Phoenix Solar
The solar energy system described in this manual, when properly installed and maintained, meets
or warranty of this product by the SRCC .
Water Heater
INSTALLATION
OPERATION
MAINTENANCE
Phoenix Water Heater Models
PH130-80S / 130-119S
PH199-80S / 199-119S
the minimum standards established by the SRCC. This certification does not imply endorsement
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held
liable for typographical errors in literature.
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The following defined terms are used throughout this manual to bring attention to the presence of
hazards of various risk levels, or to important product information.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
FOREWORD
This manual is intended to be used in conjunction with other literature provided with the Solar Water
Heater. This includes all related control information. It is important that this manual, all other documents
included with this system, and additional publications including Solar Water Heating System Design and
Installation Guidelines, be reviewed in their entirety before beginning any work.
Installation should be made in accordance with the regulations of the local code authorities and utility
companies which pertain to this type of water heating equipment.
This manual must only be used by a qualified heating installer/service technician. Read all instructions in
personal injury, death or substantial property damage.
FOR THE INSTALLER
this manual before installing. Perform steps in the order given. Failure to comply could result in severe
INSTALLATION OR SERVICE OF THIS SOLAR WATER TANK IS REQUIRED TO BE PERFORMED BY
LICENSED PROFESSIONALS WHERE SOLAR, PLUMBING AND ELECTRICAL WORK IS REQUIRED.
The installer should be guided by the instructions furnished with the tank, local codes and utility company
requirements. Preference should be given to codes and requirements where they differ from the furnished
instructions.
INSTALLATIONS MUST COMPLY WITH:
Local, state, provincial, and national codes, laws, regulations and ordinances.
Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, from Solar Rating and
Certification Corporation, 1679 Clearlake Road, Cocoa, FL 32922-5703.
The latest version of the National Fuel Gas Code
Laboratories, 8501 East Pleasant Va lley Road, Cleveland, OH 44131.
In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale
Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian
Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.
Code for the installation of Heat Producing Appliances (latest version), from American Insurance
Association, 85 John Street, New York, NY 11038.
The latest version of the National Electrical Code, NFPA No. 70.
In Canada, refer to Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.
NOTE: The Phoenix gas manifold and controls met safe lighting and other performance criteria when
undergoing tests specified in ANSI Z21.10.3 – latest edition.
, ANSI Z223.1, from American Gas Association
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TABLE OF CONTENTS
PART 1: GENERAL SAFETY INFORMATION ............................................................................................ 5
A. LOCAL INSTALLATION REGULATION ............................................................................................... 5
B. WATER TEMPERATURE ADJUSTMENT ............................................................................................ 5
C. FREEZE PROTECTION/WINTERIZING .............................................................................................. 5
PART 2: GENERAL INFORMATION ........................................................................................................... 6
A. PREFACE ............................................................................................................................................. 6
B. INTRODUCTION ................................................................................................................................... 6
C. SYSTEM DESCRIPTION...................................................................................................................... 6
D. PHOENIX SOLAR WATER HEATER ................................................................................................... 6
E. SOLAR WATER HEATER LOCATION ................................................................................................. 6
F. INSPECTION OF THE SOLAR WATER HEATER ............................................................................... 7
G. SOLAR PIPING CONNECTION ........................................................................................................... 7
H. GENERAL SOLAR PANEL ORIENTATION ......................................................................................... 8
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I. GENERAL SOLAR PANEL INSTALLATION.......................................................................................... 8
J. COLLECTOR LOOP PIPE INSULATION .............................................................................................. 9
K. COLLECTOR PIPING ........................................................................................................................... 9
L. COLLECTOR SENSOR PLACEMENT ............................................................................................... 10
PART 3: WATER HEATER INSTALLATION ............................................................................................. 10
A. INSTALLATION CHECKLIST ............................................................................................................. 10
B. POTABLE WATER PIPING ................................................................................................................ 11
C. SOLAR HEAT EXCHANGER PIPING ................................................................................................ 12
D. TANK SENSOR PLAC E MEN T ........................................................................................................... 13
E. NECESSARY COMPONENTS FOR SOLAR WATER HEATER INSTALLATION ............................. 13
F. PHOENIX SOLAR PIPING WITH AIR HANDLER .............................................................................. 16
G. TANK CONTROL ................................................................................................................................ 17
H. CIRCULATOR SIZING ........................................................................................................................ 17
I.CHARGING THE SYSTEM ................................................................................................................... 18
J. COMMISSIONING THE SYSTEM ....................................................................................................... 18
PART 4: MAINTENANCE ........................................................................................................................... 19
A. SHUTDOWN PROCEDURES ............................................................................................................ 19
B. VACATION SHUTDOWN.................................................................................................................... 19
C. ESTIMATED LIFE OF COMPONENTS .............................................................................................. 20
PART 5: TROUBLESHOOTING................................................................................................................. 24
MAINTENANCE NOTES ............................................................................................................................ 30
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INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.
USER – This manual is for use only by a qualified installer/service technician. Refer to user’s information
manual for your reference. Have this heater serviced/inspected by a qualified service technician annually.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL
PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
Households with small children , disabled, or elderly persons may require a 120oF or lower
temperature setting to prevent scalding.
HTP CUSTOMER INSTALLATION RECORD FORM ........................................................................ 31
PART 1: GENERAL SAFETY INFORMATION
A. LOCAL INSTALLATION REG UL ATION
Installation of this solar water heater may be governed by individual local rules and regulations for this
type of product, which must be observed. Always use the latest edition of codes. The installation,
adjustment, service, and maintenance of the solar water heater must be done by a licensed professional
who is qualified and experienced in the installation, service, and maintenance of solar hot water systems.
B. WATER TEMPERATURE ADJUSTMENT
If the solar water heater is going to have a set temperature above 120
rated mixing valve to avoid severe burns or death from scalding temperature.
o
F, you must use an ASSE 1017
C. FREEZE PROTECTION/WINTERI ZI NG
NOTE: Consider piping and installation when determining heater location.
To winterize the heater, drain the entire system. Pump one gallon of non-toxic, NSF food grade propylene
glycol, FDA rated as GRAS (Generally Recognized As Safe), into the tank. Consult the glycol
manufacturer for specific instructions on concentration percentage as well as freeze and burst protection
methods. Check the concentration of antifreeze to assure protection is adequate to protect the bottom of
the heater from freezing.
NOTE: Failure to follow the procedures described in this manual voids the manufacturer warranty.
PART 2: GENERAL INFORMATION
A. PREFACE
By using the sun’s energy to heat water, solar hot water heating systems help reduce the nation’s
dependence on polluting fossil fuels. This reliable, efficient solar water heater meets the certification
requirements of SRCC-OG-300.
B. INTRODUCTION
Solar system performance and efficiency varies with factors such as: household hot water load, ambient
air temperature, roof pitch, collector orientation, and seasonal intensity.
Your solar system uses a circulation pump to circulate heat transfer fluid throughout the system.
Depending on system design, you may use distilled water (often used in drain back systems), or a
propylene glycol/water solution (in closed loop systems) as heat transfer fluid. Drain back and propylene
glycol systems provide freeze protection to the solar components.
This manual intends to familiarize you with the proper installation and maintenance of your solar water
heating system. This system must be installed by a licensed solar or plumbing contractor in accordance
with SRCC Standard OG-300 and all applicable national, state, and local codes.
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C. SYSTEM DESCRIPTION
Some of the components in the Phoenix Solar Water Heating System include: the solar collector(s), a
Phoenix Solar Water Heater, a circulator pump, a differential solar control, and an expansion tank.
Depending on the type of solar system, dis tilled water or non-toxic, FDA rated Generally Recognized As
Safe (GRAS) propylene glycol will be used as heat transfer fluid.
D. PHOENIX SOLAR WATER HEATER
The Phoenix Solar Water Heater has an internal solar heat exchanger for use with solar collectors. And
when there is not sufficient solar energy, the Phoenix Solar Water Heater utilizes a gas-fired backup to
provide hot water. (Refer to solar piping details in this manual for suggested piping application.)
E. SOLAR WATER HEATER LOCATION
Choosing a location for your solar water heater is an ex tr em el y impor tant part of the installation process.
The heater location should be centralized to the piping system, in an area where it will not be exposed to
freezing temperatures. All piping should be insulated to protect against freezing and heat loss.
In addition, the solar water heater should be installed with plenty of clearance for service. If minimum
clearances are not met, it may not be possible to service the heater without removing it from its location.
Finally, the solar water heater should also be installed in a place where T&P discharge or a leak will not
result in damage to the surrounding area. If such a location is not available, install an auxiliary catch pan.
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Many heat transfer fluids are classified as toxic. Do not introduce heat transfer fluids into any fittings on
the heater except those clearly marked for that purpose.
Figure 1 - Clearances
F. INSPECTION OF THE SOLAR WATER HEATER
When receiving your solar water heater, inspect it for possible damage. Check markings on the rating
plate to be certain the power supply corresponds to that for which the water heater is equipped.
G. SOLAR PIPING CONNECTION
When making a connection to the heat exchangers, use Teflon tape and joint compound to prevent leaks.
The heat exchanger connections are 1” NPT. Do not apply heat directly to heat exchanger thread
connection when sweating f ittings .
In closed loop glycol systems, freeze protection fluid must be non-toxic, propylene glycol, FDA rated as
GRAS. To protect the heat exchanger and other system components, regular scheduled maintenance
must be established to monitor and maintain proper heat transfer fluid pH levels.
The system components should carry temperature and pressure ratings equivalent to the design of the
solar collector. To ensure system is appropriate for installation climate, the solar collector ratings should
be verified against the collector manufacturer specifications. Collector and storage tank temperatures can
be read from the system controllers. Typical tank operating temperatures range from 40-80
supply line to the 175
o
F tank high limit. The collector temperature sensor should be 5-20oF higher than
the tank sensor during normal charging operation. During idle period, when there is no sun, the collector
sensor will read the ambient temperature; in full sun, the sensor will read as high as 250
vary depending on installation climate.
Using proper concentrations of glycol, solar systems can be operated at ambient temperatures as low as
o
F. Freeze tolerance limits are based upon an assumed set of environmental conditions. Refer to the
-60
DOWFROST specification sheet in the back of this manual for recommended concentrations.
o
F on the cold
o
F. Temperatures
Figure 2 – Example of Solar Panel Orientation – LP-199-O
Depending on the controller model, the differential controller uses 10k ohm thermistors or 1k RTDs to
monitor the temperature difference between the collector and the solar water heater. The controller turns
on when the collector is 12-20
o
F above tank temperature and turns off when the differential drops to 4oF.
H. GENERAL SOLAR PANEL ORIENTATION
Part of the performance of your solar water heater is based on the correct orientation of the solar panels.
The collector should be mounted as close to the storage tank as possible to minimize heat loss in the
piping runs. In North America,
collectors should be oriented
facing due south. However, if
this is not possible, they may
be installed within 40 – 60
degrees of due south. Optimal
tilt is +/- 10
the site. The solar collector
must be located in an area of
the roof that will be unshaded
for the majority of the day (from
9 AM – 3 P<) year round.
Adjacent buildings and trees
should be checked for possible
winter shading.
You must consult your solar
panel installation manual for
recommended mounting and
positioning of the panels.
o
from the latitude of
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I. GENERAL SOLAR PANEL INSTALLATI ON
The contractor shall obtain all required permits and approvals for installing the solar system. The
installation shall conform to all federal, state and local regulations governing solar water heating system
installations. 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. Before the installation, the contractor shall inspect the condition of the roof and
notify the homeowner of any existing roof damage or necessary repairs. 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 as detailed in figures below.
Consult with the panel manufacturer installation manual for proper guidelines in your application.
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. The recommended elastomer for sealing roof penetrations is
Tremco “POLYroof”.
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Figure 3 - This detail is an example of a typical solar roof mount application. All equipment should be
installed in accordance with all local codes and best practices as identified with National Roofing
Contractors Association (NRCA) or other qualified body.
J. COLLECTOR LOOP PIPE INSULATION
To minimize heat loss, the collector loop cold supply and hot return lines must be well insulated with high
quality flexible closed cell insulation. The wall thickness of the pipe insulation should not be less than ¾”.
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 piping insulation material is Rubatex InsulTube 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. The required coating material is Rubatex UV Protective Coating or equal.
K. COLLECTOR PIPING
Collector piping requires the use of all copper and brass fittings in the collector loop. In glycol loops, cast
iron is also acceptable. 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.
Piping in new solar installations may have dirt, grease, solder flux, or other impurities in the piping that
over time affect the quality of the glycol HTF. A thorough cleaning is required before charging the system
with glycol.
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.
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Figure 4 – Sensor Placement – LP-199-O
The installation of all horizontal and vertical piping may not reduce the performance or rating of any
structural member or fire rated assembly. Adhere to all applicable local codes and ordinances.
L. COLLECTOR SENSOR PLACEMENT
The collector sensor must be located on the hot water return line as close to the collector as possible.
Some collectors have insertion areas to measure temperatures more accurately at the collector manifold.
Sensors are typically accurate to +/- 1/2
properly installed and weatheri zed. To
maximize sensor accuracy, attach the
flanged portion of the sensor to the 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.
The low voltage wiring used to connect the
sensors to the controller should be a
minimum 18 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, Beldon Wire and Cable
no. 8461 or equal.
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).
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F if
PART 3: WATER HEATER INSTALLA TION
A. INSTALLATION CHECKLIST
Location
• Sufficient room to service water heater
• Provisions made to protect area from water damage
• Centrally located to fixtures
• Protected from freezing temperatures
• Area free of flammable vapors
Potable Water Supply
• All related piping free from leaks
• Thermal expansion tank installed
• Water heater and fixtures have been properly purged of air
• ASSE 1017 rated thermostatic mixing valve (if water temperature is set above 120
Relief Valve
• Temperature and Pressure relief valve properly installed and discharge line runs to open drain
• Discharge line not exposed to freezing temperatures
• Discharge line constructed of copper
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F)
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