe the sun is out. Otherwise, keep the system
shut ff until the collectors are no longer stagnating.)
Checkout and Startu/?. Preoperational Checkout- Page 59

~~

6.. Flow switches are functioning. --

!Procedure:
IForeach flowswitch,disconnectone lead from
the flow switch and verify that the pump(s) shut off.
Reconnect the lead and verify that the pump(s)
Itum on. Note: Each step of the flow switch
Icheckout must be done after the time delay relay
Ihas opened. Shut the DTC off momentarily to
Irestart the system after each step.
ITum the DTC to "OFF." Verify that there is an open
I
circuit between the leads of each flowmeter.
ITum the DTC to "ON."
--
7. All temperaturesensorsandswitchesare
:

Ifunctioning properly.
I
Procedure:
If the DTC has a digital sensor readout, use
Ithe readout to verify that there is no short or
I break in any sensor/switch circuit, and that the
I sensor readings are appropriate for the ambient
I and system operating conditions.
I If the DTC is not digital, use an ohmmeter to
I determine that there is continuity in the circuits
I and appropriate resistance readings. Disconnect
I each sensor from its control terminals. Attach the
I meter leads to the sensor wire. Measure the
I resistance through the sensor circuit. Use a
Itemperature vs. resistance chart (See Table 1.
I This chart should be provided by the DTC manu-
Ifacturer for each specific system) to convert the
I resistance to temperature. Note any apparent
I

Iproblems.
I
Ilf possible, measure the temperature at the ~int
I of sensor mounting with a digital thermometer or
I probe thermometer and PIT port and compare
I that temperature with the digital readout and the
I sensor resistance check. Do this for each sensor
I immediately after measuring its circuit resistance
I with the ohmmeter.
I
When using a digital thermometer, coat the
probe with heat-conducting grease and insert it
under the insulation. (Note: This may be
difficult to do if the insulation and jacketing have
been correctly applied. Be prepared to remove

Installation Manual
Checkout and Startup I Preoperational Checkout- Page 60

TABLE 1

THERMISTOR 10K OHM

RESISTANCE VS. TEMPERATURE
CHARACTERISTICS I

OF °c R of °C R of °C R

32 0.0 32654 106 41.1 5093 180 82.2 1170

34 1.1 30859 108 42.2 4873 182 83.3 1129
36 2.2 29174 110 43.3 4663 184 84.4 1090
38 3.3 27592 112 44.4 4464 186 85.6 1053
40 4.4 26105 114 45.6 4274 188 86.7 1017
42 5.6 24709 116 46.7 4093 190
I
87.8 982
44 6.7 23395 118 47.8 3921 192 88.9 949
46 7.8 22160 120 48.9 3758 194 90.0 917
48 8.9 20998 122 50.0 3602 196 91.1 886
50 10.0 19903 124 51.1 3453 198 92.2 857
52 11.1 18873 126 52.2 3312 200
I
93.3 828
54 12.2 17903 128 53.3 3177 202 94.4 801
56 13.3 16988 130 54.4 3048 204 95.6 775
58 14.4 16126 132 55.6 2925 206 96.7 749
60 15.6 15313 134 56.7 2808 208 97.8 725
62 16.7 14546 136 57.8 2697 98.9 702
64 17.8 13822 138 58.9 2590 2110
212 100.0 679
66 18.9 13139 140 60.0 2488 214 101.1 658
68 20.0 12493 142 61.1 2391 216 102.2 637
70 21.1 11883 144 62.2 2298 218 103.3 617
72 22.2 11307 146 63.3 2209 220 104.4 597
74 23.3 10762 148 64.4 2124 222 105.6 579
76 24.4 10247 150 65.6 2043 224 106.7 561
78 25.6 9760 152 66.7 1966 226 107.8 543
80 26.7 9298 154 67.8 1891 228 108.9 527
82 .27.8 8862 156 68.9 1820 230 110.0 511
84 28.9 8448 158 70.0 1753 232
I 111.1 495
86 30.0 8056 160 71.1 1688 234 112.2 480
88 31.1 7685 162 72.2 1625 236 113.3 466
90 32.2 7333 164. 73.3 1566 238 114.4 452
92 33.3 6999 166 74.4 1509 240 115.6 438
94 34.4 6683 168 75.6 1454 24 116.7 425
96 35.6 6382 170 76.7 1402 244 117.8 413
98 36.7 6097 172 77.8 1351 246 118.9 401
100 37.8 5827 174 78.9 1303 248 120.0 389
102 38.9 5570 176 80.0 1257 250 121.1 378
104 40.0 5326 178 81.1 1213

Installation Manual
Checkout and Startu/!..
7.3.6 Record Baseline
Operating Data (aftercomple-
tion of all tests)
Preoperational Checkout- Page 61
and replace insulation and jacketing as required.)
Be sure the probe is in good physical contact
with the surface of the pipe, tank, etc., and is
covered with insulation.
I
~ When using a probe thermometer and PIT port,
use caution during removal of the safety cap
and insertion of the probe to protect hands and
eyes. Coat the probe with a silicone grease
before insertion. Do not leave a probe in a PIT
port for long periods of time. When the temper-
ature has been read, remove the probe and
replace the safety cap.
~ 1m
8. lAIl adjustable setpoints on each control have
j
been set to specifications. . --
9. iThe "On-Auto-Qff" switch on the DTC functions
correctly. Leave the switch on "AUTO." --
The system is now operating normally.
Fori dralnback and recirculating systems: The system will tolerate a
delay of a few days before proceeding to the operational testing and
sub~equent interconnecting of the solar system with the building load.
(Note: If freezing is even a remote possibility, either drain the collector
loo~ or proceed directly to the operational testing to verify operation of
the !systemfreeze protection.)
FO~closed-loop systems: The system must not be operated discon-
ne~ed from the building load for any length of time due to the effects of
staQnationon the glycol solution. Proceed immediately with the opera-
tiorlal testing and subsequent interconnecting of the solar system with
the!building load.
Reoord the following information on a separate page:
Pressure at each pressure gauge or PIT port
Inlet and outlet pressures for each heat exchanger
Temperature at each thermometer or PIT port
Inlet and outlet temperatures for each heat exchanger
. Flow rate at each flow setting/measuring device
Suction and discharge pressure for each pump
Voltage and amperage at each pump
. For a drainback system: Water levels in the drainback tank with
the collector loop pump off and on; time to drain.
r All DTeadjustable
setpointsettingsandsensorreadouts.
Installation Manual
Checkout and Startup IPreoperational Checkout- Page 62

Takethe measurementsin as shdrta timeas possible. Notethe date

and timethe measurementswere~akenand the name of the personwho
tookthem. Put this record with the system Operation and Mainte-
nance Manual. '
7.3.7 Tools
The followingtools are needed to perform the preoperational checkout:

pH test kit
Glycoltest kit
Pressure gauge or differentialpressure
I gauge with adapter(s) for
. PIT ports
Ifcircuit setters are used tp set/measure flow rates, the
manufacturer's readout device and conversion scale
If PIT ports are used, a prpbe thermometer (digitalor bi-metal)
Digitalthermometer with probes for flat and curved surfaces
Digitalmultimeter (or sep~rate voltmeter and ammeter)
. Ohmmeter
Continuitytester
. Screwdriver
Heat-conducting grease
. Silicone grease
Hard hat.

Installation Manual