Instruction Manual Residential Solar Water HeatinG SYstems - Hotwater
Instruction ManualRESIDENTIAL SOLAR WATER HEATING SYSTEMSSTANDARD SYSTEMSWITH DOUBLE WALL HEAT EXCHANGERFOR POTABLE WATER HEATING ONLYCUSLISTEDSolar Water Heater Solar CollectorSRCC OG-100 Solar Water Heating SystemSRCC OG-300ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WASPURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.Keep this manual in the pocket on heater for future referenceWhenever maintenance adjustment or service is required.PRINTED 03111320009-001
SAFE INSTALLATION, USE AND SERVICEYour safety and the safety of others is extremely important in the installation, use, and servicing of this waterheater.Many safety-related messages and instructions have been provided in this manual and on your own water heater towarn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout thismanual. It is very important that the meaning of each safety message is understood by you and others who install,use, or service this water heater.This is the safety alert symbol. It is used toalert you to potential personal injury hazards.Obey all safety messages that follow thissymbol to avoid possible injury or death.DANGERWARNINGCAUTIONCAUTIONDANGER indicates an imminently hazardoussituation which, if not avoided, will result in deathor injury.WARNING indicates a potentially hazardoussituation which, if not avoided, could result indeath or injury.CAUTION indicates a potentially hazardoussituation which, if not avoided, could result inminor or moderate injury.CAUTION used without the safety alert symbolindicates a potentially hazardous situationwhich, if not avoided, could result in propertydamage.All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safetymessage, and how to avoid the risk of injury.The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list ofsubstances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requiresbusinesses to warn of potential exposure to such substances.WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or otherreproductive harm.This appliance can cause low-level exposure to some of the substances listed in the act.Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally twoweeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To preventthe possibility of injury under these conditions, we recommend the hot water faucet be opened for several minutes atthe kitchen sink before using any electrical appliance which is connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water begins to flow. Do notsmoke or have any open flame near the faucet at the time it is open.IMPORTANT DEFINITIONS Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields ofplumbing and electrical installation of these appliances. This would include a thorough understanding of therequirements of the National Electrical Code and applicable local electrical and plumbing codes (and toolsnecessary to confirm proper installation and operation of the water heater) as they relate to the installationof electric water heaters. The qualified installer must have a thorough understanding of the water heaterInstruction Manual. Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields ofplumbing and electrical installation of these appliances. This would include a thorough understanding of therequirements of the National Electrical Code and applicable local electrical and plumbing codes (and toolsnecessary to confirm proper installation and operation of the water heater) as they relate to the installationof electric water heaters. The service agency must have a thorough understanding of the water heaterInstruction Manual.2
GENERAL SAFETY3
INTRODUCTIONThank You for purchasing this water heating system.Properly installed and maintained, it should give you yearsof trouble free service.Preparing for the installation1. Read the “General Safety” section of this manual first andthen the entire manual carefully. If you don’t follow thesafety rules, the water heater will not operate properly. Itcould cause DEATH, SERIOUS BODILY INJURY, AND/OR PROPERTY DAMAGE.Abbreviations Found In This Instruction Manual: ANSI - American National Standards Institute ASME - American Society of Mechanical Engineers GAMA - Gas Appliance Manufacturers Association NEC - National Electrical Code NFPA - National Fire Protection Association UL - Underwriters Laboratories Inc. SRCC - Solar Rating and Certification Corp.This manual contains instructions for the installation,operation, and maintenance of the solar water heater.It also contains warnings throughout the manual thatyou must read and understand. All warnings and allinstructions are essential to the proper operation ofthe water heater and your safety. READ THE ENTIREMANUAL BEFORE ATTEMPTING TO INSTALL OROPERATE THE WATER HEATER.System descriptionThis Solar Water Heating System consists of four mainparts — the solar collectors, the solar pump station, thesolar storage tank, and the plumbing for the heat transferfluid.2. The installation must conform with these instructionsand the local code authority having jurisdiction and therequirements of the power company. In the absence oflocal code requirements follow NFPA-70, the NationalElectrical Code (current edition), which may beordered from: National Fire Protection Association, 1Batterymarch Park, Quincy, MA 02169.The solar pump station uses a pump to circulate a heattransfer fluid through the “collector loop”. This collectorloop includes the solar collectors, the fluid lines or “lineset” and a heat exchanger. The collector loop is a “closedloop”, meaning there is no contact of the heat transfer fluidwith your potable water or with the atmosphere. The collector loop contains only a small volume of heat-transfer fluidwhich is non-toxic and freeze-protected to -30 F (Freezetolerance limits are based upon an assumed set of environmental conditions). Though freeze protection may not benecessary in all areas, the heat-transfer fluid also containscorrosion inhibitors which protect the system components,has an elevated boiling point, and is suitable throughoutNorth America.3. If after reading this manual you have any questions ordo not understand any portion of the instructions, call thelocal utility or the manufacturer whose name appears onthe rating plate.4. Carefully plan your intended placement of the water heaterand collectors. INSTALLATION OR SERVICE OF THISWATER HEATER REQUIRES ABILITY EQUIVALENTTO THAT OF A LICENSED TRADESMAN IN THE FIELDINVOLVED. PLUMBING AND ELECTRICAL WORK AREREQUIRED.When exposed to sunlight, the solar collectors get hot.As the heat-transfer fluid passes through the collectors,it absorbs the heat and then travels down the line-set tothe tank. The hot fluid passes through the heat exchangerand heat is transferred to the potable water. After giving upits heat to the potable water, the cool heat-transfer fluid ispumped back to the solar collectors to be heated again.Hot potable water is stored in the solar storage tank.Examine the location to ensure the water heater complieswith the “Facts to Consider About the Location” sectionin this manual.5. For California installation this water heater must bebraced, anchored, or strapped to avoid falling or movingduring an earthquake. See instructions for correctinstallation procedures. Instructions may be obtainedfrom California Office of the State Architect, 400 P Street,Sacramento, CA 95814.The auxiliary or back-up electric-heating guarantees hotwater even under poor solar conditions (at night or whenvery cloudy). The minimum acceptable temperature setpoint is specified in local plumbing codes.6. Massachusetts Code requires this water heater to beinstalled in accordance with Massachusetts 248-CMR2.00: State Plumbing Code and 248-CMR 5.00.You can save the most money on your water-heating billsby using the backup heater on your system as little as possible. If the sun shines brightly between 10 am and 3 pm,enough heat will normally be generated to keep the waterhot throughout the rest of the day and night.7. The solar energy system described by this manual, whenproperly installed and maintained, meets the minimumstandards established by the SRCC. This certificationdoes not imply endorsement or warranty of this productby SRCC.However, on days when the sky is cloudy or when largequantities of hot water are being used, we recommendleaving the backup heater turned on and set to 120 F toprovide adequate hot water.4
TABLE OF CONTENTSSAFE INSTALLATION, USE AND SERVICE. 2Important Definitions . 2GENERAL SAFETY . 3INTRODUCTION . 4System Description . 4Preparing for Installation. 4TABLE OF CONTENTS . 5SYSTEM DIAGRAM/TYPICAL INSTALLATION . 6SYSTEM COMPONENT PART . 7STORAGE TANK INSTALLATION . 7Local Codes . 7Temperature-Pressure Relief Valve . 7-8Closed System/Thermal Expansion. 8Locating the Solar Water Heater . 8Water Piping .8-9Installation in Residential Garages. 9Filling the Solar Water Heater with Water. 9Wiring of Element . 10Thermostat . 10Temperature Regulation . 10-11Temperature Settings . 11Temperature Adjustment . 11Tank Sensor . 11Draining . 11-12Element . 12Element Replacement . 12Anode . 12Water Heater Sounds . 12SOLAR COLLECTOR INSTALLATION . 13Collector Location . 13General Considerations . 13Collector Orientation .13-14Spanner Mounting .15-17Attaching Collector to Mounting Brackets . 18Collector Piping . 19Collector Piping Detail . 20Sensor Wiring at Collector . 20Sensor Mounting at Collector . 20Piping Through the Roof . 20Piping Insulation . 20PUMP STATION INSTALLATION . 21Pump Station . 21Safety Instructions . 21Safety Equipment . 22Wall Mounting the Solar Pump Station . 22Plumbing Configuration . 23Function . 23Flowmeter . 23Start-up and Operation of the Solar Pump Station . 24Leak Detection . 24Flushing . 24Filling . 24Preparation of the Heat Transfer Fluid . 24Filling the Solar Loop.24-25Draining. 25PUMP STATION CONTROL INSTRUCTIONS . 26Control Instructions . 26System Description .26-33TROUBLESHOOTING .34-36SYSTEM MAINTENANCE . 37REPAIR PARTS . 38HEAT TRANSFER FLUID PROPERTIES . 39SOLAR RATING / MODELS / WARRANTY.INSERT SHEET5
SYSTEM DIAGRAM/TYPICAL INSTALLATION6INSTALL THERMAL EXPANSIONTANK IF WATER HEATER ISINSTALLED IN A CLOSEDWATER SYSTEM810VACUUM RELIEFVALVEINSTALL PERLOCAL CODES1115Flow Direction4Discharge Pipe(DO NOT CAPOR PLUG)2193MetalDrainPan1076” Maximum Air GapPiped To AnAdequate DrainAt Least 2” Greater Than TheDiameter Of The Water Heater.INSTALL VACUUMRELIEF IN COLDWATER INLET LINE ASREQUIRED BY LOCALCODES.INSTALL THERMAL EXPANSIONTANK OR DEVICE IF WATER HEATERIS INSTALLED IN A CLOSED WATERSYSTEM.Figure 1.6INSTALL SUITABLE METAL DRAINPANS UNDER HEATERS TO PREVENTDAMAGE DUE TO LEAKAGE. REFERTO WATER HEATER LOCATION, see“ LOCATIN G THE SOLAR WATERHEATER” section.
SYSTEM COMPONENT PARTItemComponentFunction1Solar collectorAbsorbs the sun’s heat energy and transfers this to the heat transferfluid circulating through the collector.2Solar storage tankStores potable water heated by solar generated heat or installedback-up electric resistance element.3Double Wall Heat exchanger (insideSolar pump station)Transfers the heat from the collector loop to the potable water in thesolar storage tank.4Solar Loop Expansion tankAllows for the expansion and contraction of the heat transfer fluid asit heat and cools.5Temperature and Pressure reliefvalveRequired by plumbing code to automatically open and dump water ifthe storage tank exceeds 150 PSI of pressure or 210 F in temperature.6Air ventPurges air from the collector loop fluid during the installation.7Drain valveUsed to drain the heat transfer fluid from the collector loop.8Mixing valveUsed to temper hot water from the solar storage tank with cold inletwater to maintain appropriate temperature hot water delivered fromthe system.9Solar pump stationControls the flow of heat transfer fluid from the collectors to the tankthrough the heat exchanger. For a detailed description of the solarpump station see page 20.10Temperature sensorTank and collector sensor work together to turn the circulatingpump(s) on and off at preset temperature differentials.11Cold Water Cut-Off ValveIsolates the tank from incoming water supply.STORAGE TANK INSTALLATIONIn cold climates, it is recommended that the discharge pipebe terminated at an adequate drain inside the building. Becertain that no contact is made with any live electrical part.The discharge opening must not be blocked or reduced in sizeunder any circumstances. Excessive length, over 15 feet, oruse of more than two elbows can cause restriction and reducethe discharge capacity of the valve.Never operate the electrical heating element without beingcertain the solar water heater is completely filled with water.If any air is left in the top of the tank, the heating elementwill burn out.LOCAL CODESThe installation of this solar water heater must be inaccordance with these instructions and all applicable localcodes and electric utility requirements. In the absence oflocal codes, install in accordance with the latest edition of theNational Electrical Code (NFPA-70).No valve or other obstruction is to be placed between thetemperature-pressure relief valve and the tank. Do notconnect tubing directly to discharge drain unless a 6” airgap is provided. To prevent bodily injury, hazard to lifeor damage to property, the temperature-pressure reliefvalve must be allowed to discharge water in quantitiesshould circumstances demand. If the discharge pipe is notconnected to a drain or other suitable means, the water flowmay cause property damage.TEMPERATURE-PRESSURE RELIEF VALVEFor protection against excessive pressures and temperaturesin this water heater, install temperature-pressure protectiveequipment required by local codes, but not less than acombination temperature-pressure relief valve certified bya nationally recognized testing laboratory that maintainsperiodic inspection of production of listed equipment ormaterials, as meeting the requirements for Relief Valves forHot Water Supply Systems, the latest edition of ANSI Z21.22.This valve must be marked with a maximum set pressure notto exceed the marked hydrostatic working pressure of thewater heater (150 lbs./sq. in.).Install the temperature-pressure relief valve directly into thefitting of the water heater. Position the valve downward andprovide a discharge pipe that must terminate a maximumof six inches above a floor drain or external to the building.The Discharge Pipe: Shall not be smaller in size than the outlet pipe size of thetemperature-pressure relief valve, or have any reducingcouplings or other restrictions. Shall not be plugged or blocked. Shall be of material listed for hot water distribution. Shall be installed so as to allow complete drainage of both thetemperature-pressure relief valve, and the discharge pipe. Must terminate a maximum of six inches above a floor drain7
or external to the building. In cold climates, it is recommendedthat the discharge pipe be terminated at an adequate draininside the building. Shall not have any valve between the relief valve and tank.When installing the temperature-pressure relief valve, usetwo or three turns of Teflon tape or other suitable threadsealer around the threaded end of the valve.is not intended for outdoor installation.2. It is handy to have a floor drain, tub or sink nearby.That will make it easy to drain water from the waterheater. It is also a good place to end the drain line ofthe temperature-pressure relief (T & P) valve.3. The solar water heater or the pipes and the connectionsmay, in time, leak. Put the solar water heater in a placewhere a water leak will not damage anything.4. You must not put the water heater in an area whereit might freeze You must turn off the electricity to thewater heater before you drain it, to protect the heatingelements.5. Make sure that you are able to reach the drain valveand all access panels when the water heater is in place.This will make it easy to service the water heater.6. The water heater must be level before you begin thepiping.WATER HEATERS EVENTUALLY LEAK. The installationof the water heater must be accomplished in such a mannerthat if the tank or any connections should leak, the flowof water will not cause damage to the area adjoining thewater heater or to lower floors of the structure. When suchlocations can’t be avoided, a suitable metal drain pan shouldbe installed under the water heater. Such a pan should beno greater than 1 1/2 inches deep, have a minimum lengthand width of at least two inches greater than the heaterdimensions and must be piped to an adequate drain.Figure 2.The temperature-pressure relief valve should be manuallyopened once a year. Caution should be taken to ensure that(1) no one is in front of or around the outlet of thetemperature-pressure relief valve discharge line, and (2)the water manually discharged will not cause any bodilyinjury or property damage because the water may beextremely hot.If after manually operating the valve, it fails to completelyreset and continues to release water, immediately closethe cold water inlet to the water heater, follow the draininginstructions, and replace the temperature-pressure reliefvalve with a new one.This solar water heater, as all water heaters, will eventuallyleak. Do not install without adequate drainage provisionswhere water flow will cause damage. Note: normalcondensation from a solar water heater may appear to bea leaking tank.If the temperature-pressure relief valve on the applianceweeps this may be due to thermal expansion. The watersupply serving this solar water heater may have a checkvalve installed. Contact the water supplier or local plumbingcontractor on how to control this situation. Do not plug thetemperature-pressure relief valve.WATER PIPINGCLOSED SYSTEM/thermal expansionThis solar water heater is design certified to be used with apotable water system. When connecting water piping withsolder joints use only lead free solder.As water is heated, it expands (thermal expansion). In aclosed system, the volume of water will grow. As the volumeof water grows, there will be a corresponding increasein water pressure due to thermal expansion. Thermalexpansion can cause premature tank failure (leakage). Thistype of failure is not covered under the limited warranty.Thermal expansion can also cause intermittent temperaturepressure relief valve operation: water discharged from thevalve due to excessive pressure build up. The temperaturepressure relief valve is not intended for the constant reliefof thermal expansion. This condition is not covered underthe limited warranty.A properly-sized thermal expansion tank should be installedon all closed systems to control the harmful effects ofthermal expansion. Contact a plumbing service agency oryour retail supplier regarding the installation of a thermalexpansion tank.This solar water heater shall not be connected to anyheating systems or component(s) previously used with anon-potable water heating appliance.If this solar water heater is also used for space heatingapplications, all piping and components connected to thesolar water heater shall be suitable for use with potablewater.This appliance has been design certified as a solar waterheater complying with Standards for Safety - UL174 forthe U.S. and can/csa-c22.2 No 110 F379.1 and F379.2LOCATING THE SOLAR WATER HEATERIf you have a choice of where to install the solar water heater,these ideas may help you decide.1. Put the solar water heater indoors as close as possibleto where you use the most hot water. This water heater8
for Canada. The particular application of this appliancedescribed (above paragraph) may be subject to review andapproval by local code officials.Toxic chemicals such as used for treatment of boilers or nonpotable water heating appliances shall never be introducedinto a potable water space heating system.d. The cold water supply line must have a shut-off valveand union.4. Use a union to connect the hot water supply pipe to thesolar water heater’s hot water outlet.Operating an empty or partially filled solar water heater willresult in damage to the tank.If a solar water heater is installed in a closed water system;such as one having a back flow preventer, check valve orwater meter with check valve in the cold water supply line,means shall be provided to control thermal expansion.Contact the water supplier or local plumbing contractor onhow to control this situation.INSTALLATION IN RESIDENTIAL GARAGESThe solar water heater must be located and/or protectedso it is not subject to physical damage by a moving vehicle.FILLING THE SOLAR WATERHEATER WITH WATERHOT WATER OUTLETTOP SOLAR WATERLOOP CONNECTIONSCOLD WATERINLETMIXING VALVETEMPEREDWATEROTLETTEMPERATURE-PRESSURERELIEF VALVEFigure 3.The solar water heater will work better if you keep the hotwater runs short. You will also get hot water faster and withless heat loss.The illustration shows the correct valves and fittings that youwill need to install the solar water heater. Threaded (3/4”)water connections are supplied through the tank top.ACCESS COVERDRAIN LINESIDE SOLARWATER LOOPCONNECTIONS6” AIR GAPDRAIN VALVETO SUITABLEDRAINFigure 5.Before filling the solar water heater with water, the pumpstation storage tank loop must be connected to the waterheater. See “Filling The Storage Tank Loop” section of themanual.The solar water heater is equipped with top and side pumpstation water loop connections. Cap or plug the connectionsthat are not used in your application.1. Close the solar water heater drain valve. The drainvalve is on the lower front of the solar water heater.2. Open the cold water supply to the solar water heater.NOTE: THIS VALVE MUST BE LEFT OPEN WHENTHE SOLAR WATER HEATER IS IN USE.3. Fill the solar water heater until a constant flow of waterruns out an opened hot water faucet. This will let outair in the solar water heater and the piping. Close thefaucet and solar loop air vent after all air has beenpurged and the water comes out with constant flow.You must not turn the electricity on until the solar waterheater is full of water. IF ANY AIR IS LEFT IN THE TOPOF THE SOLAR WATER HEATER OR IN THE PUMPSTATION STORAGE TANK LOOP THE HEATINGELEMENT WILL BURN OUT IMMEDIATELY.4. Check all the new water piping for leaks. Fix as needed.Figure 4.1. Buy the fittings that you need to connect the pipes.Remember that you have to connect both the hot andcold water pipes.2. Apply a light covering of pipe joint compound to eachoutside thread before making connection.3. Connect the cold water supply pipe to the cold water inletof your solar water heater as follows:a. Look at the top cover of the solar water heater. Thehot and cold connections are marked there.b. A non-metallic dip tube is supplied to carry cold waterfrom the tank top to the bottom. Be sure that it is inthe cold water inlet.c. If using copper tubing, solder tubing to an adapterBEFORE you attach the adapter to the cold waterinlet. DO NOT solder the cold water supply pipedirectly to the cold water inlet connection. It mightharm the dip tube.9
WIRING OF ELEMENTBLACKDetermine voltage and wattage from the rating plateattached to the solar water heater. All external wiring,connection, and overcurrent protective devices must beprovided and installed in accordance with the latest editionof the National Electrical Code, local codes, and local utilityrequirements. The solar water heater must be electrically“grounded” by the installer. A green ground screw has beenprovided on the solar water heater’s junction box.The grounding electrode conductor shall be of copper,aluminum, or copper clad aluminum. The material shallbe resistant to corrosion, and shall be of one continuouslength without a splice or joint.Rigid metal conduit, intermediate metal conduit, or electricalmetallic tubing may be used for the grounding meansif conduit or tubing is terminated in fittings approved forgrounding.REDFBLACKF (60 C)RED(49 C)F(66 C)ELEMENTTHERMOSTATFigure 7.Each thermostat is factory preset at 120 F to reduce therisk of scald injury. This setting has proven by experienceto be most satisfactory from the standpoint of operationalcosts and household needs.Solar water heaters installed in Florida require thethermostat(s) to be set at 125 F. If you wish to adjust thesettings, see the “Temperature Adjustment” section of thisinstallation manual on page 11.Figure 6.Flexible metal conduit or flexible metallic tubing shall bepermitted for grounding if all the following conditions aremet:TEMPERATURE REGULATION1. The length in any ground return path does not exceed6 feet.2. The circuit conductors contained therein are protectedby overcurrent devices rated at 20 amperes or less.3. The conduit or tubing is terminated in fittings approvedfor grounding.Never use this solar water heater unless it is completelyfull of water.SOLAR WATER HEATERS EQUIPPED FOR ONE TYPEVOLTAGE ONLY. This solar water heater is equippedfor one type of voltage only. Check the rating plate nearthe bottom access panel for the correct voltage. DO NOTUSE THIS SOLAR WATER HEATER WITH ANY VOLTAGEOTHER THAN THE ONE SHOWN ON THE MODELRATING PLATE. Failure to use the correct voltage cancause problems which can result in DEATH, SERIOUSBODILY INJURY OR PROPERTY DAMAGE. If you haveany questions or doubts consult your electric company.HOTTER WATER CAN SCALD: Solar water heaters areintended to produce hot water. Water heated to a temperaturewhich will satisfy clothes washing, dish washing, and othersanitizing needs can cause scalds resulting in seriouspersonal injury and/or death. Some people are more likelyto be permanently injured by hot water than others. Theseinclude the elderly, children, the infirmed, or physicallyhandicapped. If anyone using hot water in your home fitsinto one of these groups or if there is a local code or statelaw requiring a certain temperature water at the hot watertap, then you must take special precautions. Please seeFigure 8 and Table 2 for information regarding thermostatsettings. In addition to using the lowest possible temperaturesetting that satisfies your hot water needs, some type ofmixing device, such as a mixing valve should be used at theIf wiring from the fuse box or circuit breaker box was aluminum for the old tank, replace it with copper wire. If you wishto reuse the existing aluminum wire, have the connectionat the solar water heater made by a competent
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER. instruction manual residential solar Water heatinG sYstems standard sYstems With douBle Wall heat eXchanGer FOR POTABLE WATER HEATING ONLY solar Water heater C US LISTED solar collector srcc oG-100 solar Water heating system srcc .
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