Instruction Manual RESIDENTIAL SOLAR WATER HEATING SYSTEMS STANDARD SYSTEMS WITH SINGLE WALL HEAT EXCHANGER FOR POTABLE WATER HEATING ONLY C US LISTED Solar Water Heater ™ Solar Collector SRCC OG-100 ™ Solar Water Heating System SRCC OG-300 ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use, and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY 3
INTRODUCTION Thank You for purchasing this water heating system. Properly installed and maintained, it should give you years of trouble free service. Preparing for the installation 1. Read the “General Safety” section of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY, AND/ OR PROPERTY DAMAGE.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE............................2 Important Definitions ..................................................2 GENERAL SAFETY .................................................................3 INTRODUCTION ......................................................................4 System Description ....................................................4 Preparing for Installation.............................................4 TABLE OF CONTENTS .........................
SYSTEM DIAGRAM/TYPICAL INSTALLATION 6 INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM 8 10 VACUUM RELIEF VALVE INSTALL PER LOCAL CODES 1 1 11 5 Flow Direction 4 Discharge Pipe (DO NOT CAP OR PLUG) 2 9 Metal Drain Pan 3 10 7 6” Maximum Air Gap Piped To An Adequate Drain At Least 2” Greater Than The Diameter Of The Water Heater. INSTALL VACUUM RELIEF IN COLD WATER INLET LINE AS REQUIRED BY LOCAL CODES.
SYSTEM COMPONENT PART Item Component Function 1 Solar collector Absorbs the sun’s heat energy and transfers this to the heat transfer fluid circulating through the collector. 2 Solar storage tank Stores potable water heated by solar generated heat or installed back-up electric resistance element. 3 Heat exchanger (Not Shown) Transfers the heat from the collector loop to the potable water in the solar storage tank.
• Shall not have any valve between the relief valve and tank. When installing the temperature-pressure relief valve, use two or three turns of Teflon® tape or other suitable thread sealer around the threaded end of the valve. heater. It is also a good place to end the drain line of the temperature-pressure relief (T & P) valve. 3. The solar water heater or the pipes and the connections may, in time, leak. Put the solar water heater in a place where a water leak will not damage anything. 4.
If this solar water heater is also used for space heating applications, all piping and components connected to the solar water heater shall be suitable for use with potable water. This appliance has been design certified as a solar water heater complying with Standards for Safety - UL174 for the U.S. and can/csa-c22.2 No 110 F379.1 and F379.2 for Canada. The particular application of this appliance described (above paragraph) may be subject to review and approval by local code officials.
THERMOSTAT Each thermostat is factory preset at 120°F to reduce the risk of scald injury. This setting has proven by experience to be most satisfactory from the standpoint of operational costs and household needs. Solar water heaters installed in Florida require the thermostat(s) to be set at 125°F. If you wish to adjust the settings, see the “Temperature Adjustment” section of this installation manual on page 11. Figure 5.
HIGH LIMIT CONTROL RESET BUTTON RESET BUTTON ADJUSTABLE THERMOSTAT WITH HIGH LIMIT Figure 8. A non-adjustable high temperature limit control operates before steam temperatures are reached. The high limit is in the same area as the upper thermostat and must be reset manually when it activates. BECAUSE THE HIGH LIMIT ACTIVATES ONLY WHEN ABNORMALLY HIGH WATER TEMPERATURES ARE PRESENT, IT IS IMPORTANT THAT A QUALIFIED SERVICE AGENT BE CONTACTED TO DETERMINE THE REASON FOR OPERATION BEFORE RESETTING.
1. Turn “OFF” the electrical supply to the solar water heater. Make sure the electrical supply to the solar water heater is turned OFF. Failure to heed this will result in the possibility of DEATH, SERIOUS BODILY INJURY OR PROPERTY DAMAGE. 2. Open a nearby hot water faucet until the water is no longer hot, then turn off the cold water supply and open the drain valve, leaving the hot water faucet open. 3. The drain valve must be left open during the shut-down period.
SOLAR COLLECTOR INSTALLATION COLLECTOR LOCATION Proper location and orientation of the solar collectors is important for maximum system efficiency. The collectors should be unshaded from 10:00 am through 3:00 pm each day in every month of the year and should be located as close to the storage tank as possible to minimize heat loss in the piping runs.
COLLECTOR TILT 48” A” Figure 11.
The most important structural consideration is to securely anchor the solar collector and the mounting hardware to the structural members of the roof with the stainless steel hardware provided. The solar collector must be attached to the mounting hardware as detailed in Figure 17.
DRILL POINTS (CLEARANCE HOLE for 5/16” BOLT) B” C” B” MOUNTING BRACKETS C” A” RAFTER D” RAFTER BASED ON 16” CENTER RAFTERS VERTICAL MOUNTING Figure 14. DRILL POINTS (CLEARANCE HOLE for 5/16” BOLT) B” C” A” B” C” RAFTER D” BASED ON 16” CENTER RAFTERS MOUNTING BRACKET RAFTER RAFTER HORIZONTAL MOUNTING Figure 15.
NOTICE * IF MOUNTING WITH AN OPTIONAL TILT MOUNT KIT, FOR OPTIMAL COLLECTOR ANGLE REFER TO ITS INSTRUCTION SHEET FOR THE APPLICABLE “A” DIMENSION. COLLECTOR A Vert. 3.5’ X 7’ 86* Vert. 4’ X 8’ 97* Vert. 4’ X 10’ 121* Horiz. 3.5’ X 7’ 42.25* Horiz. 4’ X 8’ 47* Horiz. 4’ X 10’ 47* B 32 35 35 62 72 94 C 14 16 16 28 28 30 D 7-1/4 11-3/4 11-3/4 13-1/2 12 9 Table 4.
Attaching collector to mounting brackets Once all of the mounting brackets have been secured to the roof the solar collector(s) can be installed. Refer to Figure 17 for these instructions. collector can then be set on the lower mounting brackets while the top clips are fastened over the lip on the collector frame. 1. Insert the stainless steel channel nut w/spring inside of the mounting bracket. 4.
COLLECTOR PIPING Care should be taken in the spacing of collectors as attachment of piping is easiest with properly aligned collectors. The connection between the collector panels is made with copper unions or couplings. To aid in installation the collector array layout should be planned on the ground and the unions or couplings soldered to the adjoining headers prior to lifting the collectors to the roof.
COLLECTOR PIPING DETAIL PIPING THROUGH THE ROOF The outlets of the collector are 1” copper pipe nipples. See Figure 19. They should be piped as shown with provisions for an air vent. The air vent must be oriented vertically as this must be the highest point in the system in order for air to escape. This will prevent air lock and subsequent loss of system efficiency. Teflon® tape or high temperature, high quality pipe sealant should be used when making threaded connections.
PUMP STATION INSTALLATION PUMP STATION Safety instructions The following instructions describe the installation, startup, function and operation of the solar pump station. The solar pump station may only be used in the collector circuit of a solar thermal installation. The technical data specified in these instructions must be observed. Improper usage excludes any liability claims.
PUMP STATION INSTALLATION Safety Equipment the solar pump station back cover, insert the retaining clips half way onto the mounting retaining stud (see Figure 23) behind the isolation ball valves (J, Q), push the assembly onto the bracket mounting stud and push the clip down into place. Ensure assembly is properly locked into place. For protection against excessive pressures in the collector loop a pressure relief valve is integrated into the solar pump station.
11. Check and set the pressure of the air bladder in the expansion tank to 25 psi. If the pressure is higher bleed pressure out until it is correct. If the pressure is too low add air by use of a compressor or bicycle pump until the pressure is correct. 12. Plumb the solar pump station to the storage tank and to the collector: The tank connections should use ¾” copper pipe and can be connected using the threaded adaptors provided.
Flowmeter 6. Connect an air pressure hose to the fill valve (P) below the pressure gauge (O) and open this valve. The flowmeter (U) serves to measure and display flow volume of the system in a range of 0.5-3.5 US gpm. It has an integrated restrictor (S) with adjustment valve which allows fine adjustment of the flow volume of the solar installation. In order to guarantee the flawless function of the measuring device the installation must be flushed and free from foreign substances.
solution provides freeze protection down to -30° F and burst protection down to -60° F. rate. If the flow rate is higher than necessary turn the flow restrictor (S) on the flowmeter with a flat head screwdriver to reduce the flow to the actual required. See Table 5. Use of heat-transfer fluid other than a maximum 50/50 mix by volume of Propylene Glycol and distilled or demineralized water is not permitted.
PUMP STATION CONTROL INSTRUCTIONS The power supply is connected to the following terminals: CONTROL INSTRUCTIONS 19 = Neutral - N 20 = Line power - L 12 = Ground The control is equipped with two relays, one for the integrated pump in the solar pump station and one for use in specialty custom applications requiring a second pump: • Relay 1 (primary pump) 18 = Line power - R1 17 = Neutral - N 13 = Ground • Relay 2 (secondary pump – optional, not included) 16 = Line power - R2 15 = Neutral - N 14 = Ground
System Monitoring Display The system monitoring display consists of 3 blocks: channel indication, the tool bar, and system screen. Complete monitoring display Channel indication The channel indication consists of two lines. The upper line is an alphanumeric 16 segment indication in which the channel name or menu item is shown. The lower 7 segment indication shows the channel value and the adjustment parameters are indicated.
Startup / System settings The AC power cord should be plugged in to an appropriate 115V outlet. The controller will enter an initialization phase in which the operating control lamp will flash red and green. After the initialization period the controller will be in automatic operation with the default settings active. The pre-adjusted system scheme is ARR 1. Other system settings are available, but this setting should not be changed for the system included in this package.
SMX: Maximum tank temperature Adjustment range: 40 to 205 °F Recommended setting: 160 °F If the maximum tank temperature is reached the control will prevent the pump from operating and heating the tank any further. Note: The controller will only allow the tank temperature to exceed the maximum tank temperature setting when the optional system cooling function (OCX) is active and the maximum collector temp (CMX) has been exceeded.
OREC: Recooling function Adjustment: OFF / ON Recommended setting: ON The recooling function is used to cool the tank when the maximum tank temperature (S MX) is exceeded, such as when the collector cooling function (OCX) is activated and the tank may reach 190 °F (emergency shut down of the tank). When the collector is 5° cooler than the tank the pump will run to dump excess heat from the tank in the piping and at the solar collector until the tank is cooled to the maximum tank temperature setting.
HND 1, HND 2: Pump operating mode Adjustment range: OFF / AUTO / ON Recommended setting: AUTO For system setup and service work the operating mode of the pump can be manually adjusted by selecting the adjustment value for HND 1 (primary pump) or HND 2 (optional secondary pump, not included).
TROUBLESHOOTING PROBLEM No hot water Not enough hot water CHECK THIS POSSIBLE CAUSE CORRECTIVE ACTION Storage water heater No power to auxiliary back-up heating element Check high temperature protection and push reset button on the heater thermostat. (Use caution when dealing with electricity.) Storage water heater thermostat Thermostat defective Replace Thermostatic mixing valve Improper adjustment Check water temperature at house faucet and adjust valve setting Valve defective Replace.
PROBLEM Not enough hot water (cont.) CHECK THIS Compare with system schematic. Check for proper connections. Seal all splices against moisture Isolation valves Closed Open Thermostatic mixing valve Improper adjustment Check water temperature at house faucet and adjust valve setting Valve defective Replace. System must not be run without thermostatic mixing valve due to scald risk.
PROBLEM Pump does not start Pump starts, but cycles continuously Pump cycles after dark Pump runs continuously Pump operated but no fluid flows from collectors Noisy system CHECK THIS Electrical power supply POSSIBLE CAUSE CORRECTIVE ACTION Controller plug disconnected Reconnect control plug to power outlet Blown fuse or breaker tripped on overload Determine cause and replace fuse or reset breaker Pump Motor failure Replace pump Sensors Defective sensors, sensor error Check wiring continui
SYSTEM MAINTENANCE Heat Transfer Fluid (HTF) Quality Solar Panel Clarity The chemical composition of the HTF may change over time. The HTF quality should be monitored on a periodic basis – at least annually. After summer and before any chance of the first freeze is an ideal time. A drop in ph can indicate the system has been stagnating frequently. The cause should be determined and corrected. If you live in a dusty climate, once a month wash off dirt that settles on the solar panel glass.
REPAIR PARTS REPAIR PARTS SCHEDULE ORDERING REPAIR PARTS The following parts may be ordered through the store or dealer from whom you purchased the solar water heater, or direct from the factory listed on the model & rating plate located on the lower front of the solar water heater and by phone at 1-800-433-2545. Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly.
DOWFROST HEAT TRANSFER FLUID Potential Health Effects Eye Contact: May cause slight temporary eye irritation. Corneal injury is unlikely. Skin Contact: Prolonged contact is essentially nonirritating to skin. Repeated contact may cause flaking and softening of skin. Skin Absorption: Prolonged skin contact is unlikely to result in absorption of harmful amounts. Inhalation: At room temperature, exposure to vapor is minimal due to low volatility.
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