Instruction Manual RESIDENTIAL SOLAR WATER HEATING SYSTEMS STANDARD SYSTEMS WITH DOUBLE 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 11 5 Flow Direction 4 Discharge Pipe (DO NOT CAP OR PLUG) 2 1 9 3 Metal Drain Pan 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 Double Wall Heat exchanger (inside Solar pump station) Transfers the heat from the collector loop to the potable water in the solar storage tank.
or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building. • 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. is not intended for outdoor installation. 2. It is handy to have a floor drain, tub or sink nearby.
for Canada. The particular application of this appliance described (above paragraph) may be subject to review and approval by local code officials. Toxic chemicals such as used for treatment of boilers or nonpotable water heating appliances shall never be introduced into a potable water space heating system. d. The cold water supply line must have a shut-off valve and union. 4. Use a union to connect the hot water supply pipe to the solar water heater’s hot water outlet.
WIRING OF ELEMENT BLACK Determine voltage and wattage from the rating plate attached to the solar water heater. All external wiring, connection, and overcurrent protective devices must be provided and installed in accordance with the latest edition of the National Electrical Code, local codes, and local utility requirements. The solar water heater must be electrically “grounded” by the installer. A green ground screw has been provided on the solar water heater’s junction box.
TEMPERATURE ADJUSTMENT hot water taps used by these people or at the solar water heater. Mixing valves are available at plumbing supply or hardware stores. Follow manufacturers instructions for installation of the valves. Before changing the factory setting of the thermostat, read the Temperature Adjustment section. KEEPING THE THERMOSTAT SETTING AT 120°F WILL REDUCE THE RISK OF SCALDS. Never allow small children to use a hot water tap, or to draw their own bath water.
freezing temperatures, it must be drained. Water, if left in the tank and allowed to freeze, will expand and damage the solar water heater. 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.
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 For protection against excessive pressures in the collector loop a pressure relief valve is integrated into the solar pump station. Drain tubing must be installed in the valve outlet so that any discharge will exit only within 6 inches above, or at any distance below the structural floor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances.
Installing the ½” copper to and from the collector using the compression fittings. Function Check valves 1. Push the union nut and the cutting ring onto the copper pipe . The pipe must protrude at least 3/8” (3 mm) from the cutting ring in order to ensure the force transmission and the sealing. 2. Insert the support sleeve into the copper pipe. 3. Insert the copper pipe with the plugged-on individual parts (, and ) all the way into the housing of the compression fitting . 4.
START-UP AND OPERATION OF THE SOLAR PUMP STATION FLUSHING 9. Disconnect the air pressure hose from the fill valve (d) 10. Connect a water hose from a water source with at least 40 PSI supply pressure to the fill valve (d). 11. Connect a discharge hose to the drain valve (h) and open this valve. Place the other end of the discharge hose into an appropriate drain. 12. Turn the supply ball valve (b) to 90° (horizontal) so that the valve is closed. 13.
23. 24. 25. 26. 27. 28. 29. HP transfer pump and another hose from the transfer pump to the fill valve (d) then open this valve. Turn on the transfer pump to fill the system with the glycol solution and allow to circulate for 15 minutes in order to flush as much air as possible from the system. Open the air vent at the top of the collector array until all of the air has been dispersed then close the air vent. Open the vent on the air scoop (j) with a flat head screwdriver.
PUMP STATION CONTROL INSTRUCTIONS CONTROL INSTRUCTIONS 9/10 = VBus (see VBus note) The power supply is connected to the following terminals: 19 = Neutral - N 20 = Line power - L 12 = Ground The control is equipped with two relays, one for the solar loop pump (upper - primary) and one for the water loop pump (lower - secondary) • Relay 1 (primary pump) 18 = Line power - R1 17 = Neutral - N 13 = Ground WARNING • Relay 2 (secondary pump) 16 = Line power - R2 15 = Neutral - N 14 = Ground ESD SENSITIVE Ele
SENSOR DESCRIPTION S1 Collector sensor S2 Secondary loop heat exchanger sensor S3 Tank sensor S4 Primary loop heat exchanger sensor RELAYS DESCRIPTION R1 Primary loop pump R2 Secondary loop pump OPERATION AND FUNCTION OPERATION CONTROL LAMP BACKWARDS FORWARDS 2 3 1 SET (SELECTION / ADJUSTMENT MODE) Figure 32. The controller is operated by 3 push buttons below the display. The forward key (1) is used for scrolling forward through the indication menu or to increase the adjustment values.
STATUS STANDARD FLASHING An adjustment value is being changed - SET MODE Relay 1 active Relay 2 active Maximum tank temperature reached Tank Emergency shutdown active Collector emergency shutdown active Collector minimum limitation active Antifreeze function activated Antifreeze function active Manual operation relay 1 ON Manual operation relay 2 ON Manual operation relay 1 / 2 OFF Sensor error Blinking control symbols • Pump is blinking while running • Sensors are blinking if the respective sensor indic
Time: Adjust the current time for the real time clock. The hours and minutes have to be adjusted separately, first the hours, then the minutes. Time format is 24 hours, e.g.
n1%, n2%: Current pump speed Display range 30 to 100% Indicates the current pump speed of the corresponding pump: h P1, h P2 Operating hours counter Display channel The operating hours counter adds up the solar operating hours of the respective relay (h P1, h P2). Full hours are shown on the display. - n1%: current pump speed pump 1 – primary loop - n2%: current pump speed pump 2 – secondary loop The total operating hours can be reset.
TMN: Minimum runtime Adjustment range 1 to 10 min Recommended setting: 2 min Solar loading will be carried out for the adjustable minimum runtime TMN during which the switch-off condition will be ignored to stabilize the system. If the temperature difference between the upper heat exchanger sensor S4 and the lower heat exchanger temperature sensor S2 falls below the switch-off temperature difference DTF both loops will be switched off.
CMN: Minimum collector temp. Adjustment range: 50 to 195 °F Recommended setting: 50 °F Channel only available when OCN is active This function is unnecessary if the system backup heating element has a set point maintained at 120 °F. OCF: Antifreeze function Adjustment: OFF / ON Recommended setting: OFF This function is used to transfer heat from the storage tank to the collector in order to avoid freezing of the heat transfer medium in some system types.
MED%: Concentration of antifreeze by volume % Adjustment range: 20 to 70% Recommended setting: 50 Channel only available when OHQM is active. The antifreeze concentration by % volume should be entered in this channel for OHQM to give an accurate reading.
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 PROPERTIES 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.
