SRCC OG-300 Certified Solar Water Heating System Type: AC

AC
SRCC OG-300 Certified Solar Water Heating System
Type: AC Circulating Pump and Differential Control
Installation, Operation and Maintenance Manual
SOLARAY
AC
DOMESTIC SOLAR WATER
HEATER SYSTEM
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
The SolaRayTM domestic solar water heating system has gone through an extensive design, technical and
performance review by the Solar Rating & Certification Corporation (SRCC). The installation of your
SolaRay system is intended to be executed by properly licensed and experienced professional contractors in accordance with SRCC Standard OG-300, "Operating Guidelines and Minimum Standards For
Certifying", and must conform to applicable federal, state and local regulations, codes, ordinances and
standards governing the installation of solar water heating systems.
The solar energy system described by this manual, when properly installed and maintained, meets the
minimum standards established by the SRCC. This certification does not imply endorsement or warranty
of this product by the SRCC.
OG-300 system certification is granted to SunEarth by the SRCC. It may not be used for any commercial purpose without the prior written consent of SunEarth. SunEarth must approve any deviation from
the materials and methods described in this manual in writing.
SunEarth SolaRay solar water heating systems can be protected against freeze damage to
temperatures as low as -60°F (-51°C). This system should not be installed in any area that has
experienced ambient air temperatures below -60°F. Use Table 4, Section 4 of this manual to
determine the required concentration of propylene glycol and distilled water to provide adequate freeze protection in your specific climate.
Dow Chemical “Dowfrost HD” propylene glycol heat transfer fluid shall be used in this system
as the primary freeze protection agent. Unauthorized fluid substitutions can result in a threat
to health, welfare and safety and may cause the system piping to freeze.
All component warranties, express or implied, are voided if uninhibited glycol, potable or distilled water
are substituted for the specified heat transfer fluid described in this manual, or if the heat transfer fluid
is not maintained in accordance with the manufacturer’s instructions.
Freeze tolerance limits are based upon an assumed set of environmental conditions. Extended periods
of cold weather, including ambient air temperatures above the specified limit may cause freezing in
exposed parts of the system. It is the owner’s responsibility to protect the system in accordance with
SunEarth’s instructions if the ambient air temperature approaches the specified freeze tolerance limit.
TABLE OF CONTENTS
Preface
1)
Introduction..........................................................................................................................1
2)
System Description and Operational Principle..................................................................1
3)
Installation Requirements - General ................................................................................3
4)
Installation Requirements - Specific ..................................................................................4
5)
Start Up Procedures ..........................................................................................................14
6)
Three Modes of System Operation ..................................................................................14
7)
Isolating the Major Components and Shut Down Procedures ......................................15
8)
Summer Vacation Recommendations ..............................................................................15
9)
Maintenance and Troubleshooting ..................................................................................16
10) Solaray System Component Parts ....................................................................................17
11) Estimated Component Life................................................................................................19
12) System Model Numbers ....................................................................................................19
13) Collector Specifications ....................................................................................................20
14) SunEarth Collector Warranty Statement ........................................................................22
PREFACE
Let us first offer two words of grateful appreciation. Thank You! We sincerely appreciate your
business. SunEarth also wishes to say thank you
for "going solar". Solar water heating systems
help to reduce our nation’s dependence on polluting fossil fuels, minimize the greenhouse gas
emissions associated with conventional water
heating and, very importantly, lower your monthly utility costs.
Established in 1978, SunEarth is a leading U.S.
solar equipment manufacturer. Our products
include industry standard ImperialTM and EmpireTM
solar water heating collectors, CopperHeartTM
integral collector storage systems, SunSiphonTM
packaged thermosiphon systems, SunBurstTM all
copper absorber plates, and Solar StrutTM mounting hardware. We also build specialty collectors
for unique architectural and building applications. SunEarth SRCC OG-300 certified solar
water heating systems are sold by leading solar,
plumbing and building contractors throughout
the United States.
Your SolaRay solar water heating system has
been designed to meet exacting SRCC OG-300
certification requirements. The components
found in your system have been selected by your
installation contractor for their proven reliability,
longevity and performance in your specific region
of the country.
1) INTRODUCTION
Solar water heating systems are climate and site
specific appliances. Different types of solar systems are installed around the world in accordance with regional weather and water quality
conditions. System performance varies as a function of the household hot water load, including
daily showers, laundry and kitchen uses, average
ground water and ambient air temperatures, the
home’s roof pitch and orientation, and, of
course, the seasonal intensity of solar radiation.
These variables, some of which change from
home to home on the same neighborhood
street, will determine how much energy and
money your SolaRay system will save on an annual basis.
Your SolaRay solar system is known as a "forced
circulation" system because it utilizes a mechan-
ical pump to efficiently circulate the Dow
Chemical Dowfrost HD propylene glycol heat
transfer fluid (HTF) throughout the system. The
HTF protects the collector piping from freezing
and inhibits scaling deposits that can reduce performance in "open-loop" systems utilizing
potable water as the HTF. Proper application and
maintenance of the HTF can protect your Solaray
solar water heating system to minus 60°
Fahrenheit.
This manual is intended as a basic solar water
heating primer. Our goal is to familiarize you
with the proper installation, operation, and maintenance of your SolaRay solar system. This system is required to be installed by properly
licensed solar or plumbing contractors in accordance with SRCC Standard OG-300 and all applicable national, state and local codes, ordinances
and regulations governing solar water heating
installations, as well as good trade practices.
Failure to follow the procedures and practices
described in this manual can void the manufacturer's warranty for specific component parts.
This manual covers installations utilizing one or
two SunEarth solar collectors with a single solar
storage tank and also two tank systems that
include a solar storage tank and a conventional
water heater. For simplicity, the singular form
will be used throughout this manual when referring to all of these components and system permutations. Frequent reference is made throughout this manual to specific component parts. The
placement of each component can be seen in
system schematic figures 16 and 17. A description of each component and its function is found
in Section 10.
2) SYSTEM DESCRIPTION AND OPERATIONAL
PRINCIPLE
The key components in the SolaRay solar water
heating system include the SunEarth solar collector, solar storage tank with integral heat
exchanger, circulation pump, differential thermostat, expansion tank, pressure gauge, mixing
valve and the non-toxic propylene glycol heat
transfer fluid (HTF).
The SunEarth solar collector is the heart of the
SolaRay system. Simply stated, when the sun is
shinning, heat energy is absorbed by the solar
collector’s all copper absorber plate and transP.1
fig. 1
COLLECTOR ORIENTATION
ferred to the HTF circulating through the solar
collector. The system pump efficiently circulates
this heated fluid through the collector piping and
integral tank heat exchanger. The heat exchanger consists of a 120’ length of copper tubing
wrapped around the solar storage tank. As the
HTF passes through the heat exchanger the heat
in the fluid is transferred by conduction to the
potable water in your solar storage tank. As this
process is continuously repeated during the average sunny day the temperature in your solar storage tank rises.
The circulating pump in a solar water heating system may be favorably compared with the human
heart. To continue the analogy, the differential
thermostat, or controller, is the brain in the system. The controller uses 10K ohm thermistors, or
sensors, to constantly monitor the temperature
difference between the hottest and coldest
points in the system and to automatically turn
the circulating pump on and off throughout the
day.
When the solar collector absorber plate is
P.2
approximately twelve degrees hotter than the
temperature in the bottom of your solar storage
tank, the controller will turn the circulating pump
on. When the temperature difference has been
reduced to four degrees, the controller automatically turns the pump off.
Both single and double tank Solaray systems are
designed to provide three separate modes of system operation. The system will, (1) accommodate 100% solar operation, (2) serve as a preheater to your solar storage tank or back-up
water heater, or (3) bypass the solar collector and
run 100% on utility power. Section Six provides
fig.2
STAGGERED MOUNT
COLLECTOR SPACING
TABLE 1
LATITUDE
COLL. TILT
25°N
35°
FLAT
ROOF
PITCH
5°
9°
14°
18°
23°
27°
30°
34°
37°
40°
43°
45°
1/12
2/12
3/12
4/12
5/12
6/12
7/12
8/12
9/12
10/12
11/12
12/12
A
29
25
22
17
14
10
7
4
0
0
0
0
0
30°N
40°
B
A
B
96
33
113
83
29
93
74
26
82
66
22
72
61
18
66
58
14
60
58
11
58
58
8
58
58
5
58
58
3
58
58
0
58
58
0
58
58
0
58
DIMENSIONS A AND B
instructions for setting the system for automatic
operation in each of these three modes.
The Dowfrost HD HTF protects your SolaRay solar
system against freezing. Dowfrost HD can provide reliable freeze protection at temperatures as
low as minus 60° Fahrenheit if properly applied
and maintained. Use of uninhibited propylene glycol, plain water or a concentration
of these two fluids as the HTF in this system
is strictly prohibited.
Propylene glycol can degrade over time. The
process of degradation is accelerated in presence
of oxygen and/or heat. We strongly encourage
you to establish a preventative maintenance
schedule with your installation contractor. The
HTF pH level must be maintained between 8 and
10 in order to prevent glycol oxidation and corrosion of the collector piping. SunEarth’s collector warranty specifically excludes freeze
damage for any reason and absorber plate
damage resulting from the oxidation of the
propylene glycol HTF.
35°N
45°
A
B
37
145
33
113
30
77
26
82
22
74
18
66
15
61
13
58
9
58
7
58
4
58
2
58
0
58
ARE DESIGNATED
40°N
50°
A
B
41
145
37
132
34
110
30
92
26
82
22
72
19
66
17
62
13
58
11
58
8
58
6
58
4
58
IN INCHES
45°N
55°
A
44
41
38
34
30
26
23
21
17
15
13
10
8
B
145
133
115
95
85
74
68
65
60
58
58
58
58
50°N
60°
A
B
48
145
44
141
41
118
38
98
34
87
30
77
27
70
25
66
22
62
19
58
17
58
14
58
13
58
3.2
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.
3.3
The solar collector must be located in a
structurally sound area of the roof that will
fig.3
In order to completely protect the integrity of the
solar collector and piping, the system is designed
to be drained manually if subject to extended
periods of disuse or persistent hard freeze conditions below minus 60° Fahrenheit. (See Sections
8.1 and 8.2 below).
3) INSTALLATION REQUIREMENTS - GENERAL
3.1
The contractor shall obtain all required permits and approvals.
SIDE PITCH MOUNTING
P.3
fig.4
fig.5
REVERSE PITCH MOUNTING
be unshaded for the majority of the day all
year round. Adjacent buildings and trees
should be checked for possible winter
shading. An instrument such as the Solar
Pathfinder can be used for solar site analysis. (Solar Pathfinder can be reached at
605-528-6473).
3.4
Before the installation the contractor shall
inspect the condition of the roof and notify the homeowner of any existing roof
damage or necessary repairs.
COMPOSITION SHINGLE MOUNTING
4.2 Collector Tilt
Optimal annual efficiency is achieved by tilting
the solar collector at an angle that equals your
latitude plus an additional 10°. This tilt angle
favors the lower winter sun when collector performance is at it’s lowest and minimizes overheating during the hottest summer months.
The solar collectors in a two collector staggered
mount installation must be spaced far enough
apart to prevent winter shading. Figure 2 and
3.5 The homeowner and contractor shall confirm the location of all roof and ground
mounted components in advance of the
installation.
4) INSTALLATION REQUIREMENTS - SPECIFIC
4.1 Collector Orientation
The performance of solar water heating systems
in the Northern Hemisphere is optimized when
the collector is mounted facing True South.
Performance, however, suffers very little when
the collector is oriented no more than 45° East or
West of True South. The collector should be
unshaded by any permanent obstacle between
9:00 a.m. and 3:00 p.m. on any day of the year.
fig.6
SHINGLE ROOF MOUNTING
P.4
fig.7
fig.9
TILE ROOF MOUNTING
FLUSH MOUNTING
fig.10
fig.8
TILE ROOF MOUNTING
STAND OFF MOUNTING
Table 1 show the correct spacing between collectors to prevent shading on December 21, when
the sun is at its lowest angle.
To ensure proper water drainage from the glazing the collectors must maintain a minimum
angle from horizontal of at least 10°. Never
mount the collector directly or parallel to a flat
roof surface. Use SunEarth "Solar Strut" tilt
mount kits to rack the collectors to the proper
angle.
4.3 Basic Mounting Procedures
The SunEarth solar collector in your SolaRay solar
system can be mounted in either a vertical or horizontal orientation on the roof (See Figure 1).
Although the collector is protected from freeze
conditions by the glycol HTF and does not normally need to be drained, it is still important to
slope the collectors just slightly to allow for complete drainage if necessary. The recommended
slope is 1/4" per foot of horizontal run.
The collector should be mounted as close to the
storage tank as possible to minimize heat loss in
the piping runs. If the home has attic access,
mounting the collectors near the roof peak provides for additional attic workspace.
The solar collector should be mounted on the
P.5
fig.11
4.3.2 The collector must be raised from the roof
surface to allow for rainwater and debris to pass
under the collectors and for proper ventilation of
the roofing material. There should be at least 1
1/2" of clearance between the roof surface and
the bottom of the solar collectors.
4.3.3 In selecting mounting hardware and fasteners it is extremely important to avoid galvanic
corrosion resulting from the direct contact of
incompatible metals. Use of SunEarth anodized
aluminum "Solar Strut" mounting hardware and
stainless steel lag or hanger bolts, lock washers
and round washers is recommended. In climates
subject to severe winters or high humidity use of
galvanized fasteners is prohibited.
4.3.4 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. Tremco "POLYroof" is the recommended elastomer for sealing roof penetrations. Henry Co. 204, 208 or 209 roof mastic or
Dow Corning Glazing Sealant also are acceptable
sealants.
TILT MOUNT
4.3.5 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.
fig.12
STAND OFF TILT MOUNT
roof in accordance with these general principles:
4.3.1 The most important structural consideration is to securely anchor the solar collector and
the Solar Strut mounting hardware to the structural members of the roof with stainless steel
hanger or lag bolts. The solar collector must be
attached to the mounting hardware as detailed
in Figures 5–12. (Note: The drawings in this
manual detail mounting hardware for the
SunEarth Empire series collector. Drawings for
the Imperial series collector are available upon
request).
P.6
4.4 Collector Loop Pipe Insulation
The collector loop cold supply and hot return
lines must be well insulated with a high quality
flexible closed cell insulation to minimize heat
loss. The wall thickness of the pipe insulation
should not be less than 3/4". A 1" wall thickness
is required in all areas prone to annual hard
freeze conditions. When it comes to pipe insulation the rule is simple: thicker is better. The specified insulation material is Rubatex Insul-Tube 180
or equal.
To the extent possible, slide the insulation material over the pipe without cutting or taping. All
butt joints must be sealed with contact adhesive.
The use of rigid polyethylene pipe insulation is
prohibited. The temperatures generated by your
collector in the summer months or under stagnation conditions can melt this type of material.
Any above ground exterior pipe insulation is subject to UV degradation and must be wrapped
with foil tape or painted with two coats of high
quality water-based acrylic resin coating as supplied by the insulation manufacturer. Rubatex
UV Protective Coating or equal is the required
coating material.
4.5 Collector Plumbing
SunEarth requires the use of all copper and brass
fittings in the collector loop plumbing.
Couplings rather than unions should be used to
join the collectors to avoid leaks and fluid loss.
Use only lead-free solder. Engelhard Silvabrite
100 or equal is required. Use of 50/50 lead solder is expressly prohibited. Use of galvanized
steel, CPVC, PVC, or any other type of plastic
pipe is prohibited.
fig.14
COLLECTOR PLUMBING - VERTICAL MOUNT
Piping in new solar installations can be covered
with dirt, grease, solder flux or other impurities
that over time affect the quality of the glycol HTF.
A thorough cleaning is required before charging
the system with glycol. Carefully review the
cleaning procedures in "Charging The System"
outlined below.
All vertical piping between the storage tank and
the collector shall be supported at each story or
at maximum intervals of ten feet (10'). Copper
plumbers tape or tube strap is required. The pipe
insulation may not be compressed or crimped by
the strapping material.
The installation of all horizontal and vertical piping may not reduce the performance or rating of
fig.13
COLLECTOR
SENSOR
fig.15
COLLECTOR PLUMBING - HORIZONTAL MOUNT
any structural member or fire rated assembly.
Adhere to all applicable local codes and ordinances.
4.6 Collector Sensor Placement
The collector sensor must be located on the hot
water return line as close to the collector as possible. Sensors are typically accurate to +/- 1/2°F
if properly installed and weatherized. To maximize sensor accuracy, attach the flanged portion
of the sensor to the SunEarth collector header
pipe with a stainless steel hose clamp. Wire nuts
used to connect the sensor and low voltage
wiring shall be all plastic, sealed with silicone and
thoroughly wrapped in electrician’s tape.
P.7
fig.16
SINGLE TANK SYSTEM SCHEMATIC
The sensor "bundle" must be placed under the
rubber pipe insulation covering the collector
header. Thoroughly wrap and weatherize the
insulation with electrician’s tape or insulation
tape as provided by the manufacturer (Rubatex
Insul-Tape or equal). See Figure 13 for collector
sensor installation detail.
sors to the controller should be a minimum18
AWG. The wiring should be bare or tinned copper, two conductor, PVC insulated, with a PVC
UV rated gray jacket suitable for exterior use.
Use Eastman Wire & Cable No. 5704, Belden
Wire and Cable No. 8461 or equal.
4.7 Low Voltage Wiring
4.8 Installing the Solar Storage Tank and
Expansion Tank
The low voltage wiring used to connect the sen-
In plumbing the solar storage tank and expansion
P.8
fig.17
DOUBLE TANK SYSTEM SCHEMATIC
tank make sure that all the components are
accessible and easy to reach. Provide for clear
access to the storage tank, pump, expansion
tank, mixing valve, time clock and other key components. If a component in the potable water
side of the system may require future service or
maintenance make the connections with brass
unions. Use only brass nipples and unions and
copper and brass fittings in plumbing the solar
storage tank and expansion tank. The use of galvanized fittings or nipples, di-electric unions,
CPVC, PVC or other plastic pipe is prohibited.
Hard copper connections to the city cold water
supply line and the home hot water feed lines are
recommended. The gaskets in standard water
heater flex hose connectors can become brittle
and compressed over time and begin leaking on
the water heater. If not detected in a timely
P.9
manner even a small drip or leak may cause serious damage to the tank’s electrical components
or, in extreme cases, may cause the tank to leak
from the outside in.
fig.18
Tank plumbing is required to provide for the isolation of the solar storage tank from the city cold
water supply line by means of an isolating ball
valve (No. 23).
Line thermometers shall be installed in the collector supply and return lines to allow for a simple diagnostic check of proper system operation.
On a sunny day the hot water return line should
be approximately 5 – 12° warmer than the water
in the collector supply line. Compare the temperature readings in the two line thermometers
(No. 3).
In a single tank system install a third thermometer (No. 3) directly after the mixing valve above
the solar storage tank. In a two tank system you
may install the third thermometer either directly
above the hot outlet on the solar storage tank or
after the mixing valve on the back-up water
heater.
TANK SENSOR
The temperatures generated by your SolaRay system will vary throughout the year. In the
Northern Hemisphere the water temperature will
be hottest in the spring and summer months
while cooler temperatures are to be expect from
November through March. On sunny days system temperatures may range between 110ºF to
180ºF depending upon the season and hot water
demand. The mixing valve described above
blends the hot and cold water supplies to deliver
hot water to your fixtures at a safe, controlled
temperature.
The circulation pump shall be the Grundfos
model UPS15-42F, 115 volt, or equal. The pump
shall be prewired with a 6’ line cord so that it can
be plugged directly into the 115 volt receptacle
on the side of the differential control. Two way
ball valves must be installed on either side of the
circulating pump (Nos.12 and 14) so that the
pump can be isolated from the collector loop.
Repairs or routine system maintenance can be
completed without introducing air into the system or draining the HTF.
WARNING: SCALDING CAN OCCUR WITHIN
FIVE SECONDS WHEN WATER TEMPERATURES APPROACH 140ºF. THE MIXING VALVE
SHOULD BE ADJUSTED BY YOUR CONTRACTOR TO PROVIDE WATER TO YOUR FIXTURES
AT NO MORE THAN 120ºF.
The expansion tank shall have a minimum 150
PSIG working pressure and have a total volume
of not less than 4.4 gallons. The standard factory charge should be 40 PSIG. The expansion tank
shall be Rheem/Ruud Therm-X-Guard Model RRT12 or equal (No. 8).
4.9 Tank Sensor Placement
A high quality thermostatic mixing valve is a
required component in all OG-300 certified systems and should be plumbed in line with brass
union connections for ease of future repair or
replacment (No. 32). The specified mixing valve
shall be the Heatguard model HGBASE or equal
and shall have an operating range between 95°F
and 140°F. The mixing valve shall be set to 120°F.
Thoroughly weatherize the wire connections in
accordance with the roof sensor detail above.
Replace the fiberglass insulation batting and
close the access cover.
P.10
The 3/4" cold water supply line to the solar storage tank must be insulated with minimum 7/8"
X 1/2" pipe insulation to a minimum distance of
5' behind the storage tank, or to the wall if closer than 5'.
Figure 18 details the proper placement of the
solar storage tank sensor. Make sure the sensor
is secured to the threaded stud on the storage
tank with a 10-24 stainless steel nut.
4.10 Tank Insulation
SunEarth requires that the solar storage tank
must have a minimum insulation value of R-20.
Most solar storage tanks now come with R-16.7
factory insulation. Conventional back-up electric water heaters have insulation values between
R-12 and R-20. The R value expresses the thermal conductivity of the insulation material. The
higher the "R"value the more effective the insulation material is at preventing heat loss.
Whereas solar storage tanks do not come with
sufficient factory insulation to meet SunEarth’s
insulation specification, a supplemental insulation jacket also must be installed. We recommend an aluminum foil "bubble-pack" insulation
material such as manufactured by Reflectix (or
equal). When properly applied, the insulation
jacket will increase the overall level of the solar
tank insulation to approximately R-22. In two
tank retrofit installations an installation jacket
also must be installed on the back-up water
heater.
If your Solaray system is installed in a new home,
SunEarth specifies that the conventional water
heater in a two tank system have an insulation
value of R-20 (Rheem 82VR52-2, Ruud EVR5202
or equal). Tanks with R-20 insulation or higher
do not require a supplemental insulation jacket.
For best results, cut three 1" strips of material
and affix these to the top, middle and bottom of
your water heater or storage tank with the manufacturer’s tape. This space creates an air gap
between the heater and the insulation and prevents heat conduction. Wrap the material around
the water heater or storage tank and secure the
seams with the manufacturer’s tape.
Thoroughly insulate the top of the water heater.
Fit the insulation snuggly around the brass nipples or unions and temperature and pressure
relief valve on the top of the water heater. If you
have an electric water heater, cut two windows
in the insulation around the access plates covering the upper and lower thermostats and heating
elements. Insulate the area over the assess
plates, but make sure that these areas always
remain accessible for service or repair as necessary.
The storage tank should not be placed directly on
an uninsulated floor or concrete slab. The tank
should be placed on a well insulated pad with a
minimum R-value of 10. A 2" rigid polystyrene
insulation pad such as manufactured by Frost
King (or equal) is recommended.
4.11 Electrical and Wiring Requirements
A properly licensed contractor must make the
230 volt electrical connection to the water heater
or solar storage tank and the electronic time
switch (Optional No. 33). If your solar contractor
is not allowed by law to make these connections
consult a licensed electrician.
Never activate the circuit breaker controlling
the electrical heating element until the solar
storage tank is completely filled with water.
This will prevent “dry firing” of the heating element. The electrical heating element will be
destroyed almost instantaneously if not completely submerged in water when activated.
Make sure the water heater circuit breaker is off
until the solar storage tank is completely filled.
We recommend the use of a 115 volt differential
control with a factory installed six foot line cord.
The installation requires one 115 volt outlet to be
installed near the solar storage tank. Plug the
control into the outlet. The circulation pump line
cord is plugged into the receptacle on the side of
the controller. A 230 volt control and circulation
pump may be substituted, but troubleshooting
the components in the future becomes more difficult.
The specified differential thermostat is the
Independent Energy "Goldline" model GL-30LCO (No. 18).
4.12 Charging the System
Once the components are plumbed you are ready
to fill the solar storage tank with water and to
charge the collector loop with a mixture of heat
transfer fluid (HTF) and distilled or deionized
water. The use of regular tap water as a mixing
agent is prohibited.
Proceed as follows:
4.12.1 Begin by filling the solar tank with water.
Do this by opening the cold water isolation ball
valve to the solar tank (No. 23). When the tank
is filled, inspect all threaded fittings and solder
joints for leaks.
4.12.2 Fill and pressurize the solar collector loop
with water. Begin by connecting a washing
machine hose to the upper charge valve (No. 9)
P.11
fig.19
ELECTRICAL COMPONENTS
and fill the collector loop with water. The isolation ball valve (No. 10) remains closed at this
point. While the hose is still connected to the
upper charge valve and the water is running,
open the lower purge/drain valve (No. 11) and let
the water run out until it is free of impurities or
debris that might have entered the piping as the
components were plumbed. Run the water long
enough to eliminate any air bubbles that may be
trapped in the system.
Close the lower purge/drain valve. The collector
loop now has been subjected to city pressure and
P.12
the pressure gauge should read somewhere in
the range of 50 - 75 PSI in most cases (No. 7).
Make a final inspection of the collector plumbing
connections to ensure that there are no leaks
anywhere in the collector loop piping.
4.12.3 After you have determined the integrity
of the entire piping system turn on the circulating pump. Do this by setting the manual switch
within the controller to the “on” position. Run
the pump for a full five minutes and carefully
check to ensure there is proper fluid flow and
that all the air has been purged from the solar
Table 4
Percent (volume) Glycol Concentration Required
Temperature F
For Freeze Protection
For Burst Protection
20
18%
12%
10
29
20
0
36
24
-10
42
28
-20
46
30
-30
50
33
-40
54
35
-50
57
35
-60
60
35
collector glycol loop. An inexpensive flow meter
such as manufactured by Blue White Industries or
Letro is recommended as an optional system
component. A flow meter allows you to monitor
and adjust the flow rate through the piping and
also to visually inspect the HTF fluid quality.
Set the controller to the "off" position and proceed to the next step.
4.12.4 Mix the Dowfrost HD propylene glycol
and distilled water mixture in accordance with
Table 4 and Table 5 in a large clean bucket. You
will need a second empty bucket as well. The
charging process also will require a low flow
diaphragm pump (Flojet or equal) to fill and pressurize the collector loop.
Connect the discharge side of the pressure pump
to the upper charge faucet (No. 9) Place the
pump suction side hose in the glycol solution.
Close the isolation ball valve (No. 10) and connect a second hose to the lower charge faucet
(No. 11). Place the other end of the hose in the
empty bucket.
Table 5
Total Collector Loop Fluid Capacity In Gallons*
1 Collector System
4 Gallon
2 Collector System
5 Gallons
* Assumes a total 100’ pipe run using 3/4" Type
M hard copper tubing. The Rheem/Ruud heat
exchanger has a 2.2 gallon fluid capacity.
Open the upper charge faucet and allow the
pressure from the expansion tank to push the
water in the glycol loop back to prime the pressure pump. When the hose in the bucket containing the glycol mixture stops bubbling you
may begin charging the collector loop with glycol.
With both charge faucets now open, run the
Flojet pressure pump until the pinkish glycol mixture begins flowing into the empty bucket.
Quickly switch the hose from the empty/return
bucket to the bucket containing the glycol mixture. Continue to circulate the fluid using the
pressure pump until the bubbling has stopped
and the air has been purged.
4.12.5 After charging the collector loop, shut
the lower charge faucet and let the pressure
pump drive up the loop pressure to the appropriate level (Generally in the range of 25 PSI). To
more accurately calculate the proper pressure
measure the height of the solar collector above
the solar storage tank and divide this number by
2.31. Then add 20 PSI to this number. As a word
of caution, the pressure in the glycol loop should
not exceed 45 PSI when the system is operational
on a good sunny day. Contact your solar contractor if the charged collector loop pressure
exceeds this threshold.
Your SolaRay solar water heating system must be
charged and the fluid quality maintained by an
experienced contractor. If the system is drained
during the winter, or you notice a significant drop
in collector loop pressure, contact your installation contractor immediately for service. The glycol HTF provides the freeze protection for your
system and must be properly maintained. An
experienced contractor should periodically check
the HTF fluid quality.
4.12.6 Dowfrost HD HTF
To ensure maximum effectiveness for corrosion protection, the glycol inhibitor package
is designed for a minimum 25-30 percent
concentration of glycol in water. Table 4
shows the concentrations of Dowfrost HD
required to provide freeze and burst protection at
various temperatures. Use the mixture most
appropriate for your climate. Do not use a higher glycol to water concentration than necessary,
as this will adversely impact the relative heat
transfer efficiency of the solution.
P.13
Generally, for an extended margin of protection,
you should select a temperature that is at least
5°F lower than the expected lowest ambient
temperature. These figures are examples only
and should not be regarded as specifications. As
use conditions are not within our control, neither
SunEarth nor Dow Chemical guarantees that
freeze damage may not occur at temperatures
other than shown.
designed to accommodate three separate modes
of operation. Your solar water heating system
can, (1) provide 100% solar operation during
good weather, or (2) serve as a preheater to your
electric water heater adding solar energy when
and as available, or (3) completely bypass the
solar collector loop and solar storage tank and
run 100% on utility power during inclement
weather.
Water used to dilute the HTF must meet certain
minimum standards for purity. Impurities in the
dilution water can increase metal corrosion,
reduce the effectiveness of corrosion inhibitors,
increase inhibitor depletion rate, and cause the
formation of scale and other deposits on the heat
exchanger's internal heat transfer surfaces.
Single Tank Operating Instructions:
Distilled or deionized water is required.
The HTF pH level must be maintained
between 8 and 10 to minimize corrosion and
glycol oxidation in the piping system.
5) SYSTEM START-UP PROCEDURES
Throughout the installation procedures outlined
in Section 4 above, emphasis has been placed on
the correct procedures for plumbing and wiring
the components, checking for plumbing leaks,
pressurizing the collector glycol loop, and eliminating any trapped air that can impact fluid quality and pump performance. Having completed
these tasks it is time to start up your SolaRay
solar water heating system.
When the glycol loop has been fully charged and
the pressure is around 25 psi (check the pressure
gauge, No. 7), set the differential controller to
the "Automatic" setting. This will activate your
circulating pump. The Goldline controller allows
you to set the "on" differential. Turn the red
rotary switch inside the control housing to 12.
The controller also allows you to limit the finished
solar storage tank temperature if desired. Turn
the red rotary switch inside the controller marked
"Hi Limit" to the 160° setting. SunEarth does
not recommend that the Hi Limit be set any
lower than 160°.
Adjust the valve settings in accordance with
Section 6 below.
6) THREE MODES OF SYSTEM OPERATION
Both single and double tank Solaray systems are
P.14
6.1 100% Solar Operation:
Turn off the circuit breaker to your solar storage
tank. If a water heater time switch has been
installed, set the switch to the "off" position. If
you have a mechanical timer remove the trippers
from the face of the switch.
6.2 Solar Preheat
Leave the circuit breaker to your solar storage
tank on and set the tank thermostat to the lowest acceptable temperature setting. The electric
resistance heating elements will come on only
when the tank temperature falls below the thermostatic set point. If the solar heated water
entering the tank is warmer than the thermostatic set point, the electric heating elements will
not come on. If you have a water heater timer,
you may preset the timer to turn the heating element on and off at specified times throughout
the day if desired.
6.3 100% Utility Power
Leave the circuit breaker to your solar storage
tank on and close the isolation ball valves in the
collector loop (Nos. 5 and 10). In this mode of
operation you must turn off the circulation
pump. To turn the pump off open the controller
and change the operational setting from automatic to off. Failure to turn off the pump can
quickly damage the pump motor, shaft, bearings
or impeller.
Two Tank System Instructions:
6.4 100% Solar Operation
fig.19a
100% SOLAR
OPERATION
Follow the instructions for single tank systems
above. You also must change the position of the
three way ball valves above both the solar storage tank and the back-up water heater (Nos. 24
and 26). Valve handle No. 24 must be in the horizontal position. Valve handle No. 26 must be in
the vertical position. See Figure 19a, 100% Solar
Operation.
6.5 Solar Preheat
fig.19b
SOLAR
PREHEAT
Follow the instructions for the single tank system
for setting the thermostat and the heating elements for automatic operation. The three way
valve above the solar storage tank (No. 24) must
be in the vertical position. Each valve handle
(Nos. 24, 25 and 26) must be placed in the horizontal position. See Figure 19b, Solar Preheat.
6.6 100% Utility Power
fig.19c
100% UTILITY
POWER
Follow the instructions for the single tank system
above. All three
ball valves above
the heaters (Nos.
24, 25 and 26)
must have the
valve
handles
placed in the horizontal position.
See Figures 19c
100%
Utility
Power and 19d.
7) ISOLATING
THE
MAJOR
COMPONENTS
AND SYSTEM
SHUT DOWN PROCEDURES
Your SolaRay solar water heating system is
designed so that the key components can be easily isolated for emergency repairs or routine
maintenance. By shutting a single valve you can
isolate the entire system from the pressurized
cold water supply line (No. 23). In the case of a
storage tank or fitting leak immediately shut this
valve and call your installation contractor for
service.
The collector loop can be isolated from the solar
storage tank by closing isolation ball valves Nos.
5 and 10. If the pressure in this loop drops or you
find a glycol leak shut these valves and contact
your installation contractor. Turn the circulating
pump off by setting the controller to the “off”
position.
In two tank systems the solar storage tank can be
isolated from the back-up water heater.
Set the valve handle on the three way ball valve
(No. 24) to the horizontal position and close the
isolation ball valve (No. 25). By closing these two
valves the tank can be serviced or replaced. The
operation of the back-up water heater will not be
effected.
The back-up water heater in two tank systems
also can be isolated from the rest of the system.
Close the cold water supply line ball valve (No.
23) and set the three way valve handle above the
conventional water heater (No. 26) to the vertical
position. Set the two way ball valve handle (No.
30) directly above the heater to the horizontal
position.
8)
SUMMER
VACATION RECOMMENDATIONS
AND
PROCEDURES
fig.19d
VALVE POSITION DIAGRAM
2-TANK SYSTEM
Solar water heating systems can
build up very high
temperatures
when there is no
daily draw on the
system. If a short
summer vacation
is planned the
best way to dissiP.15
pate heat in the system is to set the controller to
the "on" position. The circulating pump will run
twenty-four hours a day and cool off the water in
the solar storage tank at night. The collector
radiates heat back to the atmosphere at night,
preventing the system from stagnating at very
high temperatures. This will not harm the pump
or add substantially to your monthly utility bill.
Remember to set the control to the "Automatic"
setting upon your return!
During extended summer vacations (4 weeks or
more) it is advisable to either cover the solar collectors with an opaque material or to manually
drain the collector loop HTF. SunEarth recommends that you cover the collectors if practical.
If you choose to drain the HTF in the collector
loop follow these steps:
8.1 Turn the controller to the “off” position (No.
18).
8.2 Connect one end of a garden hose to the
purge/drain valve (No 11) and place the other
end in a five gallon bucket. Open the valve and
gravity will drain the heat transfer fluid into the
bucket. A licensed recycler, reclaimer or incinerator must dispose of the Dowfrost HD. DO NOT
DUMP DOWFROST HD INTO A STORM
SEWER, ON THE GROUND OR INTO ANY
BODY OF WATER.
BE CAREFUL. THE HTF MAY BE EXTREMELY
HOT!
8.3 If the system is installed with an optional
time clock make sure the clock is not preset to go
"ON" during your absence. If you have a
mechanical time switch, remove the "on" tripper
from the clock face (No. 33).
When you return home contact your service contractor to recharge the system with HTF. After
the system has been recharged, set the controller
to the “automatic” position. Reset the time
switch.
9) MAINTENANCE AND TROUBLESHOOTING
The following simple procedures are intended to
optimize the performance of your SolaRay solar
water heating system and also to extend the life
of the primary components.
9.1 Fluid Quality: It is extremely important to
P.16
monitor the quality of the Dowfrost HD HTF on a
periodic basis. The chemical composition of the
heat transfer fluid may change over time. System
pH must be maintained between 8 and 10 to
avoid damage to the collector loop and absorber
plate piping.
The specified glycol HTF is Dow Chemical
"Dowfrost" HD. An extremely complete manual
is available from the Dow Chemical Co. by calling
1-800-447-4369 Extension DOWFROST. Dow
Chemical's "Engineering and Operating Guide
for Dowfrost and Dowfrost HD" describes in
detail the necessary procedures to maintain the
integrity of the HTF. Ask your installation contractor to establish a maintenance schedule to
inspect, balance or replace the glycol HTF as
needed.
9.2 The second most important component in
your system, at least from a longevity standpoint,
is often ignored and never seen. We are referring
to the sacrificial "anode rod" installed in your
solar storage tank (No. 20). Typically constructed
from magnesium, anode rods are installed in
"glass lined" water heaters and storage tanks to
inhibit corrosion.
As the name implies, the "sacrificial" anode rod
is consumed so that the tank lining is not. At a
certain point in the process, the anode rod is no
longer completely effective and the corrosive
processes begin to eat away at the tank's glass
lining. In time the solar storage tank, like any
other gas or electric water heater, will begin to
leak. The process is not reversible and the tank
must be replaced.
System temperatures and water quality affect the
rate at which the anode rod is consumed. In
general, the higher the average system temperature the faster the rate of corrosion. By changing
the anode rod after the fifth year of system operation, and every three to five years thereafter, it is
possible to extend the life of the solar storage
tank. Periodic replacement of the anode rod in
your solar storage tank can significantly extend
the tank life.
9.3 The solar storage tank also should be flushed
annually to minimize sediment build-up on the
bottom of the tank. If you live in an area with
high mineral content in your water, flush the tank
on a semi-annual basis. Disconnect the power to
the solar tank at the circuit breaker or time switch
(if present) before flushing. Turn the controller to
the off position.
Open the flush valve on the bottom of the storage
tank (No. 15) and drain a sufficient volume of
water to eliminate the sediment. After the procedure is complete make sure the tank is completely
full of water before restoring power to the thermostat and heating element. Turn the controller
to the "on" position.
9.4 If you live in a dusty climate it is a good idea
to wash off the dirt that settles on the collector
glass once a month. Clean glass allows the collector to maintain a high level of thermal performance.
tive sensor replace it immediately.
Note that in a two tank system nighttime heat loss
will be harder to detect, especially if you are operating in the solar preheat mode. Check the line
thermometers (No. 3) in the collector loop piping
to detect night thermosiphoning.
9.10 If the weather is poor and the auxiliary heating element will not fire, the bright red reset button on the thermostat may have to be depressed
to be reset. Single tank systems have one heating
element and thermostat. Double tank systems
with conventional electric water heaters have two
heating elements and thermostats (see fig 17, No.
29).
Never remove the protective access plate
on the exterior of the solar storage tank
or conventional water heater without disconnecting the 230 volt power supply at
In the unusual instance of collector glass the circuit breaker.
9.5 Check the exterior pipe insulation annually
and patch or repair any exposed surfaces or
degraded areas. Repaint as necessary.
9.6
breakage, the glass should be replaced immediately. This will reduce the likelihood of water accumulating inside the collector and deteriorating the
insulation. Contact your installation contractor.
9.7 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.
9.8 If it’s been a sunny day and you don’t have hot
water, first make sure that the controller is set in
the automatic position. If the controller is properly set and the pump has not been running, unplug
the line cord from the controller receptacle and
plug the pump directly into a nearby 115 volt outlet. If the pump does not run it may need to be
replaced. If the pump does run when plugged
directly into the wall outlet, the problem may be
located in the controller or one of the 10k ohm
sensors. Contact your installation contractor for
service.
9.9 If you have a full tank of hot water before bed
and the solar storage tank is cold in the morning,
the check valve (No. 4) may not be seating correctly and should be cleaned or replaced. Also
make sure that the circulating pump is not running
after 6:00 p.m. If the pump is running and the
control indictor light "Solar" #1 is on after 6:00
p.m., check both sensors to see that they calibrate
to 10K ohm resistance at 77°F. If you find a defec-
After the circuit breaker has been turned off,
remove the access plate on the storage tank or
water heater and depress the red reset button on
the thermostat. If it clicks when depressed the
heating element should fire immediately when you
reconnect the circuit breaker. It the reset button
does not click and you do not have hot water after
one hour, the heating element or thermostat may
be defective. Contact your installation contractor
for service.
In two tank systems the conventional electric
water heater will be wired for electrical back-up.
The solar tank will serve solely as a storage tank
and will not be wired.
10) SOLARAY SYSTEM COMPONENT PARTS
See Figures 16 and 17 for the location of the specific components numbered below.
1) SunEarth Solar Collector(s): Absorbs the sun's
heat energy and transfers this heat to the HTF circulating through the collector.
2) Collector Sensor: Wired to the system controller. Works in conjunction with the tank sensor
to automatically turn your circulating pump on
and off at preset temperature differentials.
3) Tank and Line Thermometers: Used to determine proper system operation. Line thermometers
will show an approximate 5 - 12° temperature difP.17
ference between the collector supply and return
lines on sunny days. In a single tank system the
tank thermometer will read the temperature of
the water after the mixing valve feeding your fixtures. In two tank systems the thermometer will
read the finished solar tank temperature.
4) Check Valve: This valve is installed to stop or
minimize convective evening heat loss in the system. The heat in the solar storage tank will rise
through the collector loop piping in the evening
into the much cooler solar collector and dissipate
heat unless prevented from doing so by a check
valve. Check valves are also sometimes referred
to as one way valves.
5) Isolation Ball Valve: Used in conjunction with
component No. 10 to isolate the solar collector
loop from the solar storage tank.
6) Pressure Relief Valve: Will release glycol loop
HTF at 150 PSI. If this valve opens and HTF fluid
is expelled contact your contractor immediately.
This valve also can be opened to drain the HTF
from the charged glycol loop for replacement.
7) Pressure Gauge: Indicates the pressure in the
charged glycol collector loop.
8) Expansion Tank: Pre-charged with air to allow
for the expansion and contraction of the glycol
HTF as it heats and cools.
9) Charge Valve: Used to charge the collector
loop with glycol and also to eliminate air from
the system.
10) Isolation Ball Valve: Used in conjunction with
component No. 5 to isolate the solar collector
loop from the solar storage tank. Also used with
the charge valves to fill and pressurize the collector glycol loop (Nos. 9 and 11).
11) Drain/Purge Valve: Used to charge the collector loop with glycol, purge air from the loop
and drain the heat exchange fluid.
12) Isolation Ball Valve: When closed in conjunction with No. 14 will isolate the circulation pump
for repair or replacement.
13) Circulating Pump: Circulates the HTF
through the collector loop.
14) Isolation Ball Valve: When closed in conjunction with No. 12 will isolate the circulation pump
for repair or replacement.
P.18
15) Flush Valve: Used to drain the solar storage
tank and to flush sediment from the tank on an
annual basis.
16) Tank Sensor: Wired to your controller. Works
in conjunction with the collector sensor to turn
your circulating pump on and off at preset temperature differentials.
17) Cold Water Dip Tube: Forces incoming city
cold water to the bottom of the solar storage
tank to prevent mixing with the warm water at
the top of the tank.
18) Differential Thermostat: Known as the controller. Automatically turns the circulating pump
on and off when there is sufficient heat to be
gained from the solar operation. The controller
also may be set to limit high temperature build
up in the solar storage tank.
19) Heat Exchanger: Transfers heat from the
solar collector loop to the potable water in the
solar storage tank. The heat exchanger is double
walled and vented. If a leak in the heat exchanger piping occurs there is no possibility that the
potable water in your solar storage tank can be
contaminated with the glycol HTF.
20) Anode Rod: The "sacrificial" anode rod is
installed in your solar storage tank to prevent
corrosion to the tank lining by neutralizing
aggressive water action. Anode rods have a
finite life and require periodic replacement
depending on annual tank temperatures and
water quality. Determine a replacement schedule
with your installation contractor.
21) Heating Element & Tank Thermostat: The
solar storage tank is equipped with an auxiliary
4500 watt, 230 volt electrical heating element.
The thermostat controls the temperature setting
of the auxiliary heating element.
22) Temperature and Pressure Relief Valve:
Universally required by the plumbing code on
water heaters. Will automatically release and
dump water at either 150 PSI of pressure or 210°
F in temperature.
23) Cold Water Supply Line Isolation Ball Valve:
When open allows potable water to fill the solar
storage tank or back-up water heater. When
closed isolates the solar storage tank and backup water heater from the pressurized city cold
water supply line.
24) Three Way Ball Valve: Used in conjunction
with component No. 26 to establish the proper
mode of system operation.
25) Isolation Ball Valve: Used in conjunction with
component No. 24 to completely isolate the solar
storage tank for repair or replacement as necessary.
26) Three Way Ball Valve: Used in conjunction
with component No. 24 to establish the proper
mode of system operation.
estimates for automobiles, these component
design lives represent average figures for closed
loop forced circulation systems of this type
installed in the United States.
To obtain warranty service contact your installation contractor or call SunEarth Inc. for the name
of an authorized service agent near you.
12) SOLARAY SYSTEM MODEL NUMBERS
TYPE: 12 VOLT DC CIRCULATING PUMP AND
PHOTOVOLTAIC MODULE
27) Cold Water Dip Tube: See No.16 above.
28) Anode Rod: See No. 18 above.
MODEL NUMBERS
SINGLE TANK SYSTEMS
29) Heating Elements and Thermostats: See No.
19 above. In a two tank system the back-up
electric water heater has two heating elements
and two thermostats.
30) Temperature and Pressure Relief Valve: See
No. 22 above.
31) Optional Isolation Ball Valve. Use with component No. 26 to completely isolate the back-up
water heater for repair or replacement.
32) Mixing Valve: Automatically blends hot water
from the solar storage tank with incoming city
cold water to an acceptable set point. A mixing
valve must be installed on every SolaRay solar
water heating system.
DOUBLE TANK SYSTEMS
TE32P-80-1
TE32P-80-2
TE32C-80-1
TE32C-80-2
TE40P-80-1
TE40P-80-2
TE40C-80-1
TE40C-80-2
TE64P-80-1
TE64P-80-2
TE64C-80-1
TE64C-80-2
TE80P-80-1
TE80P-80-2
TE80C-80-1
TE80C-80-2
Example: TE64C-80-2
T
= Tank Type, Double Wall Vented Heat Exchanger
E
= Empire Series Collectors
33) Optional Time Switch: Allows you to automatically or manually turn the auxiliary heating
element in the solar storage tank on and off. A
time switch is a highly recommended option.
64 = Nominal 64 Square Foot Collector Area
11) ESTIMATED COMPONENT LIFE
2
You can expect a long useful life from the primary components in your SolaRay solar water
heating system by adhering to the routine service
and maintenance tips provided above.
G = Supplemental Gas Water Heater
The SunEarth solar collectors have a design life of
twenty-five to thirty years. The HTF must be
maintained as specified in this manual to maximize collector life. Photovoltaic modules have
design lives in excess of twenty years. The solar
storage tank should last 10 to 20 years in most
water quality areas by periodically replacing the
anode rod. The 12 volt DC circulating pump
generally runs 20,000 hours before the brushes
or motor require replacement. Like EPA mileage
C = Chrome Absorber
80 = 80 Gallon Solar Tank
= 2 Tank System
Note: To substitute a semi-selective absorber plate
coating, delete "C" and add "P".
To substitute the Imperial Series Collectors, the
prefix becomes TI.
WWW.SUNEARTHINC.COM
PLEASE VISIT OUR WEB SITE FOR NEW
PRODUCT UPDATES, ANSWERS TO FREQUENTLY ASKED QUESTIONS (FAQ) AND
USEFUL INFORMATION ABOUT SOLAR
WATER HEATING SYSTEMS.
P.19
THIS PAGE LEFT INTENTIONALLY BLANK
Std
W id . H e a d e
th, I
nch r
es
Std.
Diam Head
ete er
Nom r, Inche
inal s
H ea
to C der, Ce
ente nter
r, In
che
s
M ax
Rate Flow
G PM
M ax
O p e im u m
ratin
g
PSIG Press
Fluid
U.S. Capaci
G a ll t y
ons
D es
ig
Rate n Flow
G PM
Pres
at D sure Dr
esig op
n
Rate Flow
Dry
Wei
g
Lbs. ht,
A pe
Sq F rture
t
N et
Gro
ss A
Sq F rea
t
D ep
Inch th
es
Len
g
Inch th
es
W id
Inch th
es
Sun
M od Earth
el N
o.
13) EMPIRE COLLECTOR SPECIFICATIONS
36 1/8
78 1/4
3 1/4
19.70
17.30
60
0.60
0.51
.015
12
160
39 3/4
1
73 1/2
EC/EP24
36 1/8
98 1/4
3 1/4
24.61
21.88
80
0.78
0.62
.017
12
160
39 3/4
1
93 5/8
EC/EP32
48 1/8
98 1/4
3 1/4
32.79
29.81
106
1.00
0.83
.018
12
160
51 3/8
1
93 5/8
EC/EP40
48 1/8
122 1/4
3 1/4
40.81
37.33
141
1.20
1.04
.020
12
160
51 3/8
1
115 5/8
EC/EP20
THERMAL PERFORMANCE RATINGS*
MODEL EC
Category
(Ti-Ta)
Ti = inlet fluid temp
Ta = ambient air temp
CLEAR
DAY
2000
Btu/ft2 /Day
MILDLY
CLOUDY DAY
1500
Btu/ft2 /Day
MODEL EP
Inch-Pound Units
Btu/ft2 /Day
Inch-Pound Units
Btu/ft2 /Day
CLOUDY
DAY
1000
Btu/ft2 /Day
Category
(Ti-Ta)
Ti = inlet fluid temp
Ta = ambient air temp
CLEAR
DAY
2000
Btu/ft2 /Day
MILDLY
CLOUDY DAY
1500
Btu/ft2 /Day
CLOUDY
DAY
1000
Btu/ft2 /Day
1,332
680
1,005
A(-9oF)
1,284
659
971
A(-9oF)
1,218
565
890
B(9oF)
1,169
542
854
B(9oF)
o
1,040
402
720
C(36 F)
984
372
677
C(36oF)
o
o
699
127
405
D(90 F)
619
89
343
D(90 F)
o
o
390
137
E(144 F)
280
62
E(144 F)
A-Pool Heating (Warm Climate) B-Pool Heating C-Water Heating (Warm Climate) D-Water Heating (Cool Climate) E-Air Conditioning/Industrial Process Heat.
Thermal performance is obtained by multiplying the collector output for the appropriate application and insolation level by the total gross collector area.
*Collector ratings are derived from the Solar Rating & Certification Corp (SRCC) Document RM-1 and Standard OG-100.
The following shall be the specifications for the solar collectors. Collectors shall be SunEarth Empire model ________, and shall be of the
glazed liquid flat plate type. Collectors shall be tested in conformance with ASHRAE 93-1986, and SRCC 100-81. The collectors also shall be
certified by the SRCC and the Florida Solar Energy Center (FSEC).
GENERAL
The dimensions of the collector shall be _________ inches in length, _________ inches in width and 3 1/4 inches in depth. The collector casing shall be an anodized aluminum extrusion (alloy 6063 T5), minimum thickness .060 inch, with an architectural dark bronze finish. The casing shall have notched framewalls for ease of plate removal and reinstallation. Sheet metal screwed fasteners shall be stainless steel (18-8
#10). The backsheet shall be painted textured aluminum not less than .014 inch thickness. A 1 inch vent plug shall be installed in each of the
four corners of the backsheet to minimize condensation.
GLAZING
The collector glazing shall be one sheet of low iron tempered glass, with a minimum of 1/8 inch thickness (5/32 inch on EP/EC 40), and
a minimum transmissivity of 91 percent (89 on EP/EC 40). The glazing shall be thermally isolated from the casing by a continuous EPDM
gasket. There shall be a continuous secondary silicone seal between the glass and casing capstrip to minimize moisture from entering the
casing.
INSULATION
The insulation shall be foil-faced polyisocyanurate foam sheathing board of a minimum 1 inch thickness, siliconed in place to the aluminum
backsheet, covered by low-binder fiberglass of a minimum 1 inch thickness, providing thermal isolation of the foam from the absorber plate.
Total thermal resistance shall be a minimum of R-12. The sides and ends of the collector shall be insulated with a minimum of 1 inch foil-faced
polyisocyanurate foam sheathing board.
ABSORBER PLATE AND PIPING
The absorber shall consist of a roll-formed copper plate of no less than .008 inch thickness. Risers shall be a minimum of 1/2 inch O.D. Type
M copper tubing on no more than 4 1/2 inch centers continuously soldered to the plate utilizing a non-corrosive solder paste with a melto
ing point of 460 F. The risers shall be brazed to 1 1/8 inch O. D. Type M copper manifolds utilizing a copper phosphorous brazing alloy with
no less than 15 percent silver content, and conforming to the American Welding Society’s BCuP-5 classification. EPDM grommets shall isolate
the manifold from the aluminum casing. The absorber plate shall be designed for 160 psig maximum operating pressure.
ABSORBER COATING AND PERFORMANCE CURVE
A) Black Chrome (EC Series): The absorber coating shall be black chrome on nickel with a minimum absorptivity of 95 percent and a maximum emissivity of 12 percent. The instantaneous efficiency of the collector shall be a minimum Y-intercept of 0.714 and a slope of no less
than -0.7271 (BTU/ft2–hr)/F.
B) Moderately Selective Black Paint (EP Series): The absorber coating shall be a moderately-selective black paint with a minimum absorptivity
of 94 percent and a maximum emissivity of 56 percent. The instantaneous efficiency of the collector shall have a minimum Y-intercept of
0.682 and a slope of no less than -0.7995 (BTU/ft2–hr)/F.
Specifications subject to change without notice.
P.21
St d
Wid . Heade
th, I
nch r
es
Std.
Diam Head
ete er
Nom r, Inche
inal s
Hea
to C der, Ce
ente nter
r, In
che
s
Ma
x
Rat Flow
eG
PM
M
Ope aximum
ratin
g
PSIG Press
Fluid
U.S. Capacit
Gall y
ons
Des
ig
Rate n Flow
GPM
Pres
at D sure Dr
esig op
n
Rate Flow
Dry
Weig
Lbs. ht,
Net
Ape
Sq F rture
t
Gro
ss A
Sq F rea
t
Dep
Inch th
es
Len
g
Inch th
es
Wid
Inch th
es
Sun
Mod Earth
el N
o.
IMPERIAL COLLECTOR SPECIFICATIONS
IC/IP24
36 1/4
98 1/8
3 1/4
24.61
21.88
98
0.78
0.62
.017
12
160
39 3/4
1
IC/IP32
48 1/4
98 1/8
3 1/4
32.79
29.81
119
1.00
0.83
.018
12
160
51 3/8
1
93 5/8
IC/IP40
48 1/4
122 1/8
3 1/4
40.81
37.33
157
1.20
1.04
.020
12
160
51 3/8
1
115 5/8
THERMAL PERFORMANCE RATINGS*
MODEL IC
CLEAR
DAY
2000
Btu/ft2 /Day
Category
(Ti-Ta)
A(-9oF)
o
B(9 F)
o
C(36 F)
o
D(90 F)
o
E(144 F)
MILDLY
CLOUDY DAY
1500
Btu/ft2 /Day
CLOUDY
DAY
1000
Btu/ft2 /Day
Category
(Ti-Ta)
Ti = inlet fluid temp
Ta = ambient air temp
1,332
1,005
680
A(-9oF)
1,218
1,040
890
565
402
B(9oF)
127
D(90 F)
699
390
720
405
137
MODEL IP
Inch-Pound Units
Btu/ft2 /Day
Inch-Pound Units
Btu/ft2 /Day
Ti = inlet fluid temp
Ta = ambient air temp
93 5/8
-
C(36oF)
o
o
E(144 F)
CLEAR
DAY
2000
Btu/ft2 /Day
1,284
1,169
984
619
280
MILDLY
CLOUDY DAY
1500
Btu/ft2 /Day
CLOUDY
DAY
1000
Btu/ft2 /Day
971
854
677
343
659
542
62
372
89
-
A-Pool Heating (Warm Climate) B-Pool Heating C-Water Heating (Warm Climate) D-Water Heating (Cool Climate) E-Air Conditioning/Industrial Process Heat.
Thermal performance is obtained by multiplying the collector output for the appropriate application and insolation level by the total gross collector area.
*Collector ratings are derived from the Solar Rating & Certification Corp (SRCC) Document RM-1 and Standard OG-100.
The following shall be the specifications for the solar collectors. Collectors shall be SunEarth Imperial model ________, and shall be of the
glazed liquid flat plate type. Collectors shall be tested in conformance with ASHRAE 93-1986, and SRCC 100-81. The collectors also shall be
certified by the SRCC and the Florida Solar Energy Center (FSEC).
GENERAL
The dimensions of the collector shall be _________ inches in length, _________ inches in width and 3 1/4 inches in depth. The collector casing shall be an anodized aluminum extrusion (alloy 6063 T5), minimum thickness 1/8 inch, with an architectural dark bronze finish. The casing shall have notched framewalls for ease of plate removal and reinstallation. Machine nut and bolt fasteners shall be stainless steel (18-8
10/32). Mounting hardware shall attach to collector frame wall and require no penetration of the casing. The collector shall be wind load
tested to 180 mph (84 psf). The backsheet shall be painted textured aluminum not less than .014 inch thickness. A 1 inch vent plug shall be
installed in each of the four corners of the backsheet to minimize condensation.
GLAZING
The collector glazing shall be one sheet of low iron tempered glass, with a minimum of 1/8 inch thickness (5/32 inch on IP/IC 40), and
a minimum transmissivity of 91 percent (89 on IP/IC 40). The glazing shall be thermally isolated from the casing by a continuous EPDM
gasket. There shall be a continuous silicone seal between the glass and casing capstrip to minimize moisture from entering the casing.
INSULATION
The insulation shall be foil-faced polyisocyanurate foam sheathing board of a minimum 1 inch thickness, siliconed in place to the aluminum
backsheet, covered by low-binder fiberglass of a minimum 1 inch thickness, providing thermal isolation of the foam from the absorber plate.
Total thermal resistance shall be a minimum of R-12. The sides and ends of the collector shall be insulated with a minimum of 1/2 inch foilfaced polyisocyanurate foam sheathing board.
ABSORBER PLATE AND PIPING
The absorber shall consist of a roll-formed copper plate of no less than .008 inch thickness. Risers shall be a minimum of 1/2 inch O.D. Type
M copper tubing on no more than 4 1/2 inch centers continuously soldered to the plate utilizing a non-corrosive solder paste with a melto
ing point of 460 F. The risers shall be brazed to 11/8 inch O.D. Type M copper manifolds utilizing a copper phosphorous brazing alloy with
no less than 15 percent silver content, and conforming to the American Welding Society’s BCuP-5 classification. EPDM grommets shall isolate
the manifold from the aluminum casing. The absorber plate shall be designed for 160 psig maximum operating pressure.
ABSORBER COATING AND PERFORMANCE CURVE
A) Black Chrome (IC Series): The absorber coating shall be black chrome on nickel with a minimum absorptivity of 95 percent and a maximum emissivity of 12 percent. The instantaneous efficiencey of the collector shall be a minimum Y-intercept of 0.714 and a slope of no less
than -0.7271 (BTU/ft2–hr)/F.
B) Moderately Selective Black Paint (IP Series): The absorber coating shall be a moderately-selective black paint with a minimum absorptivity
of 94 percent and a maximum emissivity of 56 percent. The instantaneous efficiency of the collector shall have a minimum Y-intercept of
0.682 and a slope of no less than -0.7995 (BTU/ft2–hr)/F.
Specifications subject to change without notice.
P.22
(Performance specifications subject to testing error of +/- 3%)
PRODUCT WARRANTY STATEMENT
IMPERIAL, EMPIRE, SUNWISE AND SOLARSTAR COLLECTORS
SUNBURST ABSORBER PLATES AND COPPERHEART ICS
TEN YEAR WARRANTY
Under conditions of normal use and service SunEarth Imperial, Empire, SunWise and SolarStar
solar collectors, "SunBurst" absorber plates, and CopperHeart ICS units are warranted to the original or subsequent users for a period of ten (10) years from the date of sale. SunEarth's liability
under this warranty shall be limited to repairing or replacing at SunEarth's option, without charge,
F.O.B. SunEarth's factory or an authorized SunEarth distributor or service station, the Imperial,
Empire, SunWise or SolarStar collector, "SunBurst" absorber plate, or CopperHeart ICS unit.
SunEarth will not be liable for any costs of transportation, inspection, removal, reinstallation, or
any other labor or freight charges that may arise in connection with a warranty claim except as
expressly delineated in this warranty statement.
FIELD LABOR
Field labor to repair or replace any defective Imperial, Empire, SunWise, or SolarStar solar collector, "SunBurst" absorber plate, or CopperHeart ICS unit is reimbursable up to $100 in year one,
$75 in years two through five, and $50 in years six through ten.
FREIGHT AND SHIPPING EXPENSES
During the first year of warranty coverage SunEarth will pay the shipping costs for the new or
repaired Imperial, Empire, SunWise or SolarStar solar collector, "SunBurst" absorber plate, or
CopperHeart ICS between SunEarth and the nearest local distributor, dealer, or authorized service center. After the first year freight and packing costs are the responsibility of the owner and
are not covered under this warranty.
THIS WARRANTY WILL NOT APPLY
This warranty does not apply to conditions resulting from a failed component or part that is not
part of the Imperial, Empire, SunWise or SolarStar solar collector, "SunBurst" absorber plate, or
CopperHeart ICS unit; to freeze damage; to conditions resulting from misuse, abuse, neglect,
accident, or alteration; to minor discoloration of the collector framewall or absorber plate over
time; to glass breakage; to conditions resulting from the introduction of harmful chemicals, caustic fluids, or liquids deleterious to copper tubing, including improperly applied or maintained
heat transfer fluids; to propylene glycol pH levels above 10 or below 8; to periods of stagnation
in excess of 90 days; to excessive pressure; to erosion corrosion of the copper tubing resulting
from excessive flow rates; to improper plumbing configurations that do not conform to
SunEarth’s manifolding requirements; to clouding or similar occurrence resulting from the normal intrusion of moisture into the box; to conditions resulting from floods, earthquakes, winds,
fire, lightning, or circumstances beyond SunEarth's control; to installation methods that do not
conform to relevant national, state or local codes and ordinances, good industry practices or
applicable SunEarth manuals, diagrams, technical bulletins or written installation instructions; and
to applications other than medium temperature (110 - 160F) domestic water heating. If the
Imperial, Empire, SunWise or SolarStar solar collectors, "SunBurst" absorber plate or CopperHeart
ICS are purchased outside the continental United States certain conditions of this warranty may
not apply. Please contact your local SunEarth distributor.
HOW TO MAKE A CLAIM
To obtain service under this warranty, the defective product must be returned to the distributor
or dealer of SunEarth products nearest you, an authorized SunEarth service center, or SunEarth
directly. Each claim must be accompanied by documentation indicating the homeowner's name,
address, phone number, date of installation, date of failure, reason for failure, product model and
serial numbers, and the installation contractor’s name and phone number. If you have questions
regarding this warranty contact your installation contractor or SunEarth at 909-605-5610.
LIMITED WARRANTY
EXCEPT AS EXPRESSLY PROVIDED HEREIN, THE IMPERIAL, EMPIRE, SUNWISE OR SOLARSTAR
COLLECTOR, "SUNBURST" ABSORBER PLATE, OR COPPERHEART ICS UNIT IS PROVIDED
WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTY OR NON-INFRINGEMENT. SOME STATES DO NOT
ALLOW THE EXCLUSION OF IMPLIED WARRANTIES, SO THE ABOVE EXCLUSION MAY NOT
APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY
ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
LIMITATIONS OF REMEDIES
IN NO EVENT WILL SUNEARTH BE LIABLE TO YOU FOR ANY DAMAGES, INCLUDING ANY
LOST PROFITS, LOST SAVINGS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES,
ARISING OUT OF THE USE OR INABILITY TO USE THE IMPERIAL, EMPIRE, SUNWISE OR
SOLARSTAR COLLECTOR, "SUNBURST" ABSORBER PLATE, OR COPPERHEART ICS, OR FOR
ANY CLAIM BY ANY OTHER PARTY. SOME STATES DO NOT ALLOW THE LIMITATION OR
EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE
LIMITATION MAY NOT APPLY TO YOU.
EXCLUSIVE AGREEMENT
THE WARRANTY CONTAINED HEREIN CONSTITUTES THE ENTIRE, COMPLETE, FINAL AND
EXCLUSIVE AGREEMENT, AND SUPERSEDES ANY PROPOSAL OR AGREEMENT ORAL OR
WRITTEN, AND ANY OTHER COMMUNICATIONS, BETWEEN SUNEARTH AND THE BUYER
WITH RESPECT TO THE SUBJECT MATTER HEREOF.
Revised 07/99
4315 Santa Ana St. • Ontario, CA. 91761
Phone: (909) 605-5610 • Fax: (909) 605-5613
email: info@sunearthinc.com • www.sunearthinc.com