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American Water Heater 318281-000 User's Manual

1. A Heat quantity measurement is possible for this system in conjunction with the flow meter In order for this function measure the heat gain of the system the optional temperature sensor 4 return flow sensor must be added and connected to the copper pipe between the coil outlet on the tank marked to pump and the solar pump station For OHQM to give an accurate reading the volume flow readable at the flowmeter gal min must be adjusted in the channel FMAX For OHQM to give an accurate reading the type of heat transfer fluid type antifreeze must be set in the channel MEDT 0 water 1 propylene glycol 2 ethylene glycol 3 Tyfocor LS G LS Caution for this system type only type 1 propylene glycol should be selected Use of any other type of heat transfer fluid in this system may cause damage to the system or present a health hazard MED Concentration of antifreeze by volume Adjustment range 20 to 70 Default setting 45 Recommended setting 50 Channel only available when is active kWh MWh Heat quantity value shown in the kWh and MWh display channels The sum of both channels form the total heat output Channel only available when is active HND 1 HND 2 Pump operating mode Adjustment range OFF AUTO ON Default setting AUTO LANG Controller language Adjustment range De En It Fr Default setting En UNIT Temperature units Adjustment FAH C
2. Adjust the value using button 1 or 2 until the desired value is shown then press button 3 so that permanently appears The adjusted value is now saved System Monitoring Display AN 0 0 system monitoring display consists of 3 blocks channel indication the toolbar and system screen 5888x Complete monitoring display Channel indication The channel indication consists of two lines The upper line is an alphanumeric 16 EEEN 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 88 88 indicated Temperatures are indicated in F C Temperature differences are indicated in F K Toolbar k 4 0 The symbols in the toolbar indicate the current system status SYMBOL STANDARD FLASHING xx Maximum tank limit reached maximum tank Collector cooling function active temperature exceeded Antifreeze function activated Collector minimum temperature reached Collector security shutdown or tank security shutdown active max temperature reached AN 2 Sensor error Manual operation active 2 Displayed channel indication is adjustable Adjustment mode for displayed channel System Screen 2 The system screen active system scheme shows the scheme selected on the fE controller It consists of several component symbols which are depending on the oe current status of
3. Excessive condensation Glazing dirty Check orientation Face collector within 45 of due South Remove obstacle and shading or relocate collectors Check tilt for geographic area Ensure tilt is equal to latitude plus 15 Compare with system schematic and correct Orientation Shaded by tree s or other obstructions Improper tilt Improperly plumbed Differential Controller Improper operation cycling late turn on Faulty sensor AN is shown and control reads 888 8 instead of temperature Faulty sensor a is shown and control reads 88 8 instead of temperature Check sensor placement and insulation from ambient conditions Sensor line break Check the line and repair or replace Short circuit Check the line for breaks metal contact water exposure and corrosion PROBLEM CHECK THIS POSSIBLE CAUSE CORRECTIVE ACTION Not enough hot water cont Differential Controller Improper wiring or loose Compare with system connections 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 Insufficient Insulation Add insulation where required High heat losses Check insulation for splits deterioration absence Nighttime thermo
4. necessary to confirm proper installation and operation of the water heater as they relate to the installation of electric water heaters The service agency must have a thorough understanding of the water heater Instruction Manual GENERAL SAFETY AWARNING CAUTION Read dn this de bia Improper installation and use may result manuali ana sa messages petore installing operating or servicing this in property damage water heater Do not operate water heater if flood damaged Failure to follow these instructions Inspect and replace anode and safety messages could result in Install in location with drainage death or serious injury e Fill tank with water before operation This manual must remain with water Be alert for thermal expansion heater Refer to this manual for installation and service A WARNING A WARNING Deis ona panels or servicing the water Overheated water can cause heater make sure the electrical watertank explosion supply to the water heater is turned OFF Properly sized temperature and pressure relief valve must iFailure to do this could resurtin be installed in opening bodily injury or provided property samagss ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for sca
5. physically or mentally disabled are at highest risk for scald injury ADANGER Feel water before bathing or showering Temperature limiting valves are available The indirect coil in this unit is a single wall and may only be used in a closed loop fill only with a mixture of propylene glycol containing corrosion inhibitors such as Dowfrost HD 5096 by volume maximum and distilled or de mineralized water Never fill with a toxic liquid Use of any heat transfer fluid other than that specified or failure to operate the heat exchanger in a closed loop will void the warranty and may result in poor performance equipment damage or risk to health and safety This solar water heater shall not be connected to any heating systems or component s previously used with a non potable water heating appliance 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 Toxic chemicals such as used for treatment of boilers or non potable water heating appliances shall never be introduced into a p
6. CEL Celsius The final two channels indicate the current program and version number for the controller To exit out of the system setting mode press the backward button 2 repeatedly until you reach the first display channel COL 30 TROUBLESHOOTING PROBLEM CHECK THIS POSSIBLE CAUSE CORRECTIVE ACTION No hot water Storage water heater No power to auxiliary back up Check high temperature heating element protection and push reset button on the heater thermostat Use caution when dealing with electricity Storage water heater Thermostat defective Replace thermostat 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 Undersized for hot water Replace demand load Thermostat set too low Increase set point temperature Element failure Replace element Thermostat failure Replace thermostat Element disconnected Reconnect element and set thermostat to 120 F Heat loss due to defective Inspect valve and repair or check valve in solar pump replace station Cold water supply dip tube Missing or defective Replace dip tube Collectors Absorber coating degredation Replace collector Collector panel area Increase collector area undersized Inspect and clean weep holes and vents at bottom Clean as required Not enough hot water Storage water heater Check valve
7. HE Adjustment OFF ON Default setting OFF Recommended setting OFF OHQM Heat quantity measurement OHH Mise Adjustment OFF ON ae Default setting OFF Recommended setting OFF FMAX Volume flow in gal min Adjustment range 0 0 to 20 0 in steps of 0 1 Default setting 6 0 Recommended setting pump station flow meter reading FMHX 50 Channel only available when is active MEDT Type of antifreeze ME 1 EN Adjustment range 0 to 3 Default setting 1 Recommended setting 1 Channel only available when is active 29 This function is used to transfer heat from the storage tank to the collector in order to avoid freezing of the heat transfer medium is some system types This system uses a solution of propylene glycol and water and is freeze resistant to 30 F therefore this function is not necessary 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 203 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 The tube collector function is only needed for systems that use vacuum tube solar collectors This function is not necessary for this system
8. HEATERS TO PREVENT DAMAGE DUE TO LEAKAGE REFER RELIEF IN COLD TO WATER HEATER LOCATION SEE WATER INLET LINE AS LOCATING THE SOLAR WATER REQUIRED BY LOCAL HEATER SECTION CODES INSTALL THERMAL EXPANSION TANK OR DEVICE IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM INSTALL VACUUM Figure 1 6 TABLE 1 Solar collector Absorbs the sun s heat energy and transfers this to the heat transfer fluid circulating through the collector Solar storage tank Stores potable water heated by solar generated heat or installed back up electric resistance element Heat exchanger Not Shown Transfers the heat from the collector loop to the potable water in the solar storage tank Expansion tank Allows for the expansion and contraction of the heat transfer fluid as it heat and cools Temperature and Pressure relief Required by plumbing code to automatically open and dump water if valve the storage tank exceeds 150 PSI of pressure or 210 F in tempera ture Air vent Purges air from the collector loop fluid during the installation and is shut off later on to prevent glycol losses in steam phase 7 Used to drain the heat transfer fluid from the collector loop Mixing valve Used to temper hot water from the solar storage tank with cold inlet water to maintain appropriate temperature hot water delivered from the system Solar pump station Controls the flow of heat transfer fluid from the collectors to the tank heat exchanger For
9. devices and water softening methods can increase the rate of anode rod depletion Once the anode rod is depleted the tank will start to corrode eventually developing a leak Certain water conditions will cause a reaction between the anode rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfide gas dissolved in the water IMPORTANT Do not remove this rod permanently as it may void any warranties A special anode rod may be available if water odor or discoloration occurs NOTE This rod may reduce but not eliminate water odor problems The water supply system may require special filtration equipment from a water conditioning company to successfully eliminate all water odor problems Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water softener may decrease the life of the water heater tank The anode rod should be removed from the water heater tank every 3 years for inspection NOTE artificially softened water requires the anode rod to be inspected annually The following are typical but not all signs of a depleted anode rod The majority of the rod s diameter is less than 3 8 Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod shows signs of either or both it should be re
10. large quantities of hot water are being used we recommend leaving the backup heater turned on and set to 120 F to provide adequate hot water 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 This manual contains instructions for the installation operation and maintenance of the solar water heater It also contains warnings throughout the manual that you must read and understand All warnings and all instructions are essential to the proper operation of the water heater and your safety READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER 2 The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company In the absence of local code requirements follow NFPA 70 the National Electrical Code current edition which may be ordered from National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 3 If after reading this manual you have any questions or do not understand any portion of the instructions call the local utility or the manufacturer whose name appears on the rating plate 4 Carefully plan your intended placement ofthe water heater and collectors INSTALLATION OR SERVICE
11. or with the atmosphere The collector loop contains only a small volume of heat trans fer fluid which is non toxic and freeze protected to 30 F Freeze tolerance limits are based upon an assumed set of environmental conditions Though freeze protec tion may not be necessary in all areas the heat transfer fluid also contains corrosion inhibitors which protect the system components has an elevated boiling point and is suitable throughout North America 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 to the tank The hot fluid passes through the heat exchanger and heat is transferred to the potable water After giving up its heat to the potable water the cool heat transfer fluid is pumped back to the solar collectors to be heated again Hot potable water is stored in the solar storage tank The auxiliary or back up electric heating guarantees hot water even under poor solar conditions at night or when very cloudy The minimum acceptable temperature set point is specified in local plumbing codes You can save the most money on your water heating bills by 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 water hot throughout the rest of the day and night However on days when the sky is cloudy or when
12. period of time generally two weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame 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 using any electrical appliance which is connected to the hot water system If hydrogen is pres ent there will probably be an unusual sound such as air escaping through the faucet as water begins to flow Do not smoke 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 of plumbing and electrical installation of these appliances This would include a thorough understanding of the requirements of the National Electrical Code and applicable local electrical and plumbing codes and tools necessary to confirm proper installation and operation of the water heater as they relate to the installation of electric water heaters The qualified installer must have a thorough understanding of the water heater Instruction Manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing and electrical installation of these appliances This would include a thorough understanding of the requirements of the National Electrical Code and applicable local electrical and plumbing codes and tools
13. permits and approvals The installation shall conform to all federal state and local regulations codes ordinances and standards governing solar water heating system installations and the contractor shall adhere to sound building safety and trade practices Special consideration must be given to building code requirements for the penetration of structural members and fire rated assemblies Ensure the mounting surface is solid and able to withstand in excess of 330165 150kg of pull force that may be encountered during high winds Consult a structural engineer if in doubt The solar collector must be located in a structurally sound area of the roof that will be unshaded for the majority of the day all year round Adjacent buildings and trees should be checked for possible winter shading An instru ment such as the Solar Pathfinder www solarpathfinder com can be used for solar site analysis Before the installation the contractor shall inspect the condition of the roof and notify the homeowner of any existing roof damage or necessary repairs COLLECTOR ORIENTATION Proper tilt angle for solar collectors is latitude plus 15 When the collectors are mounted one behind the other This 15 additional tilt improves performance in the they should be spaced sufficiently apart so that when the winter when the sun is weaker and at a lower angle sun is at its lowest altitude the collectors will not shade The cost in performance in
14. the installation start installation and start up of the solar station as well as up function and operation of the solar pump station the connection of electrical components require technical The solar pump station may only be used in the collector knowledge commensurate with a recognized vocational circuit of a solar thermal intallation The technical qualification as a fitter for plumbing heating and air con data specified in these instructions must be observed ditioning technology or a profession requiring a compa Improper usage excludes any liability claims rable level of knowledge specialist The following must The wrapping materials that form the outer shell of the be observed during installation and start up pump station are made of recyclable materials and can e Relevant local and national codes be disposed of with recyclable materials Accident prevention regulations of the professional The solar station is a premounted valves and fittings association group checked for leakage used to circulate the solar Instructions and safety instructions mentioned in this manual fluid in the solar circuit D omponents A Controller cover Pressure relief valve B Differential temperature controller Connection for expansion tank C Temperature gauge red with immersion sleeve for insertion into the return ball valve D Front cover Temperature gauge blue with immersion sleeve for insertion into the s
15. the system either flashing permanently shown or hidden D Blinking control symbols Pump is blinking while running Sensors are blinking if the respective sensor indication channel is selected e Sensors are quickly blinking if there is a sensor error ah Operation control lamp indication Collector va Tank top sensor optional Collector Constantly green system operation normal Pump A d Red green blinking initialization phase manual operation Red blinking Tank heat exchanger Tank Tank bottom sensor 26 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 The controller is now ready for operation The following system settings should be made as indicated The operational system channels are listed in order of appearance by pressing the forward 1 button COL Shows the current collector temperature Collector Temperature Display range 40 to 482 F 1786 TST Shows the current tank temperature from tank bottom Tank temperature TS E s
16. the system with pressurized air until the pressure gauge O reads 40 psi then close the fill valve P The pressure should hold steady for 15 minutes If the pressure falls it is an indication of a leak Find and repair the leak then repeat steps 6 and 7 watching for the pressure to hold at least 15 minutes After the pressure test slowly open the drain valve T to release the air pressure on the system FLUSHING CAUTION Solar thermal installations cannot be completely emptied after flushing There is a danger of frost damage if water is used for flushing Only use water to flush the system when the outside temperature is above 32 F otherwise use the solar fluid to flush making sure to filter any debris before final filling Use a water propylene glycol mixture as a solar fluid maximum 50 propylene glycol 9 Disconect the air pressure hose from the fill valve P 10 Connect a water hose from a water source with at least 40 PSI supply pressure to the fill valve P 11 Connect a discharge hose to the drain valve T and open this valve Place the other end of the discharge hose into an appropriate drain 12 Turn the supply ball valve Q to 90 horizontal so that the valve is closed 13 Turn the slot of the flow restrictor S to the horizontal position using a flat head screwdriver The integrated ball valve is now closed and will prevent debris from entering the pump 14 15 16 17 Tur
17. 12 0 or that is dark dirty or has an acidic smell should be replaced PIPING AND EXTERNAL INSULATION On an annual basis all piping should be checked for leakage at joints and unions Any damaged external insulation should be repaired or replaced WIRING AND CONNECTIONS On an annual basis check wiring and connections including sensor wiring and splices Look for signs of overheating discoloration corrosion or loose connections Any damaged wiring should be repaired or replaced FLUID LEAKS If you detect a glycol or water leak or the glycol loop pressure drops unexpectedly contact your installation contractor immediately to diagnose the problem and recharge the system 34 SOLAR PANEL CLARITY If you live in a dusty climate once a month wash off dirt that settles on the solar panel glass Clean glass allows the solar panel to maintain a high level of thermal performance EXPANSION TANK Annually check condition of the solar expansion tank Check to see if itis waterlogged by quickly pressing schrader valve stem at bottom of the tank You should get a quick burst of air If fluid is discharged the tank may be waterlogged and need replacement Contact a qualified solar installer if the tank needs replacement VACATION For extended periods with no hotwater usage such as vacation it is recommend that the max tank temperature S MX in the solar control be set to 120 F This maximizes the storage capaicity of heat b
18. ACTION Pump does not start Electrical power supply Controller plug disconnected Reconnect control plug to power outlet Blown fuse or breaker tripped Determine cause and replace on overload fuse or reset breaker Sensors Defective sensors sensor Check wiring continuity error Repair or replace Pump starts but cycles continuously Pump cycles after dark Pump runs continuously Pump operated but no fluid flows from collectors Noisy system Differential controller On and or off temperature Reset on and off differential set points too low differentials according to recommendations Piping Reversed connections to Compare with system collectors schematic and reconnect properly Sensors Improper location Compare with system schematic and reconnect properly Differential controller Recooling function active Controller operating properly and max temperature setting No fault exceeded Sensors Defective sensors sensor Check wiring continuity error Repair or replace Differential controller Off temperature differential set Reset off differential according too low to recommendation Controller set to on position Set system operation to Auto Airstop System air locked Purge air from airstop in solar pump station by opening valve slowly Caution after air is evacuated fluid will flow out in a small stream and may be hot Cover port with a rag to catch any fluid Air vent System air locked Open air vent on the top o
19. BE DRY LOAD CARRYING AND FROST PROOF TO PREVENT MATERIAL DAMAGE TO THE INSTALLATION Mounting the solar pump station to the wall 1 Choose the position to install the solar pump station next to the storage tank noting that the tank solar loop inlet from collector and outlet to pump are on the right side of the tank 2 Removethe temperature gauges C E by grasping the frame and pulling straight forward Remove the front cover D of the solar station Remove the retainer clips behind the isolation ball valves J Q with a flat head screw driver to free the mounting plate from the station see Figure 23 Remove mounting clip with flat head screw driver to free mounting bracket Figure 23 Note To aid in later assembly while each leg of the station assembly is removed from the bracket an extension leg of 34 copper tubing can be attached to the bottom threaded connector using the female NPT sweat adaptor provided 5 Line the mounting plate up level on the wall and mark the drill holes Holes will be 5 146 mm apart Drill the two holes with a 3 8 drill bit and mount the plate with either the masonry mounting hardware or drywall hardware provided 6 After the mounting plate is secured to the wall replace the solar pump station back cover insert the retaining clips half way onto the mounting retaining stud see Figure 24 behind the isolation ball valves J Q push the assembly onto the brack
20. EL Default setting FAH es 56 HEN TI Huto LANG En IINIT T LJINL ga FAH The antifreeze concentration by volume should be entered in this channel for OHQM to give an accurate reading Standard system concentration should be a 50 propylene glycol and 50 distilled or de mineralized water The total heat quantity value can be reset When one of the heat quantity display channels is selected the symbol is permanently shown in the display The set button 3 must be pressed for approximately 2 seconds in order to go into the reset mode for the counter The display symbol Sui will be flashing and the value for heat quantity will be set to O In order to finish the reset procedure the set button 3 must be pressed in order to confirm In order to interrupt the reset procedure no button should be pressed for about 5 seconds The controller will automatically return to the indication mode with the previous total 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 Operating mode OFF relay off A flashing AUTO relay in automatic operation ON relay on A flashing The menu language can be adjusted in this channel De German En English Italian Fr French The temperature unit can be adjusted in this channel
21. Feel water before bathing or showering Temperature limiting valves are available HOTTER WATER CAN SCALD Solar water heaters are intended to produce hot water Water heated to a temperature which will satisfy clothes washing dish washing and other sanitizing needs can cause scalds resulting in serious personal injury and or death Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirmed or physically handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions Please see Figure 7 and Table 2 for information regarding thermostat settings In addition to using the lowest possible temperature setting that satisfies your hot water needs some type of mixing device such as a mixing valve should be used at the 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 SETTINGAT 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 Never leave a child or handicapped person unattended
22. If the discharge pipe is not in this water heater install temperature pressure protective connected to a drain or other suitable means the water flow equipment required by local codes but not less than a may cause property damage combination temperature pressure relief valve certified by a nationally recognized testing laboratory that maintains The Discharge Pipe periodic inspection of production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems the latest edition of ANSI Z21 22 This valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the Shall not be plugged or blocked water heater 150 Ibs sq in Shall be of material listed for hot water distribution Install the temperature pressure relief valve directly into the fitting of the water heater Position the valve downward and E Dd Sages a ee pi poih ihe provide a discharge pipe that must terminate a maximum TENGE owes and NE AScNarge of six inches above a floor drain or external to the building Must terminate a maximum of six inches above a floor drain 7 Shall not be smaller in size than the outlet pipe size of the temperature pressure relief valve or have any reducing couplings or other restrictions or external to the building In cold climates it is recommended that the discharge pipe be terminated at an ade
23. Instruction Manual RESIDENTIAL SOLAR WATER HEATING SYSTEM FOR POTABLE WATER HEATING ONLY c UL us LISTED Solar Water Heater Solar Collector SRCC OG 100 AWARNING Read and understand this instruction manual and safety messages before installing operating or servicing this water heater Failure to follow these instructions and safety messages could result in death or serious injury This manual must remain with water heater 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 KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED PRINTED IN THE U S A 0510 PART NO 318281 000 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 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 to alert you t
24. LLECTOR INSTALLATION nei Requiere te eode ge rati eei dne eset tide obese do je dre eser niei dede 13 Coll ctori Boro ror RE 13 General Considerations c EE 13 Collector Orientation 2 hoes ss tope ep prt 14 15 25 ines 15 Lag Bolts MOUNTING 2 initio Fede Io Fees ond Mase Bea eae dee RAR aE 16 Attaching Collector to Mounting Brackets 17 cei reta aere eer ce eene TRE DUAE ERES 18 Collector Piping Detail 5 pU Erud at ee qaia etr X IR e edu dee ees gute eed 19 Sensor Mounting at Coll amp ctor A cci die 19 Piping Through the ROOF 1 ire tre eere rti eoe tie dne cae ede exe e decade Le dace 19 PIPING INSUlALION 2 2 52 E EEEIEE L nate nit uude tud bea 19 Preparation of the Heat Transfer 19 PUMP STATION INSTAEEATION tho cede reb c e Co beet se dope barb tenants 20 20 Safety Instructloris s cres
25. OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OFALICENSED TRADESMAN IN THE FIELD INVOLVED PLUMBING AND ELECTRICAL WORK ARE REQUIRED Examine the location to ensure the water heater complies with the Facts to Consider About the Location section in this manual 5 For California installation this water heater must be braced anchored or 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 6 Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 SAFE INSTALLATION USE ore e deett e n db epe eden NE eere ev hee eee e eene dott nd 2 Important Definitions a 2 3 INTRODUCTIONS 4 SYSTEM EE 4 Preparing 5 ons zt eaim tete Na en ec 4 TABLE OF elei asc 5 SYSTEM DIAGRAM TYPICAL INSTALLATION eene enne e eren ens 6 SYSTEM COMPONENT
26. ONLY This solar water heater is equipped for one type of voltage only Check the rating plate near the bottom access panel for the correct voltage DO NOT USE THIS SOLAR WATER HEATER WITH ANY VOLTAGE OTHER THAN THE ONE SHOWN ON THE MODEL RATING PLATE Failure to use the correct voltage can cause problems which can result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE If you have any questions or doubts consult your electric company 2 3 If wiring from the fuse box or circuit breaker box was alumi num for the old tank replace it with copper wire If you wish to reuse the existing aluminum wire have the connection at the solar water heater made by a competent electrician Contact your local utility to arrange for a professional elec trician BLACK Figure 6 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 TEMPERATURE REGULATION Untempered hot water can cause severe burns instantly resulting in severe injury or death Children elderly and the physically or mentally disabled are at highest risk for scald injury ADANGER
27. PART te ene eed eget decree re e eene adie dee 7 STORAGE TANK INSTALLATION 7 ete Ere REGE RIEN EE MER Rene EE ERN MR 7 Local Codes o eo teu Ute eget ile ote e terti ste eniti seis 7 Temperature Pressure Relief Valve 2 7 Closed System Thermal cece ea aaaeeeeeeceaanaeceseaeanaecesegeseaaeesesseaaeceseesceqeeeeeeeneenaeeeeess 8 Locating the Solar Water Heater 8 Water PIPING 2 0 Pea dete tat oeae ee Ua corte Monet moc deo frd ate Gar rca dote fefe oo 8 Installation in Residential Garages eroi dnte reete dotem denne e edet a neo Eine iire indie 9 Filling the Solar Water Heater with res sr sienne nnns nns 9 Wiring of Element ie t cere eer RENE ERRARE en e e PR ern te A REN ANM Re uem NER 9 Thermostat Seniesa te qtii qui iet eie ter d Rc 10 Temperature REGUIATION EE 10 Temperature Settings E 10 Jemperature Adjustment hee eee tint ee be Dre tn dde FO ee rede deese eee 10 IBI lel 11 Element P 12 12 Water Heater ae A T EPA ER tC Ert RE pee 12 SOLAR CO
28. a detailed description of the solar pump station see page 20 10 Temperature sensor Tank and collector sensor work together to turn the circulating pump s on and off at preset temperature differentials STORAGE TANK INSTALLATION Never operate the electrical heating element without being IN cold climates it is recommended that the discharge pipe certain the solar water heater is completely filled with water be terminated at an adequate drain inside the building Be If any air is left in the top of the tank the heating element certain that no contact is made with any live electrical part will burn out The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 15 feet or LOCAL useofmorethan two elbows can cause restriction and reduce The installation of this solar water heater must be in the discharge capacity of the valve accordance with these instructions and all applicable local valve or other obstruction is to be placed between the codes and electric utility requirements In the absence of temperature pressure relief valve and the tank Do not National Electrical Code NFPA 70 gap is provided To prevent bodily injury hazard to life TEMPERATURE PRESSURE RELIEF VALVE or damage to property the temperature pressure relief valve must be allowed to discharge water in quantities For protection against excessive pressures and temperatures should circumstances demand
29. ally Flow Restrictor Mig Drain valve open Scale ee Figure 29 Always use a flat head screwdriver to adjust the 69 Closed Figure 30 Read the flow rate from the upper edge of the floating body Read the flow rate from the upper edge of the floating object Figure 31 START UP AND OPERATION OF THE SOLAR PUMP STATION Observe the following safety instructions when starting up the solar thermal installation VNB Ne prevent the solar fluid from boiling in the collectors the installation should not be flushed or filled during periods of strong sunshine or the panels should be covered with a blanket to keep collectors cool 23 LEAK DETECTION 1 Disconnect the expansion tank from the solar system by unscrewing the nut on the tank connector This prevents the access of dirt particles present in the pipes from entering the expansion tank Remove the temperature gauges C E and the front cover D of the solar pump station Turn the two isolation ball valves J Q to 45 using an appropriate wrench to allow flow in both directions Close the drain valve T Close the automatic airvent at the collector array turn the cap clockwise by hand until tight Connect an air pressure hose to the fill valve P below the pressure gauge O and open this valve Using an air compressor or pressurized air tank fill
30. areful not to over tighten and dish out the roof underneath the bracket For best results insert a spacer block next to the all thread that is the width of the rafter to avoid deformation of the roof See Figure 14 Mounting Bracket NOTE Apply a roofing sealant between the mounting bracket and shingles Shingles Plywood Sheeting Roof Rafter 2 x 6 2 x 4 Wood duse Figure 14 Drill Points Clearance Hole for 3 8 Bolt N 1 Figure 15 Mounting Bracket i n n I Figure 16 ATTACHING COLLECTOR TO MOUNTING BRACKETS To aid in handling the collectors on the roof the collector Once all of the mounting brackets have been secured mounting clips may be tightened to the lower mounting to the roof insert the channel nut with spring inside the brackets prior to raising the collectors The collector channel Then
31. crease in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank LOCATING THE SOLAR WATER HEATER If you have a choice of where to install the solar water heater these ideas may help you decide 1 Putthe solar water heater indoors as close as possible to where you use the most hot water This water heater is not intended for outdoor installation 2 lt is handy to have a floor drain tub or sink nearby That will make it easy to drain water from the water heater It is also a good place to end the drain line of the temperature pressure relief T amp P valve 3 The solar water heater or the pipes and the connections may in time leak Putthe solar water heater in a place where a water leak will not damage anything 4 You must not put the water heater in an area wh
32. e following terminals with no dependence on polarity 1 2 sensor 1 collector outlet 3 4 sensor 2 tank bottom 5 6 sensor 3 tank top optional not included 7 8 sensor 4 return flow temperature optional not included 25 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 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 7 Neutral N 13 Ground Relay 2 secondary pump optional not included 16 Line power R2 15 Neutral N 14 Ground OPERATION AND FUNCTION Operation cont rol lamp backwards SET Selection Adjustment mode Figure 34 The controller is operated by 3 pushbuttons below the display The forward key 1 is used for scrolling forward through the indication menu or to increase the adjustment values The backwards key 2 is used for scrolling backward through the indication menu or to decrease the adjustment values For system settings adjustment press the forward key to reach the last display channel Then hold the forward button down for 2 seconds and the system setting Screens can then be shown If an adjustable value is shown on the display is indicated To change the set value press the Set button 3 so that flashes
33. e tank and to the collector The tank connections should use copper pipe and can be connected using the threaded adaptors provided The collector connections should use 77 copper pipe and can be connected with the the compression fittings provided The total piping run in the solar loop should not exceed 200 equivalent feet Failure to limit the line length may cause poor system performance and lead to premature pump failure 12 Add the supplied copper drain valve to the lowest point in the collector loop near the tank by the bottom coil outlet labeled to pump in most cases Installing the 1 2 copper to and from the collector using the compression fittings 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 Insert the support sleeve into the copper pipe Insert the copper pipe with the plugged on individual parts and all the way into the housing of the compression fitting First screw the union nut manually Tighten the union nut O by rotating one full turn Hold the housing of the compression fitting to avoid rotation in order to avoid damaging the sealing ring Figure 26 22 PLUMBING CONFIGURATION 1 copper tube from the collector outlet top to the collector return compression fitting K 1 copper tube from the collector
34. ensor Display range 40 to 482 F 06 S3 54 Shows the current temperature of the corresponding optional Additional sensor temperature 59 sensor without control function Display range 40 to 482 F Lr d S3 and S4 are only indicated if the temperature sensors i connected TRF t Shows the current temperature of the optional temperature Temperature return flow TRE return flow sensor S4 when the heat quantity measurement Display range 40 to 482 F Bor g option is activated 4 hP The operating hours counter adds the solar operating Operating hours counter h F hours of the pump Full hours are shown on the display pt Display channel 305 The total operating hours be reset When the operating hours channel is selected the symbol is permanently shown in the display The set button 3 must be pressed for approximately 2 seconds in order to go into the reset mode for the counter The display symbol will be flashing and the operating hours will be set to O In order to finish the reset procedure the set button 3 must be pressed in order to confirm In order to interrupt the reset procedure no button should be pressed for about 5 seconds The controller will automatically return to the indication mode with the previous total Once the final display channel is reached the remaining system setting channels may only be accessed by holding the forward 2 button down for approxi
35. ere it might freeze You must turn off the electricity to the water heater before you drain it to protect the heating elements 5 Make sure that you are able to reach the drain valve and 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 the piping WATER HEATERS EVENTUALLY LEAK The installation ofthe water heater must be accomplished in such a manner that if the tank or any connections should leak the flow of water will not cause damage to the area adjoining the water heater or to lower floors of the structure When such locations can t be avoided a suitable metal drain pan should be installed under the water heater Such a pan should be no greater than 1 1 2 inches deep have a minimum length and width of at least two inches greater than the heater dimensions and must be piped to an adequate drain This solar water heater as all water heaters will eventually leak Do not install without adequate drainage provisions where water flow will cause damage Note normal condensation from a solar water heater may appear to be a leaking tank WATER PIPING This solar water heater is design certified to be used with a potable water system When connecting water piping with solder joints use only lead free solder Untempered hot water can cause severe burns instantly resulting in severe injury or death Children elderly and the
36. et mounting stud and push the clip down into place Ensure assembly is properly locked into place Mounting clip pushed halfway onto mounting stud for re assembly Figure 24 7 Connect the stainless steel corrugated hose to the safety group N Do not forget to insert the seal 8 Choose the position for the expansion tank bracket on the wall beside the solar pump station Fasten the bracket to the wall with the enclosed hardware masonary or drywall 9 Unscrew the tank connector to separate the two halves The top half should be pushed onto the mounting bracket and the lock ring tightened The bottom half should be attachet to the 32 threads on the expansion tank NOTE The tank connector allows you to isolate the expansion tank from the solar circuit Figure 25 When the nut is unscrewed the valves in each half of the tank connector are automatically closed tightly by the integrated springs Each side remains closed until the two halves are screwed back together and the valves are forced open The expansion tank should not be connected to the system until is has been flushed and charged FLOW CLOSED Figure 25 10 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 11 Plumb the solar pump station to the storag
37. f the system and purge excess air Close after purging Loss of fluid from system Locate leak and repair Isolation valves Valves in closed position Piping Clogged or damaged piping Unblock piping or repair damaged piping Pump Broken impeller shaft Replace shaft Not vented properly Install in correct orientation Undersized System piping run too long Refer to maximum piping lengths and adjust Air vents Air trapped in system Open automatic air vent and purge airstop in solar pump station by opening the valve slowly Caution after air is evacuated fluid will flow out in a small stream and may be hot Cover port with a rag to catch any fluid Bearings are dry or have Lubricate or replace excessive wear Impeller loose Tighten or replace impeller 33 SYSTEM MAINTENANCE HEAT TRANSFER FLUID HTF QUALITY 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 To test the pH level use a digital ph tester or tight range litmus paper Remove a small sample of the fluid from the airstop on the pump station The pH should be between 8 1 and 12 0 Fluid with pH between 7 5 and 8 1 can be conditioned by your contractor using an inhibitor boost Fluid with pH above
38. fasten the collector mounting clip to the a iu x us e 2 21 Hu nut with the stainless steel bolt using a flat washer and CIR WALE ME sep er uS Mp On Mas lock washer refer to Figure 17 collector The bottom clips can then be loosened and retightened over the collector lip Collector Frame Stainless Steel Bolt with lock washer amp flat washer Mounting Clip Y Y GGG P 1 Channel nut with spring one piece part Mounting Bracket i re Figure 17 COLLECTOR PIPING The piping of the system should be considered before a final decision is made on how the collectors are mounted Piping should be made of copper tube of the type meeting local codes insulated with Armacell UT Solaflex or similar The maximum total piping length allowed in this system is 200 equivalent ft Use only lead free solder Use of 50 50 lead solder is expressly prohibited Use of galvanized steel CPVC PVC PEX or any other type of plastic pipe is prohibited 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 To aid in installation the collector array layout should be planned on the ground and the unions soldered to the adjoining headers prior to lifting the collectors to the roof Similarly the top and bottom outside header that will not be used for the inle
39. he system flow rate equal to or higher than the final system flow 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 2 panel system 1 4 gpm 3 panel system 2 1 gpm Cycle the pump on and off in manual mode to check whether the starting torque is sufficient with the pump speed selected If flow does not start properly a higher speed may need to be selected and the flow reset to the proper level with the flow restrictor S Again check the installation for leaks and ensure both ball valves are open completely Replace the front cover D and re insert the red temperature gauge C in the return ball valve J and the blue temperature gauge E in the supply ball valve Q Set the controller to operate in automatic mode see Pump Station Control Instruction section After the system has been running for several days the cap on the automatic air vent at the top of the collector array should be closed by turning the cap counterclockwise by hand until tight DRAINING 1 Open the check valves in the supply and the return ball valves J Q by turning the ball valves to position 45 with an appropriate wrench Place a temperature resistant container under the drain valve at the lowest point of the solar thermal installation usually near heat exchange coil at the bottom of the tank 5 T
40. he discharged fluid can have very high temperatures Place the collecting container so that people standing nearby are not endangered when the solar thermal system is being emptied Open the drain valve at the lowest point of the solar thermal installation Open the automatic air vent at the top of the collector array 3 full turns counterclockwise by hand cap should not be completely removed This will serve as a vacuum break to aid in draining Dispose of the solar fluid observing any local code PUMP STATION CONTROL INSTRUCTIONS CONTROL INSTRUCTIONS A WARNING Before removing any access panels or servicing the solar pump station make sure the electrical supply to the solar pump station is unplugged Failure to do this could result in death serious bodily injury or property damage Prior to operation of the control on the solar pump station the collector and tank temperature sensors must be prop erly connected Remove the control cover and connect the sensors to the proper terminals display m pushbutton cable conduits with strain relief can fuse 4A Figure 32 fuse Lure ph Temp Sensor Pt1000 C LI ii S1 52 53 54 12 13 14 11213415 7 2jejojojojojojojo o ee sensor terminals earth ground terminals relay terminals power supply Figure 33 The temperature sensors should be connected to th
41. he hot water supply pipe to the solar water heater s hot water outlet Operating an empty or partially filled solar water heater will result 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 or water 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 on how to control this situation INSTALLATION IN RESIDENTIAL GARAGES The solar water heater must be located and or protected so itis not subject to physical damage by a moving vehicle FILLING THE SOLAR WATER HEATER WITH WATER 1 Close the solar water heater drain valve The drain valve 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 WHEN THE SOLAR WATER HEATER IS IN USE 3 Fill the solar water heater until a constant flow of water runs out an opened hot water faucet This will let out air in the solar water heater and the piping Close the faucet after all air has been purged and the water comes out with constant flow You must not turn the electricity on until the solar water heater is full of water IF ANY AIR IS LEFT IN THE TOP OF THE SOLAR WATER HEATER THE TOP HEATING ELEMENT WILL BURN OUT IMMEDIATELY 4 Check all the new water piping for leaks Fix as needed WIRING OF ELEMENT De
42. herproofed as shown in Figure 21 Three quarter inch holes are drilled through the roof on the same plane as the supply and return header pipes Do not drill the hole above the supply header of the collector This will prevent the collector from draining Placing the hole below the supply header is acceptable but it is more aesthetic if it is located on the same plane The flashing plate is placed over the hole with its base cemented and nailed to the roof and its upper edges slid under the adjoining shingle A hole 1 2 the diameter of the supply tube should be cut in the top of the flashing gasket and the copper tube supply and return line is then pushed up through the hole in the flashing The same procedure is then repeated for the return line and flashing The sensor wire should also be run through the return flashing by piercing a small hole in one of the corner nipples Caution making the hole for the copper pipe or the sensor wire too big will prevent a proper seal The return and supply lines should be supported under the roof to prevent undue stress on the piping assemblies at the collector Sensor Wire To Collector Figure 21 PIPE INSULATION The collector loop piping exterior and interior must be well insulated with a high quality flexible EPDM closed cell insulation to minimize heat loss The wall thickness of the pipe insulation should not be less than 27 A 1 wall thickness is required in all areas prone to annual ha
43. in a bathtub or shower TEMPERATURE SETTINGS NOTE This residential solar water heater will not supply sanitizing hot water for dishwashers The thermostat is factory set at its lowest position which approximates 120 F and is adjustable if a different water temperature is desired For best system savings this temperature should not be changed Read all warnings in this manual and on the solar water heater before proceeding TEMPERATURE SETTINGS HIGH LIMIT CONTROL ADJUSTABLE Figure 7 TABLE 2 Time for Perma nent Burns 2nd amp 3rd Degree Most Severe Bums Time for 1st Degree Burn Less Severe Bums Water Temperature F 110 116 116 122 131 140 149 154 U S Govemment Memorandum C P S C Peter L Armstrong Sept 15 1978 normal shower temp pain threshold 35 minutes 1 minute 5 seconds 2 seconds 1 second instantaneous 45 minutes 5 minutes 25 seconds 5 seconds 2 seconds 1 seconds TEMPERATURE ADJUSTMENT To adjust the temperature setting 1 Turn OFF the electrical power to the water heater at the junction box HAZARD OF ELECTRICAL SHOCK Failure to turn OFF electric power to the solar water heater will result in the possibility of DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE 2 Take off the access panel and fold away the insulation 3 Turn the water temperature dial clockwise X7 to increase the tem
44. inlet bottom to the collector supply compression fitting L 3A copper tube from the upper tank coil inlet marked from collector to the tank supply threaded fitting copper tube from the lower tank coil outlet marked to pump to the tank return threaded fitting V Figure 27 FUNCTION Check valves The solar station is equipped with check valves in the supply and the return ball valve J Q For filling venting and flushing of the installation the check valves must be turned to the correct position To set the proper position for the check valves take off the temperature gauges C E remove the top cover D and turn the ball valves into the proper position using a wrench see Figure 28 In the 45 position the balls in the ball valves push the check valves open During operation the ball valves must be in 0 position Check valve is Check valve is not Ball valve operating flow operating flow in closed only in flow both directions no flow direction Figure 28 FLOWMETER 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 The flowmeter MUST be mounted vertic
45. is applied between the hardware provided and the roof The bracket is then positioned over the 3 8 hole using sealant between the bracket and the roof A piece of stainless steel 3 8 all thread is then inserted through the hole A washer and nut secures the all thread to the bracket be sure to apply sealant caulk underneath the washer and on top of the nut The all thread rod should extend about 4 hardware provided The solar collector must be attached to the mounting hardware as detailed in Figure 17 Preserving the integrity of the roof membrane is the most important roofing consideration Ensure that all roof penetrations required to plumb and mount the solar collector are properly flashed and sealed in accordance with standard roofing practices If the region is subject to hurricane conditions additional steps may be required to secure the collector and mounting hardware to the structural members In certain areas of the country local building codes may require collector wind load testing or prescribe specific mounting procedures Consult your local building department Install the collectors as described in the Spanner Mounting instructions below the roof rafters Drill a 3 8 hole in a 2 x 4 piece of lumber and insert the all thread rod through it The 2 x 4 should span 2 rafters With a lockwasher and fender washer secure the all thread to the 2 x 4 Tighten down until the bracket is tightly secured to the roof Be c
46. ld injury Feel water before bathing or showering Temperature limiting valves are available Read this instruction manual for safe temperature setting A WARNING Fire Hazard Electric Shock Hazard Do not use this water heater with any voltage other than shown on the model rating plate Failure to use the correct voltage shown on the model rating plate could result in death serious bodily injury or property damage NIIROL 61 Thank You for purchasing this water heating system Properly installed and maintained it should give you years of trouble free service 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 SYSTEM DESCRIPTION This Solar Water Heating System consists of four main parts the solar collectors the solar pump station the solar storage tank and the plumbing for the heat transfer fluid The solar pump station uses a pump to circulate a heat transfer fluid through the collector loop This collector loop includes the solar collectors the fluid lines or line set and a heat exchanger The collector loop is a closed loop meaning there is no contact of the heat transfer fluid with your potable water
47. longer hot 3 Close the cold water inlet valve 4 Connect a hose to the drain valve and terminate it to an adequate drain or external to the building 5 Open the water heater drain valve and allow all of the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed in this manual If the water heater is going to be shut down for an ex tended period the drain valve should be left open IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak If the solar water heater is to be shut off and exposed to 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 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 Once the solar water heater is drained close the hot water faucet ELEMENT In some water areas scale or mineral deposits will build up on heating elements This build up
48. mately 2 seconds The following setting channels will then be shown ARR System arrangement setting Shows the current system configuration setting Arrangement 1 should be used for the system in this package and this setting should not be changed DTO Primarily the controller works in the same way as a standard Switch on temperature diff J ir g differential controller If the switch on difference DT O Adjustment range P ET collector temperature sensor reading minus the tank sensor 2 0 to 40 0 F ww reading is reached the pump is activated Default setting 12 0 Recommended setting 10 0 27 DTF Switch off temperature diff Adjustment range 1 0 to 38 0 F Default setting 8 0 Recommended setting 4 0 SMX Maximum tank temperature Adjustment range 40 to 205 F Default setting 140 F Recommended setting 160 F 5 gt lt iun im 4 c3 EM Collector temperature limit M E Adjustment range 230 to 400 F Default setting 285 F Recommended setting 285 F OCX Collector cooling DX Adjustment OFF ON n Default setting OFF un Recommended setting ON CMX Maximum collector temp ENX Adjustment range 210 to 380 F 258 Default setting 250 F Recommended setting 250 F Channel only available when OCX is active OCN Minimum collector limit Adjustment OFF ON Default setting OFF Recommended setting OFF FINI OFF CMN Mi
49. may cause a rumbling noise Follow the element replacement directions to remove the elements from the tank Soaking in vinegar and scraping will remove the mineral deposit Be careful not to bend the element ELEMENT REPLACEMENT Replacement elements must 1 be the same voltage and 2 no greater wattage than listed on the model and rating plate affixed to 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 Drain the solar water heater Follow the directions for draining Take off the access panel and take off the access panel and remove the insulation Disconnect the wires from the heating element terminals Use and element wrench to remove the element and gasket You should always use a new gasket when you replace the element Install new element Reconnect the wires as they were Fill the tank following the filling directions on page 9 Fill the tank completely with water BEFORE you turn on the electric supply ANODE 3 NOOO Each water heater contains at least one anode rod which will slowly deplete due to electrolysis prolonging the life of the water heater by protecting the glass lined tank from corrosion Adverse water quality hotter water temperatures high hot water usage hydronic heating
50. n on the supply water and open the fill valve P then leave running for 15 minutes to flush debris out of the solar loop After the 15 minute flush turn off the supply water at the source and allow the system to drain When water stops flowing out of the discharge hose close the fill valve P Close the drain valve T on the pump station and move this hose to the drain valve that was installed at the lowest point of the solar loop near the bottom of the tank Open this drain valve with a flat head screw driver and open the fill valve P slowly to vent the system and allow the remaining water to drain out In order to vent the system completely it is necessary to open the flow restrictor S turn with flat head screwdriver until vertical FILLING 18 19 20 21 22 23 24 25 26 Close the lower loop drain valve with a flat head screw driver and move the discharge hose from the lower valve to the drain valve T on the pump station and open this valve The other end of the discharge hose will be placed into the glycol solution container Turn the return ball valve J to 0 vertical so that flow is only allowed in the proper direction Connect a fill hose from the glycol container to a 1 2 HP transfer pump and another hose from the transfer pump to the fill valve P then open this valve Open the cap on the automatic air vent at the top of the collector array 3 full turns counterclockwise to ve
51. nimum collector temp Adjustment range 50 to 195 F Default setting 50 F Recommended setting 50 F Channel only available when OCN is active 28 If the switch off temperature DT F is reached the pump is de activated Note the switch off temperature must be at least 2 degrees lower than the switch on temperature 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 maxi mum collector temp CMX has been exceeded In this case the pump will run to transfer heat from the collector to the tank to prevent prolonged overheating of the collector In this case the tank may be heated until it reaches the emergency shutoff point of 203 F and no further heating will be done If the maximum tank temperature setting is exceeded the symbol will be shown on the display If the collector temperature limit is reached the solar pump R1 is deactivated in order to avoid damaging overheating of the solar components collector emergency shutdown If the collector temperature limit setting is exceeded the 4 symbol will be shown flashing on the display This function is used to avoid prolonged periods of excessive collector temperatures If the maximum tank temperature is reached the solar s
52. nt any air in the solar loop do not remove cap completely In order to flush as much air as possible from the system turn on the transfer pump to fill the system with the glycol solution and allow to circulate for 15 minutes or until no bubbles are returning to the collector Remove the cap from the front of the airstop 1 and open the vent with a flat head screwdriver This will release air that has been captured by the system during circulation Cover small outlet port with a rag as fluid will be ejected after the air is evacuated Turn the supply ball valve Q to 0 vertical so that flow is only allowed in the proper direction and ensure that the flow restrictor S is completely open vertical With the transfer pump still running close the drain valve and allow to system to rise to an operating pressure of 30 psi on the pressure gauge then close the fill valve and turn off the pump If the pressure has exceeded 30 psi after the pump is off then slowly open the drain valve and relieve pressure until the pressure gauge reads 30 psi then close the drain valve Remove the fill and drain hoses and close the fill and drain valves P T with the caps provided 27 28 29 30 31 Plug in the solar pump station to a 115V outlet and turn the pump on using the manual mode see Pump Station Control Instruction section Adjust the pump speed using the pump speed selector R to the lowest setting possible to set t
53. ntes ELE ee AE capac tees Sas ger E 20 Safety EgulpImienic esencia I tus oM oss ie Loads Ab ice oc rios enin a Mia ta 21 EM REC 22 22 Flowmeter Ui 23 Start up and Operation of the Solar Pump 23 E eB ic Mc 23 Flushing mu des ee ee en ee ee inten A ee 23 Fillifig ii rrr er E EE BUDE C Peter te e mex 24 Drainirig Doe scc DECLA SUIS nee PL 24 PUMP STATION CONTROL INSTRUCTIONS sse nene tnit nnne inneren 25 Control INSteU ction 25 Operations ania mA Tale iela eer rue Re De eR cael E ties Se at TENERE 25 30 TROUBLESHOOTING ss 53 E 31 33 SYSTEM MAINTENANCE Ende eset peto eiie taedio Fete ede decies enden en steed diy pa eee ca 34 REPAIR PARTS i ete enr e ie i ere A eed se ede ei eee ccm o ee el 35 6 9 e oT rn Flow Direction Discharge Pipe DO NOT CAP OR PLUG 6 Maximum Air Gap Piped To An Adequate Drain At Least 2 Greater Than The Diameter Of The Water Heater INSTALL SUITABLE METAL DRAIN PANS UNDER
54. o air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is opened WATER HEATER SOUNDS 1 The solar water heater is equipped with an immersion heating element for fastest recovery If the solar water heater occasionally makes noises this is not a defect or a safety hazard 2 Lime or scale has accumulated on the heating element causing a hissing sound Element scale removal can be accomplished by using vinegar or by scraping COLLECTOR LOCATION Proper location and orientation of the solar collectors is important for maximum system efficiency The collec tors 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 mini mize heat loss in the piping runs The best orientation is achieved when the collectors are facing due south 45 and tilted at an angle from the horizontal equal to the latitude of the location 15 Asteeper angle provides better winter performance as the sun is lower in the sky The collectors will also shed snow more effectively at the steeper angle Figure 10 below shows many alternatives for collector mounting Placing the collectors as close as possible to the peak of the roof will make installation easier by providing increased attic access Figure 10 GENERAL CONSIDERATIONS The contractor shall obtain all required
55. o potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death gt DANGER indicates an imminently hazardous A C Situation which if not avoided will result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could result in A WARNING w death or injury CAUTION indicates a potentially hazardous situation which if not avoided could result in A CAUTION minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation CAUTION which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message 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 of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses 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 other reproductive 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
56. otable water space heating system The thermostatic mixing valve provided with the system must be installed to prevent scalding from high water temperatures achieved by solar heating Figure 3 The solar water heater will work better if you keep the hot water runs short You will also get hot water faster and with less heat loss The illustration shows the correct valves and fittings that you will need to install the solar water heater Threaded 3 4 water connections are supplied through the tank top TEMPERED OUTLET Figure 4 1 Buy the fittings that you need to connect the pipes Remember that you have to connect both the hot and cold water pipes 2 Apply a light covering of pipe joint compound to each outside thread before making connection 3 Connect the cold water supply pipe to the cold water inlet of your solar water heater as follows a Look at the top cover of the solar water heater The hot and cold connections are marked there b Anon metallic dip tube is supplied to carry cold water from the tank top to the bottom Be sure that it is in the cold water inlet c If using copper tubing solder tubing to an adapter BEFORE you attach the adapter to the cold water inlet DO NOT solder the cold water supply pipe directly to the cold water inlet connection It might harm the dip tube d The cold water supply line must have a shut off valve and union 4 Use a union to connect t
57. perature or counterclockwise X to decrease the temperature Fold the insulation back in place and replace the access panel Turn ON the power supply RESET BUTTON 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 TANK SENSOR The surface mount tank sensor should be attached to the sensor stud behind the lower door by placing the hole in the sensor over the stud provided and securing in place with a nut The end of the tank sensor shall be connected to the red wires in the opening with wire nuts with no regard for polarity The other ends of the red temperature sensor extension extend from the top of the tank and shall be connected to the controller in the tank sensor position DRAINING It is recommended that the storage tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 1 Turn off power to the water heater 2 Open a nearby hot water faucet until the water is
58. placed NOTE Whether re installing or replacing the anode rod check for any leaks and immediately correct if found Figure 9 Anode Rod Depletion In replacing the anode 1 Turn off power supply to the water heater 2 Shut off the water supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 5 gallons of water from tank Refer to Draining and Flushing for proper procedures Close drain valve Exposed Support 4 Remove old anode rod Wire 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open a nearby hot water faucet to purge air from water system Check for any leaks and immediately correct any if found 7 Restart the water heater as directed in this manual See the Storage Tank Repair Parts section for anode rod location TEFLON is a registered trademark of E I Du Pont De Nemours Company Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of bodily injury under these conditions open the hot water faucet for several minutes at the kitchen sink before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar t
59. quate 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 TEMPERATURE PRESSURE RELIEF VALVE DRAIN LINE Figure 2 The temperature pressure relief valve should be manually opened once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one If the temperature pressure relief valve on the appliance weeps this may be due to thermal expansion The water supply serving this solar water heater may have a check valve installed Contact the water supplier or local plumbing contractor on how to control this situation Do not plug the temperature pressure relief valve CLOSED SYSTEM THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding in
60. rd freeze conditions When it comes to pipe insulation the rule is simple thicker is better The specified insulation material is Armacell UT Solaflex or equivalent To the extent possible slide the insulation material over the pipe without cutting or taping All butt joints must be sealed with high temperature contact adhesive The use of rigid polyethylene pipe insulation is prohibited All outdoor insulation should be protected from moisture and Ultraviolet deterioration by either paint or foil tape Insulation to complete the outdoor portion of the installation has been provided PREPARATION OF THE HEAT TRANSFER FLUID Pour 100 Propylene Glycol into a large clean bucket Add an equivalent amount of distilled or de mineralized water for a 50 50 solution by volume The use of regular tap water as a mixing agent is prohibited Distilled or de mineralized water is often available from grocery stores and drugstores This solution provides freeze protection down to 30 F and burst protection down to 60 F Use of heat transfer fluid other than a maximum 50 50 mix by volume of Propylene Glycol and distilled or de mineralized water is not permitted Use of any heat transfer fluid other than that specified by the appliance manufacturer will void warranty and may result in poor performance equipment damage or risk to health and safety PUMP STATION INSTALLATION PUMP STATION SAFETY INSTRUCTIONS The following instructions describe
61. syphoning Check for pump operation at night Improperly plumbed Compare with system schematic Check flow direction Flow blockage Flush system Check effluent for debris Low system pressure Check pressure gauge Set System pressure to correct setting check for leaks Pump No power Check breaker pump cord and controller fuse Repair or replace rated too high or toolow Adjust flow rate Faulty pump Listen for irregular noises in pump operation Feel collector feed and return line for temperature difference Ensure all air is purged from system Runs continuously Check sensors for shorts No hot water in the morning Storage water heater Circuit breaker shut off Differential controller Sensor wires reversed Ensure the collector and tanks sensors are wired to the correct position on the controller Water too hot 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 Pump does not start Differential controller Controller set to off position Set system operation to Auto Uplugged Return power to controller On and or off temperature Reset on and off differential set points too high differentials according to recommendations Loose contacts Clean contacts and tighten connections or replace 32 PROBLEM CHECK THIS POSSIBLE CAUSE CORRECTIVE
62. t or outlet should be on opposite sides should be capped with the 1 copper cap provided while on the ground See Figure 18 for details Multiple Panel Outlet Inlet Figure 18 1 Pipe Header Temperature Sensor Automatic Pipe Air Vent Outlet Solar Collector Collector Inlet Figure 19 COLLECTOR PIPING DETAIL The outlets of the collector are 1 copper pipe nipples Figure 19 They should be piped as shown with provisions for an automatic 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 The collector inlets should be piped similarly but without the automatic air vent SENSOR MOUNTING AT COLLECTOR The angled collector heat sensor is mounted to the outlet of the collector Figure 20 The stainless steel screw clamp should be used The entire sensor should be wrapped thoroughly with the insulating stretch tape So that the sensor is isolated from the outside air If possible route the sensor wire through the roof flashing and connect the sensor wire to the sensor extension wire provided with wire nuts Figure 20 PIPING THROUGH THE ROOF Piping through the roof should be weat
63. termine 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 ofthe 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 The grounding electrode conductor shall be of copper aluminum or copperclad aluminum The material shall be resistant to corrosion and shall be of one continuous length without a splice or joint Rigid metal conduit intermediate metal conduit or electrical metallic tubing may be used for the grounding means if conduit or tubing is terminated in fittings approved for grounding TO SERVICE PANEL WIRE GREEN GROUND SCREW WIRE NUT CONNECTIONS HEATER WIRING ACCESS OPENING Figure 5 Flexible metal conduit or flexible metallic tubing shall be permitted for grounding if all the following conditions are met 1 The length in any ground return path does not exceed 6 feet The circuit conductors contained therein are protected by overcurrent devices rated at 20 amperes or less The conduit or tubing is terminated in fittings approved for grounding Never use this solar water heater unless it is completely full of water SOLAR WATER HEATERS EQUIPPED FOR ONE TYPE VOLTAGE
64. the summer when the sun is each other and cause efficiency loss see Figure 13 If a high is overcome by the hours of sunlight and strength collector must be installed horizontally replace the upper of irradiation that occurs in the summer Tilt mounting vent with rubber plug as shown below in order to prevent accessory kits are available to set the proper collector rain penetration see Figures 11 amp 12 angle Please call your local dealer for more information sert rubber plug Figure 11 Only upper vent should be sealed with rubber plug O Unplugged vent hole 4 Plugged vent hole Figure 12 Figure 13 14 All persons working on roofs should have successfully completed a fall safety course and should be properly equipped with appropriate safety equipment A WARNING After completion of the collector mounting and prior to system charging the collectors must be covered by a blanket of other means to avoid solar radiation from heating the collectors The surfaces of the collector can become extremely hot and could pose a burn hazard 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 SPANNER MOUNTING In spanner mounting after the mounting feet are positioned correctly a 3 8 hole is drilled between the rafters see Figures 15 and 16 for placement of drill holes Roof sealant
65. uild up during the day using the CMX function for maximum collector temperature and will aid in preventing breakdown of the heat transfer fluid due to overheating 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 amp 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 When ordering repair parts always give the following information 1 Part description 2 Model serial number 3 Element wattage 4 Voltage 5 Part number PART DESCRIPTION SERVICE PART Primary Anode Element Gasket Element Thermostat Bracket Thermostat w Hi Limit Terminal Cover Access Panel Sensor Mounting Plug Dip Tube with Diffuser T amp P Valve Heat Trap Nipple 35 36
66. upply ball valve Circulation pump Pressure gauge Fill valve Supply isolation ball valve with integrated check valve Pump speed selector Flow restrictor Flow meter access door Supply storage tank Drain valve S T U Flowmeter V Return isolation ball valve with integrated check valve Return collector 100p Supply collector pape Figure 22 Return storage tank 20 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 Excessive length over 15 feet or use of more than two elbows can cause restriction and reduce the discharge capacity of the valve Do not connect tubing directly to discharge drain unless a 6 air gap is provided To prevent bodily injury hazard to life or damage to property the relief valve must be allowed to discharge fluid in quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the fluid may cause property damage ATTENTION TO PREVENT DAMAGE TO PROPERTY THE LOCATION OF INSTALLATION MUST
67. ystem will shut off After this point if the collector temperature reaches the maximum collector tem perature CMX the solar pump will activate until the collector temperature drops below the set point The tank temperature may continue to rise overriding the maximum tank tempera ture but only until it reached the emergency tank shutoff point of 203 F When the system is actively cooling the collectors CMX ex ceeded gt symbol will be shown flashing on the display The minimum collector temperature is a minimum switching temperature which must be exceeded before the solar pump R1 is switched on The minimum temperature will avoid short cycling of the solar pump at low collector temperatures If the collector temperature is lower than the minimum collec tor temperature set point the 5 symbol will be shown flashing on the display This function is unnecessary if the system backup heating ele ment has a set point maintained at 120 F OCF Antifreeze function Adjustment OFF ON Default setting OFF Recommended setting OFF CFR Antifreeze temperature Adjustment range 15 to 50 F Default setting 40 F Recommended setting 40 F Channel only available when OCF is active Channel only available when OCF is active OREC Recooling function Adjustment OFF ON ULF OFF LFR mm OREL m Default setting OFF urn Recommended setting ON OTC Tube collector function BET EE

American Water Heater 318281-000 User's Manual

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