Bradford-White Corp Solar Water Heater User's Manual
Contents
1. AIR VENT AIR SEPARATOR EXPANSION DRAIN CIRCULATOR TANK VALVE K TEMPERATURE lt I 7 AND PRESSURE XX ML FULL PORT RELIEF VALVE AE BALL VALVE FROM SOLAR COLLECTOR PRESSURE TO SOLAR COLLECTOR REDUCING FULL CORT VALVE EXPANSION TK BALL VALVE D N DRAIN VALVE DRAIN VALVE SOLAR WATER HEATER Figure 3 Solar Collector Piping in Closed loop Installation Water Connections continued 2 For a drainback solar heating system refer to Figure 4 The solar water heater connection labeled FROM SOLAR COLLECTOR should be piped to the solar collector supply piping Mount the circulator making sure the flow arrow points toward the water heater The use of shut off valves and unions are recommended for future service convenience Pipe and fittings between the solar collector and solar water heater must be 34 diameter or larger The piping or drainback tank must have a site glass located at a level above the circulator and water heater SOLAR COLLECTOR S VACUUM BREAKER COLD WATER SUPPLY HOT WATER OUTLET VENTING VALVE INTEGRATED MIXING DEMCE SITE GLASS EXPANSION TANK TEMPERATURE AND PRESSURE RELIEF VALVE DRAINBACK TANK FROM SOLAR COLLECTOR FULL PORT BALL VALVE TO SOLAR COLLECTOR FULL PORT BALL VALVE a DRAIN VALVE DRAIN VALVE E d SOLAR WATER HEATER Figure 4 Solar Collector Piping in Dr2. Dimension Inches MODE A B C D E F L 60 Gal 22 60 1 4 59 1 4 29 1 2 7 3 8 53 75 Gal 24 60 1 4 59 1 4 29 1 2 7 3 8 53 115 Gal 28 1 4 63 1 4 62 1 2 29 1 2 7 38 55 34 6 Specifications continued Table 2 Water Heater Capacities Tank Coil Coil Heat Approximat Approximate Capacity Volume Transfer Area e Wet Weight MODEL Gal Gal Sq Ft Dry Weight Lbs Lbs 60 Gal 60 2 5 14 2 210 695 75 Gal 75 2 5 14 2 236 832 115 Gal 115 2 5 14 2 340 1248 Table 3 Electric Backup Water Heater Ratings First Hour Standby Heat MODEL Supply Loss Rating Gallons F Hr 60 Gal 84 1 1 75 Gal 97 0 9 115 Gal 124 0 7 Solar Single wall Heat Exchanger Flow Specifications 0 40 0 35 Heat Exchanger Pressure Drop Curve 0 90 0 80 0 30 0 70 0 25 0 60 0 50 o 0 15 0 40 Total Pressure Drop PSI 0 10 0 30 0 05 0 00 4 5 6 7 Flowrate GPM 0 20 0 10 0 00 Total Head Loss Feet Figure 2 Solar Heat Exchanger Pressure Drop Chart SECTION III GENERAL INFORMATION FEATURES This water heater contains the following features HEAT EXCHANGER The heat exchanger coil is made of porcelain coated single wall carbon steel tubing and has 1 NPT female fittings If a confirmed leak occurs contact the plumbing professional who installed
3. Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved Plumbing and electrical work are required CONNECT SOLAR CONTROLLER AND THERMISTORS Sensor wires are provided for connection to the controller in a separate junction box located on top of the water heater The brown twisted wires provide thermistor wiring from the controller to the lower control cover located next to the TO SOLAR COLLECTOR connection The orange twisted wires provide thermistor wiring from the controller to the upper control cover The orange wiring would be used for controllers that have connections for a second tank location Electrical Connections continued NOTICE A solar control and thermistors are not supplied with this water heater The Tekmar 156 when installed according to manufacturer s instructions is an acceptable controller Other solar controller manufacturers such as Steca and Resol provide controllers appropriate for use with this water heater Thermistors are not included with the water heater Thermistors must be purchased with the solar controller to ensure capability with the selected control Contact the solar controller manufacturer for details Refer to Figure 8 for connecting the thermistor and pressing it against the tank This figure illustrates the opening under the upper control cover While the lower control location does not hold a thermostat the process is th
4. not enough solar heating available to meet the immediate need Approximately 1 3 of the storage tank volume needs to be removed without sufficient solar heating for the lower element to energize The typical solar water heater with electric backup has only one element In periods were solar heating is not available the amount of stored hot water is about 4 of the tank volume The dual electric element backup will allow the entire storage tank to hold hot water during these periods The unique design promotes solar heating yet does not compromise heater performance when it is not available The amount of heat transferred into the tank due to solar heating is inconsistent The more heat stored in the tank through solar heating the lower the operating costs The integrated mixing device must be installed to ensure that if higher temperatures are achieved safe water temperature delivery occurs It is recommended that storage tank temperatures are not allowed above 185 F Temperature levels above that point may activate the electric backup emergency cutoff device disconnecting the electric backup system SECTION V WATER CONNECTIONS INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE if not factory installed FAILURE TO INSTALL AND MAINTAIN A NEW LISTED TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES Hydrogen gas can be produced in an op
5. should install an ASSE approved mixing valve a device to limit the temperature of water to protect against scald injury via mixing hot and cold water supply in the water system This valve will reduce point of discharge temperature in branch supply lines This water heater was shipped with an ASSE approved mixing valve Install this valve according to the directions in the mixing device container DO NOT OPERATE THIS WATER HEATER A MIXING DEVICE If this water heater was shipped without a mixing device contact the manufacturer Water temperature over 125 F APPROXIMATE A N e F R can cause severe burns TIME TEMPERATURE instantly or death from scalds RELATIONSHIPS IN SCALDS Children disabled and elderly o are at highest risk of being 120 F More than 5 minutes scalded 125 F 1 V to 2 minutes Review this instruction manual 130 F About 30 seconds before setting temperature at water heater 135 F About 10 seconds Feel water before bathing or 140 F Less than 5 seconds showering m 145 F Less than 3 seconds Temperature limiting valves are available 150 F About 1 1 2 seconds 155 F About 1 second Figure 9 Scald Warning Table 7 Scald Relationships 20 Operating Instructions continued A CAUTION Before adjusting the thermostat turn off all power supplied to the solar water heater The minimum potable water temperature can be changed by adjusting the thermostat Be
6. the recommended capacity as necessary Do not attempt to repair the valve as this could result in improper operation and a tank explosion In areas with poor water conditions it may be necessary to inspect the temperature pressure relief valve more often than once a year N CAUTION Before manually operating the valve make sure that a drain line has been attached to the valve to direct the discharge to an open drain Failure to take this precaution could mean contact with extremely hot water discharging from the valve during this checking operation If the temperature pressure relief valve on the heater discharges periodically or continuously it may be due to thermal expansion of water in a closed water supply system or it may be due to a faulty relief valve Thermal expansion is the normal response of water when it is heated In a closed system thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled Then the relief valve will open allowing some water to escape slightly lowering the pressure Contact your water supplier or local plumbing inspector on how to control this situation ABOVE ALL DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE THIS IS NOTA SOLUTION AND CAN CREATE A HAZARDOUS SITUATION 3 Anode Inspection and Replacement This water heater is equipped with multiple sacrificial anodes Anodes protect the glass lined tank from corrosion by sacrificing themselves
7. the solar collector to transfer heat into the tank a The solar controller activates a circulator pump to flow fluid through the heat exchanger and solar collector transferring heat into the storage tank until the temperature difference is significantly reduced 2 The upper element thermostat senses that the water temperature stored in the upper portion of the tank drops below the desired setting a The upper element is energized to heat stored water to the desired temperature Once the water in the upper tank is heated to the desired temperature the element is de energized 3 The lower element thermostat senses that the water temperature stored above the solar heat exchanger drops below the desired setting a The lower element is energized to heat stored water to the desired temperature Once the water in the lower tank is heated to the desired temperature the element is de energized WATER TEMPERATURE ADJUSTMENT Table 7 details the approximate relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications N WARNING SCALDING This water heater can deliver scalding temperature water at any faucet in the system Be careful whenever using hot water to avoid scalding injury By setting the thermostat on this water heater to obtain an increased water temperature you may create the potential for scald injury To protect against injury you
8. the water heater or the manufacturer listed on the rating plate for additional guidance SINGLE WALL HEAT EXCHANGER MODELS Water heaters with single wall heat exchangers meets the Uniform Plumbing Code for installation in all potable water systems provided that e The heat transfer medium including additives is practically non toxic having toxicity rating of class of 1 as listed in Clinical Toxicology of Commercial Products e The heat transfer medium pressure is limited to maximum 30 psig by approved relief valve e The heat transfer medium is potable water or contains only substances that are recognized as safe by the U S Food and Drug Administration FDA e The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system e The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium BACKUP HEATING ELEMENTS WITH ADJUSTABLE THERMOSTATS The temperatures may be adjusted from approximately 100 F to approximately 180 F The thermostats are factory set at 120 F It is recommended that lower temperatures be used to avoid the risk of scalding Refer to the Warnings in the section on SCALDING in Section VII Operating Instructions It is further recommended in all cases that the water temperature be set for the lowest temperature that satisfies your hot water needs This will also provi
9. through electrolysis When the anode material is consumed there is no more protection and corrosion of the tank accelerates Inspection of the anodes every year allows you to identify spent anodes and replace Replace the anodes when its diameter is 3 8 of an inch or every other year which ever is first Aggressive very hot and softened water causes rapid consumption of the anode requiring frequent inspections Anodes are available from your distributor or from the manufacturer To inspect or replace an anode The anodes on this water heater are easily accessible from the top of the heater making replacement simple and quick a the water heater and if applicable solar controller electricity off Flow water until the discharge is cool or allow enough time for the potable water to cool naturally Connect a hose to the drain valve Locate the hose s discharge in an area where any remaining hot water will not cause any damage or injury b Open the drain valve to flush any sediment out of the bottom to the heater c Shut off the cold water supply Make sure all hot water fixtures and circulating pumps are turned off d Wait for water flow from the hose to stop Remove the anode using a socket of the appropriate size Do not use an impact wrench e Inspect and replace the anode as required Use pipe tape or sealant when reinstalling the anode f Close the drain valve Open a hot water fixture to allow air to escape Open the cold w
10. to determine if further adjustment is necessary Adjusting to a higher temperature may not immediately affect water temperature If a heat up cycle begins allow the heat up cycle to complete before checking the water temperature If a heat up cycle does not begin draw sufficient water or allow the water heater to remain idle until a heat up cycle is initiated After the heater s heat up cycle is complete check the water temperature at a faucet to determine if further adjustment is necessary 21 SECTION VIII MAINTENANCE This solar water heater is intended to provide a service life of many years Components that require service however may be subject to failure Failure to use the correct procedures or parts in these circumstances may make the water heater unsafe The owner should arrange to have the following inspections and simple maintenance procedure performed by qualified service personnel at the frequencies suggested 1 Solar and Domestic Water Piping Annual Check all piping for signs of leakage at joints unions and shut off valves Repair as needed 2 Temperature Pressure Relief Valve Annual The temperature pressure relief valve should be checked to ensure that it is in operating condition To check the relief valve lift the lever at the end of the valve several times The valve should seat properly and operate freely If water does not flow remove and inspect for obstructions or corrosion Replace with a new valve of
11. ATER HEATER WATER HEATER Figure 5 Water Heater Piping in a Two tank Installation The solar with electric element backup can be used to replace either the solar or backup water heater in the two tank installation Replacement installation configurations are provided in Figures 6 and 7 By replacing either tank with the new solar with backup heater replacing the remaining tank when it eventually fails may be unnecessary This is due to the solar heater s capability to satisfy the requirements of a two tank system Water Connections continued VACUUM BREAKER COLD WATER SUPPLY HOT WATER OUTLET EXPANSION TANK INTEGRATED MIXING DEVICE FULL PORT TEMPERATURE BALL VALVE AND PRESSURE d nn ANE RELIEF VALVE AIR SEPARATOR TEMPERATURE DRAIN AND PRESSURE VALV RELIEF VALVE CIRCULATOR FILL VALVE mages PRESSURE COLLECTOR REDUCING VALVE TO SOLAR EXPANSION TANK n pd DRAIN VALVE FULL PORT BALL VALVE DRAIN BACKUP VALVE WATER HEATER WATER HEATER Figure 6 Replacing the Solar Water Heater in a Two tank Installation To replace the previous solar water heater with the new solar water heater with electric backup remove the previous solar water heater The external heat exchanger and pump can also be removed The new solar water heater with electric backup has an internal heat exchanger allowing direct heat transfer to the water For installation of the ne
12. AUSE SOLUTION No hot water at faucet ECO on thermostat tripped Improper thermostat setting or calibration Determine if ECO trip is a result of excessive solar heat or electric element Correct or replace as necessary Depress red RESET button on thermostat Adjust tank thermostat to appropriate setting See Section VII Circulator does not pump fluid through solar collector Check electrical connections Check that proper valves are open Check that system is bled Replace as necessary Electrical problem Control wiring etc Check fuse and replace Check circuit breaker and reset if applicable Check power supply Scale build up If solar controller collectors circulator and tank are operating satisfactorily coil may have scale coating See Section VIII Maintenance Clogged cold water filter Clean or replace filter or strainer Water at faucet too hot Thermostat set too high Adjust thermostat setting See Section VII Improper system plumbing Compare plumbing to Section V Improper system wiring Compare wiring to Section VI Mixing Device temperature set too high Adjust Mixing Device setting Refer to Mixing Device instructions Insufficient hot water Thermostat setting too low Adjust thermostat to higher setting See Section VII Undersized solar collectors Review calculations for proper collector surface area orienta
13. RUCTIONS FOR POTABLE CONNECTIONS 1 BEFORE PROCEEDING WITH THE INSTALLATION CLOSE THE MAIN WATER SUPPLY VALVE After shutting off the main water supply open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater After the pressure has been relieved close the faucet The COLD water inlet and HOT water outlet are identified on the top of the water heater Install the mixing device supplied with the solar water heater following the installation instructions included with the mixing device Make the proper plumbing connections between the mixing device on the water heater and the plumbing system to the house Install a shut off valve in the cold water supply line 2 If this water heater is installed in a closed water supply system such as one having back flow preventer in the cold water supply provisions must be made to control thermal expansion DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion Warranties do not cover damages from thermal expansions such as pressure bulges and or deformities A properly sized expansion tank will alleviate most problems Your water supplier or local plumbing inspector should be contacted on how to control this situation 3 After installation of the water lines open the main water supply valve and fill the water heater While the water heater is filling open several h
14. SOLAR WATER HEATER WITH ELECTRIC BACKUP A Spanish language version of these instructions is available by contacting the manufacturer listed on the rating plate La version espanola de estas instruccions se puede obtener al escribirle a la f brica cuyo nombre aparece in la placa de especificaciones INSTALLATION OPERATING MANUAL WITH PARTS LISTING AND TROUBLESHOOTING GUIDE A WARNING To avoid damage or injury there must be no materials stored against the solar water heater and proper care shall be taken to avoid unnecessary contact especially by children with the solar water heater a Do not store or use gasoline or other flammable liquids in the vicinity of this water heater or any other appliance For your family s comfort safety and convenience we recommend this water heater storage unit be installed and serviced by a plumbing professional 238 47073 00B REV 2 08 CONGRATULATIONS You have just purchased one of the finest water heaters on the market today This installation operation and instruction manual will explain in detail the installation and maintenance of your new Solar Water Heater We strongly recommend that you contact a plumbing professional for the installation of this water heater We require that you carefully read this manual as well as the enclosed warranty and refer to it if questions arise If you have any specific questions concerning your warranty please consult the plumbin
15. TE Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee This water heater MUST be installed indoors out of the wind and weather A CAUTION This water heater must be located in an area where leakage of the tank water line connections or the temperature and pressure relief valve will not result in damage to the area adjacent to the water heater storage unit or to lower floors of the structure When such locations cannot be avoided a suitable drain pan must be installed under the water heater storage unit The drain pan depth must be suitable for draining and collecting water The drain pan can be purchased from your plumbing professional The drain pan must be piped to an adequate drain The piping must be at least 34 inch in diameter and pitched for proper drainage Component Location Clearance from Combustible Materials wp 97 4 Oe Table 5 Combustible Material Clearances Recommended Service Clearances Side Heat Exchanger Rear Valve Side Table 6 Service Clearances 1 Heater CAUTION Do not drop water heater Do not bump water heater jacket against floor Location For fastest delivery of hot water place the solar water heater closest to the points of use Additional Recommended Components 1 Shut off Valves Allows isolation of water heater from domestic water system and or solar system during service 2 Unions Allows water heater moveme
16. ainback Installation FILL SOLAR COLLECTOR SYSTEM 1 2 3 solar heating system appropriately with water propylene glycol water mix Verify pump flow and direction In a closed loop system purge all air from the collector water heater piping Check system for leaks Repair as necessary a Inaclosed loop system check for leaks when flow is stopped and the operating pressure is maintained Water Connections continued TWO TANK SYSTEM INSTALLATION THE TYPICAL TWO TANK SYSTEM A typical two tank system is provided in Figure 5 This system holds two separate volumes of water The cold water supply is delivered to the solar water heater If solar energy is available the water in the solar heater is heated This heated water is delivered into the backup water heater If no solar energy were available the backup water heater would heat the water through electric elements or gas combustion depending on the backup water heater SOLAR COLLECTOR S VACUUM BREAKER ST COLD WATER SUPPLY HOT WATER OUTLET TEMPERATURE AND PRESSURE RELIEF VALVE EXPANSION TANK FULL PORT FULL PORT AIR VENT BALL VALVE BALL VALVE CIRCULATOR A TEMPERATURE AIR SEPARATOR ft AND PRESSURE CIRCULATOR o S RELIEF VALVE a FILL VALVE PRESSURE REDUCING DRAIN VALVE VALVE EXPANSION TANK cs S P 6 Mx V 6 MAX DRAIN VALVE EXTERNAL NL i HEAT EXCHANGER DRAIN SOLAR BACKUP VALVE W
17. anuals which are provided with the appliance before installing starting up operating maintaining or servicing this appliance Keep this manual and literature in legible condition and posted near the appliance for reference by owner and service technician This water heater requires regular maintenance and service to operate safely Follow the instructions contained in this manual Installation maintenance and service must be performed only by an experienced skilled and knowledgeable installer or service agency Important Information continued VAN WARNING It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete DO NOT operate the water heater with jumpered or absent controls or safety devices DO NOT tamper with or alter the water heater and or controls DO NOT operate the water heater if any external part or control has been submerged in water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system that was under water This water heater is suitable for installation on combustible flooring DO NOT install this water heater on carpeting DO NOT operate this water heater without first being certain it is filled with water Flammable items pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the heate
18. anufactured under one or more of the following U S Patents RE 34 534 B1 5 341 770 4 416 222 4 628 184 4 669 448 4 672 919 4 808 356 4 829 983 4 861 968 4 904 428 5 000 893 5 023 031 5 052 346 5 081 696 5 092 519 5 115 767 5 199 385 5 277 171 5 372 185 5 485 879 5 574 822 5 596 952 5 660 165 5 682 666 5 761 379 5 943 984 5 954 492 5 988 117 6 142 216 6 395 280 6 684 821 7 007 748 7 063 132 Other U S and Foreign patent applications pending Current Canadian Patents 1 272 914 1 280 043 1 289 832 2 045 862 2 092 105 2 107 012 2 108 186 2 112 515 Complete the following information and retain for future reference Model No Serial No Service Phone Days Nights Address Supplier Supplier Phone No 26 SECTION XI NOTES 27 SECTION XI NOTES 28
19. ater supply to the heater and allow the tank to fill g Check your anode and drain valve for leaks h Turn water heater and if applicable solar controller electricity on 22 Maintenance continued 4 Sediment Annual but harsh water quality may dictate more frequent service Depending on water conditions a varying amount of sediment may collect in the tank Levels requiring service are indicated by a small temperature difference in the supply and return lines See also Scale below Repeated flushing usually clears such material As a preventive measure water should be drawn from the tank at the drain valve until it runs clear Scale Annual Hard water may cause scale to build up on the outside of the heat exchanger coil A water softener will prevent this problem See also Sediment above Symptoms would be reduced recovery capacity or reduced temperature differential between solar collector supply and return lines Repeated flushing should resolve the problem Solar Controller The solar controller manufacturer may have a recommended maintenance procedure Refer to the installation and operation manual that was received with the solar controller Solar Collector Panels The solar collector panel manufacturer may have a recommended maintenance procedure Refer to the installation and operation manual that was received with the solar collector panels 23 SECTION IX TROUBLESHOOTING GUIDE PROBLEM C
20. de the most energy efficient operation of the water heater and minimizes scale formation The thermostat located under the middle cover controls the lower heating element This ensures that only when the solar heating system cannot satisfy user demand that the lower heating element is energized Setting the water heater temperature at 120 F will reduce the risk of scalds Some states require settings to specific lower temperatures SENSOR WIRES FOR SOLAR THERMISTOR CONNECTIONS Twisted wires are provided under the lower and upper covers These wires have been provided as a means for connecting thermistors to a solar controller NOTICE Neither the solar controller nor the thermistors are provided with the solar water heater and must be purchased separately The lower thermistor wires connect a thermistor for use in comparison to the solar collector temperature to determine if an appropriate temperature difference for heat transfer is available The upper thermistor wires are an optional second thermistor connection to monitor the upper tank temperature Some solar controllers provide this option INTEGRATED MIXING DEVICE An ASSE approved temperature mixing device is supplied with the water heater The solar heating system may transfer heat into the water heater above the temperature limits set by the thermostats This may create the potential for scald injury To protect against injury you must install the supplied ASSE approved mixing valve a devic
21. e same 1 Positively assure all electrical connections are unpowered whenever removing the control covers Strip the twisted wire ends and use wire nuts to securely connect the thermistor wires 3 Pull the insulation material away slightly from the water heater tank 4 Slide the thermistor between the insulation and the water heater tank a The upper tank thermistor should be inserted as shown in the lower right hand corner b Thelower tank thermistor should be inserted half way up on the right hand side Verify that the insulation provides enough pressure to hold the thermistor in place 6 To assure that the thermistor does not move apply a small amount of high temperature silicon sealant in the insulation gap produced where the thermistor has been inserted 7 Return power to the water heater once the covers are in place COVER F OPENING eA THERMOSTAT BROWN WIRES THERMISTOR NOT INCLUDED WIRE NUTS BRACKET ELEMENT THERMISTOR NOT INCLUDED Ov J N ncc ORANGE WIRES Figure 8 Wiring and Placement for the Solar Control Thermistor SECTION VII OPERATING INSTRUCTIONS SYSTEM START UP Follow solar collector installation instructions to place collector in operation Ensure that solar fluid flow operation is established for the installed system SEQUENCE OF HEATING OPERATIONS SOLAR AND ELECTRIC BACKUP 1 The solar controller senses a large enough temperature difference between the lower tank and
22. e to limit the temperature of water to protect against scald injury via mixing hot and cold water supply in the water system This valve will reduce point of discharge temperature in branch supply lines Refer to the instructions supplied in the Integrated Mixing Device box for installation procedures and device specifications ZN CAUTION This water heater must NOT be operated without the Integrated Mixing Device included in the box with the heater General Information continued SACRIFICIAL ANODES Two sacrificial anode rods have been installed in the tank head to extend tank life The anode rods should be inspected annually to determine the amount of sacrificial decay and replaced when necessary to prolong tank life The permanent removal of these anodes for any reason will nullify the warranty Water conditions in your area will influence the time interval for inspection and replacement of the anode rod The use of a water softener may increase the speed of anode consumption More frequent inspection of the anode is needed when using softened or phosphate treated water Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information TEMPERATURE AND PRESSURE RELIEF VALVE N WARNING Keep clear of the combination temperature and pressure relief valve discharge line outlet The discharge may be hot enough to cause scald injury The water is under pres
23. eady be equipped or supplied with a combination temperature and pressure relief valve Verify that the combination temperature and pressure relief valve complies with local codes If the combination temperature and pressure relief valve does not comply with local codes replace it with one that does Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six 6 inches above or any distance below the structural floor and cannot contact any live electrical part The discharge line is to be installed to allow for complete drainage of both the temperature and pressure relief valve and the discharge line The discharge opening must not be subjected to blockage or freezing DO NOT thread plug or cap the discharge line Itis recommended that a minimum clearance of four 4 inches be provided on the side of the water heater storage unit for servicing and maintenance of the combination temperature and pressure relief valve Do not place a valve between the combination temperature and pressure relief valve and the tank SECTION IV PRE INSTALLATION UNPACKING INSPECT SHIPMENT carefully for any signs of damage If damage is noted do not install the product Contact the shipper or manufacturer listed on the rating plate All equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of the packaged water heater to the carrier in good condition NO
24. erating water heater that has not had water drawn from the tank for a long period of time HYDROGEN GAS IS EXTREMELY FLAMMABLE To prevent the possibility of injury under these conditions we recommend the hot water faucet be opened for several minutes at the kitchen sink before you use any electrical appliance that is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open Keep clear of the temperature and pressure relief valve discharge line outlet The discharge may be hot enough to cause scald injury The water is under pressure and may splash Keep clear of the temperature and pressure relief valve discharge line outlet The discharge may be hot enough to cause scald injury The water is under pressure and may splash Temperature and pressure relief valve discharge piping must be piped near the floor to eliminate potential of severe burns Do not pipe in any area where freezing could occur Do not install any shut off valves plugs or caps to the temperature and pressure relief valve or piping A CAUTION If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater Sweat the tubing to the adapter before fitting the adapter to the water connections It is imperative that heat is not applied to the nipples containing a plastic liner INST
25. fore any work is done on the water heater disconnect all power to the water heater and heat source solar collector by opening the switch s at the main electrical circuit breaker or fuse box Remove the cover and fold the insulation outward away from the control Adjust the thermostat dial using a screwdriver until the minimum acceptable temperature is achieved The thermostat has been factory preset to 120 F 49 C Remember that lower temperature settings are more energy efficient Rotate the temperature dial clockwise _ to increase water temperature Rotate the thermostat dial counter clockwise to decrease the temperature setting Replace the insulation making sure that the control is well covered and that the plastic terminal shield has not been displaced Replace the access panel The water heater is now ready for operation and the main switch can be closed TEMPERATURE DIAL Figure 10 Thermostat After the solar water heater completes a heat up cycle check the water temperature at a faucet Allow enough water to flow to ensure that the faucet water temperature reflects the tank temperature Adjust the water heater s temperature setting as necessary Adjusting to a lower temperature setting will not immediately affect water temperature Draw sufficient water or allow the water heater to remain idle until a heat up cycle is initiated After the heater s heat up cycle is complete check the water temperature at a faucet
26. g professional from whom your water heater was purchased For your records we recommend that you write the model serial number and installation date of your solar water heater in the back of this manual This manual should be kept with the solar water heater We re committed to providing you with the finest water heater made SECTIONI IMPORTANT INFORMATION READ CAREFULLY The equipment must be installed in accordance with those installation regulations required in the area where the installation is to be made These regulations must be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made All wiring on water heaters installed in the USA must be in accordance with the National Electrical Code ANSI NFPA 70 latest edition and or local regulations or in Canada installed in accordance with the Canadian Electrical Code CSA C22 1 latest edition and or local regulations The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life CAUTION Indicates an imminently hazardous Indicates a potentially hazardous situation which if not avoided will situation which if not avoided result in death serious injury or may result in moderate or minor substantial property damage injury or property damage AN WARNING OE Indicates a potentially hazardo
27. nal injury and or death The temperature at which injury occurs varies with the person s age and the time of exposure The slower response time of disabled persons increases the hazards to them NEVER allow small children to use a hot water tap or to draw their own bath water NEVER leave a child or disabled person unattended in a bathtub or shower A WARNING Installation is not complete unless a properly sized capacity pressure and temperature relief valve is installed into the side of the water heater See the General Information section of this manual for details This water heater contains very hot water under high pressure Do not unscrew any pipe fittings or attempt to disconnect any components of this water heater without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this water heater to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the water heater This water heater contains components that become very hot Do not touch any components unless they are cool Improper installation adjustments alteration service or maintenance can cause property damage personal injury or loss of life Failure to follow all instructions in the proper order can cause personal injury or death Read and understand all instructions including all those contained in component manufacturer s m
28. ng heat that was not transferred into the backup tank is then made available to the previous solar water heater before going back to the solar collector One installation advantage is that the solar heat makes up for heat losses that occur when water is not flowing Another is that more heat is absorbed into the potable water system from the solar water heating system 17 SECTION VI ELECTRICAL CONNECTIONS Install electric wiring in accordance with the National Electric ANSI NFPA 70 and or the CSA C22 1 Electric Code latest editions NDANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the water heater or building Lock out all electrical boxes with padlock once power is turned off N WARNING When installed the water heater must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electric Code latest editions Failure to properly wire electrical connections to the water heater may result in serious physical harm Electrical power may be from more than one source Make sure all power is off before attempting any electrical work CONNECT ELECTRIC HEATING ELEMENT BACKUP Before any electrical connections are made be sure that the water heater is full of water and that the valve in the cold water supply line is open The s
29. nt during service if adequate clearance cannot be provided 3 Thermal Expansion Tank If the water heater is installed in a closed water supply system such as one having a back flow preventer in the cold water line provide thermal expansion control Contact the water supplier or local plumbing inspector for additional information MOVE THE WATER HEATER TO A PERMANENT POSITION BY SLIDING OR WALKING Pre installation continued For California installation this water heater must be braced anchored strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California Office of the State Architect 400 P Street Sacramento CA 95814 SOLAR WATER HEATING WITH ELECTRIC BACKUP FUNDAMENTALS The solar heating system puts the most amount of heat into the storage tank when the bottom of the tank is cool That is where the internal heat exchanger is located This allows the collector temperature to be lower and still transfer heat into the storage tank When hot water is taken from the top of the tank cool water is delivered to the tank bottom by means of a diptube The thermostat to turn on the lower heating element is located above the internal heat exchanger s level to ensure that the heat exchanger stays in a cool zone unless backup heat is needed If the lower heating element thermostat is activated this is an indication that there is
30. olar water heater is supplied with a dual electric heating element backup system The upper thermostat incorporates a manual reset temperature limiting device Please refer to the TROUBLESHOOTING GUIDE section for manual reset operation Both upper and lower thermostats incorporate a manual adjustable temperature indicator to change the potable water temperature The thermostat that controls the lower heating element is located next to the FROM SOLAR COLLECTOR connection Refer to WATER TEMPERATURE ADJUSTMENT in the OPERATING INSTRUCTIONS section for proper instruction in adjusting water temperature Turn off all power related to the heating system before proceeding with the electrical connections Any and all wiring shall be sized and installed to satisfy the voltage and amperage used The water heater must be well grounded A green ground screw is provided at the electrical connection point for connecting a ground wire All wiring shall be done in accordance with all applicable local and state codes N WARNING Water heaters are heat producing appliances To avoid damage or injury there must be no materials stored against the water heater and proper care must be taken to avoid unnecessary contact especially by children with the water heater UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THE WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER
31. ot water faucets to allow air to escape from the water system When steady streams of water flow through the faucets close them and check all water connections for possible leaks 4 NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN THAT IT IS FILLED WITH WATER Water Connections continued INSTRUCTIONS FOR SOLAR CONNECTIONS The solar water heater connection labeled TO SOLAR COLLECTOR should be piped to the solar return piping The use of a union and a shut off valve is recommended Pipe and fittings between the solar system and the water heater should be 34 diameter or larger ZN CAUTION Maximum solar collector water supply temperature to the solar heat exchanger must not exceed 250 F 121 C ONE TANK SYSTEM INSTALLATION CONNECT SOLAR PIPING TO WATER HEATER 1 For a closed loop solar heating system refer to Figure 3 The solar water heater connection labeled FROM SOLAR COLLECTOR should be piped to the solar collector supply piping Mount the circulator making sure the flow arrow points toward the water heater The use of shut off valves and unions are recommended for future service convenience The use of an air separator and vent is recommended to eliminate air in the system Pipe and fittings between the solar collector and solar water heater must be 34 diameter or larger 22 SOLAR COLLECTOR S VACUUM BREAKER COLD WATER M HOT WATER OUTLET SUPPLY FULL PORT INTEGRATED BALL VALVE MIXING DEVICE
32. r Containers of flammable gases should not be stored or used in the same room with this water heater Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions it is recommended that a water faucet be opened for several minutes at the kitchen sink before you use any electrical appliance that is connected to the hot water system If hydrogen is present there will be unusual sounds such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open CAUTION The maximum supply temperature from the solar collector must not exceed 250 F 121 C SECTION II SPECIFICATIONS HOT WATER OUTLET 3 4 NPT COLD WATER INLET 3 4 NPT ANODES SOLAR SENSOR WIRING JUNCTION BOX OPTIONAL OUTLET FOR RECIRCULATION 60 amp 75 GAL MODELS ELECTRIC HIGH VOLTAGE WIRING JUNCTION BOX TEMPERATURE AND PRESSURE RELIEF VALVE UPPER COVER SOLAR THERMISTOR WIRES THERMOSTAT UPPER HEATING ELEMENT UNDER COVER FROM SOLAR COLLECTOR 1 NPT MIDDLE COVER THERMOSTAT UNDER COVER TO SOLAR COLLECTOR 1 NPT DRAIN COUPLING 3 4 NPT DRAIN VALVE 5 8 NH LOWER COVER SOLAR THERMISTOR WIRES LOWER HEATING ELEMENT UNDER COVER Figure 1 Tank Layout Table 1 Water Heater
33. sure and may splash For protection against excessive temperatures and pressure install temperature and pressure protective equipment required by local codes but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 and the Standard CAN1 4 4 Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves The combination temperature and pressure relief valve must be marked with a maximum set pressure not to exceed the maximum working pressure of the water heater The combination temperature and pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not less than the hourly rating of the water heater storage unit The supplied combination temperature and pressure relief valve when properly installed and unrestricted will discharge the maximum input produced by a 240 F 115 C collector supply temperature A lower collector supply temperature will reduce the input required to be discharged in the event of excessive potable water temperatures Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater storage unit Some models may alr
34. tion and available sunlight Faulty solar sensor or solar controller Check connections power and sensor resistance Replace as necessary Peak use of hot water is greater than tank storage capacity Determine peak usage and compare to tank capacity Circulator does not pump fluid Check electrical connections Check that proper valves are open Check that system is bled Replace as necessary Faulty tank thermostat Replace thermostat 24 SECTION X PARTS LIST PART NAME amp DESCRIPTION 1 Hole Closure 11 Element Gasket 2 Hex Head Anode 12 Thermostat with ECO 89T33 3 Integrated Mixing Device 13 Thermostat Mounting Bracket 4 Hot Water Outlet Anode 14 Heating Element 5 Cold Water Inlet Diptube 15 Thermostat Protector Large 6 Electrical Outlet Cover 16 Access Cover 7 Conduit Grounding Cover 17 Exchanger Escutcheon 8 Escutcheon 18 Thermostat 59T 9 T amp P Relief Valve 19 Lower Thermostat Protector 10 34 Plug 20 Brass Drain Valve Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on the rating plate of the water heater Provide the part name model and serial numbers of the water heater when ordering parts READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED M
35. us Indicates special instructions on situation which if not avoided could installation operation or result in death serious injury or maintenance which are important substantial property damage but not related to personal injury hazards TABLE OF CONTENTS IMPORTANT INFORMATION SPECIFICATIONS GENERAL INFORMATION PRE INSTALLATION WATER CONNECTIONS ONE TANK SYSTEM INSTALLATION TWO TANK SYSTEM INSTALLATION ELECTRICAL CONNECTIONS Important Information continued VAN DO NOT store or use gasoline or other flammable combustible or corrosive vapors and or liquids in vicinity of this or any other appliance IF YOU SMELL GAS DO NOT try to light any appliance DO NOT touch any electric switch do not use any telephone in your building Immediately call your gas supplier from a telephone in another building Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED Liquefied petroleum gas propane gas is heavier than air and will remain at floor level if there is a leak Basements crawl spaces closets and areas below ground level will serve as pockets for accumulation of leaking gas This water heater is supplied with adjustable thermostats to control water temperature Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious perso
36. w solar water heater with electric backup refer to INSTRUCTIONS FOR POTABLE CONNECTIONS earlier in this section and Figure 6 The potential for not transferring the solar heat into the solar water heater due to a pump malfunction is reduced when the second pump is removed from the system Water Connections continued 22 77 VACUUM BREAKER COLD WATER SUPPLY FULL PORT EXPANSION INTEGRATED TANK MIXING DEVICE BALE VALVE AR VENT FROM SOLAR CIRCULATOR E AIR SEPARATOR DRAN HEAT EXCHANGER EM DRAN le a Dx 2 FULL PORT sk BALL VALVE S CIRCULATOR H EE FULL PORT TO SOLAR REDUCING BALL VALVE SOUR m PS AT EXPANSION TANK PEE Dd DRAIN x DRAIN VALVE PREVIOUS SOLAR NEW SOLAR VALVE WATER HEATER WATER HEATER WITH BACKUP Figure 7 Replacing the Backup Water Heater in a Two tank Installation To replace the previous backup water heater with the new solar water heater with electric backup remove the backup water heater The new solar water heater with electric backup has an internal heat exchanger allowing direct heat transfer to the water For installation of the new solar water heater with electric backup refer to INSTRUCTIONS FOR POTABLE CONNECTIONS earlier in this section and Figure 7 Connect the solar piping in series from the new solar water heater to the previous solar water heater as shown in Figure 7 This allows the solar heat to transfer directly into the backup tank The remaini
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