HTP SSC-119SE User Manual

SuperStor Contender

The solar energy system described in 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.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

Solar Supplement

INSTALLATION

OPERATION

MAINTENANCE

TROUBLESHOOTING

SB Series* Models SE Series** Models SSC-50SB / SSC-80SB SSC-50SE / SSC-80SE SSC-119SB SSC-119SE

*With back-up heat exchanger **With back-up electric element

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

LP-200 REV. 3.25.14

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.

This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions and safety messages in this manual before installing, operating, or servicing this water heater. Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with this 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, SRCC OG-300, be reviewed in their entirety before beginning any work.

“The solar energy system described in 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.”

The design of the SuperStor Contender solar system is approved by the Solar Rating and Certification Corporation (SRCC). Any deviation from the approved specified SRCC components may affect your ability to certify this system.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official or electrical inspector, or others having statutory authority. In some circumstances, the property owner of his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ.

NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice.

FOR THE INSTALLER

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. Always use the latest edition of codes.

INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances.

LP-200 REV. 3.25.14

Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, available from Solar Rating & Certification Corporation, 400 High Point Drive, Suite 400, Cocoa, FL 32926-6630, www.solar-rating.org.

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.

TABLE OF CONTENTS

INTRODUCTION .......................................................................................................................................................................... 5

PART 1 - GENERAL SAFETY INFORMATION ........................................................................................................................... 5

A. PRECAUTIONS .......................................................................................................................................................................... 5

B. LOCAL INSTALLATION REGULATION ...................................................................................................................................... 6

C. CHEMICAL VAPOR CORROSION ............................................................................................................................................. 6

D. INSULATION BLANKETS ........................................................................................................................................................... 7

E. DOMESTIC HOT WATER TEMPERATURE ADJUSTMENT ...................................................................................................... 7

F. FREEZE PROTECTION .............................................................................................................................................................. 7

PART 2 – IMPORTANT INSTALLATION INFORMATION .......................................................................................................... 7

A. SCOPE OF MANUAL .................................................................................................................................................................. 7

B. LOCAL STANDARDS AND AUTHORIZED PERSONS .............................................................................................................. 7

C. TERMINOLOGY ......................................................................................................................................................................... 7

D. SYSTEM DESIGN ...................................................................................................................................................................... 8

E. FLUID QUALITY ......................................................................................................................................................................... 8

F. CORROSION ................................................................................................................................................................ .............. 8

G. FREEZE PROTECTION ............................................................................................................................................................. 8

PART 3 - GENERAL SOLAR INFORMATION ............................................................................................................................ 8

A. SYSTEM DESCRIPTION ................................................................................................ ................................ ............................ 8

B. SOLAR SYSTEM DESIGN ......................................................................................................................................................... 9

C. SOLAR COLLECTOR INSTALLATION ...................................................................................................................................... 9

D. COLLECTOR ANGLE, PLANE, AND DIRECTION ................................................................................................................... 10

1. COLLECTOR DIRECTION ........................................................................................................................................................... 10

2. COLLECTOR ANGLE (TILT) ........................................................................................................................................................ 10

3. COLLECTOR PLANE (HORIZONTAL OR VERTICAL) ................................................................................................................ 10

E. COLLECTOR PIPING ............................................................................................................................................................... 10

F. COLLECTOR LOOP PIPE INSULATION .................................................................................................................................. 11

G. COLLECTOR SENSOR PLACEMENT ..................................................................................................................................... 11

H. AVOID SHADE ......................................................................................................................................................................... 11

I. LOCATION ................................................................................................................................................................................. 11

J. LIGHTNING PROTECTION ....................................................................................................................................................... 11

K. GALVANIC REACTION ............................................................................................................................................................ 11

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L. WIND STRESS.......................................................................................................................................................................... 11

M. SNOW LOAD ........................................................................................................................................................................... 12

N. HAIL RESISTANCE .................................................................................................................................................................. 12

O. STORAGE TANKS ................................................................................................................................................................... 12

P. THERMAL EXPANSION (CLOSED LOOP SYSTEMS) ............................................................................................................ 12

PART 4 – SPECIFICATIONS ..................................................................................................................................................... 13

PART 5 - INSTALLATION ......................................................................................................................................................... 15

A. INSTALLATION CHECKLIST ................................................................................................................................................... 15

B. SOLAR WATER HEATER LOCATION ..................................................................................................................................... 16

PART 6 – PIPING ...................................................................................................................................................................... 16

A. POTABLE WATER PIPING ...................................................................................................................................................... 16

B. WATER CHEMISTRY REQUIREMENTS ................................................................................................................................. 17

C. POTABLE WATER PIPING DETAIL ......................................................................................................................................... 18

D. SOLAR HEAT EXCHANGER PIPING ...................................................................................................................................... 19

E. TANK SENSOR PLACEMENT ................................................................................................................................................. 19

F. NECESSARY COMPONENTS FOR SOLAR WATER HEATER INSTALLATION .................................................................... 19

G. SOLAR WATER HEATER WITH BOILER BACK-UP ............................................................................................................... 22

H. SOLAR WATER HEATER WITH ELECTRIC BACK-UP ........................................................................................................... 23

I. BOILER BACK-UP HEAT EXCHANGER CONNECTION (SB MODELS ONLY) ....................................................................... 24

J. BOILER TANK CONTROL ........................................................................................................................................................ 24

K. CIRCULATOR SIZING .............................................................................................................................................................. 24

L. BOILER BACK-UP HEAT EXCHANGER (SB MODELS ONLY) ............................................................................................... 24

M. ELECTRICAL CONNECTION (SE MODELS ONLY) ............................................................................................................... 25

N. THERMOSTAT ADJUSTMENT ................................ ................................ ................................................................................ 26

O. COMBINATION “THERMOSTAT AND HIGH LIMIT CONTROL (ECO)” .................................................................................. 26

PART 7 - FLUID QUALITY ........................................................................................................................................................ 26

A. SOLAR LOOP FLUID QUALITY ............................................................................................................................................... 26

B. FLUID SAFETY LABELING ...................................................................................................................................................... 26

C. FREEZE PROTECTION ........................................................................................................................................................... 26

PART 8 – START-UP PREPARATION...................................................................................................................................... 27

A. CHARGING THE SYSTEM ....................................................................................................................................................... 27

B. COMMISSIONING THE SYSTEM ............................................................................................................................................ 27

PART 9 – SERVICE/MAINTENANCE PROCEDURES ............................................................................................................. 28

A. SHUTDOWN PROCEDURES ................................................................................................................................................... 28

B. VACATION SHUTDOWN .......................................................................................................................................................... 28

C. ESTIMATED LIFE OF COMPONENTS .................................................................................................................................... 28

D. TEMPERATURE AND PRESSURE RELIEF VALVE................................................................................................................ 28

PART 10 - TROUBLESHOOTING ............................................................................................................................................. 29

A. LEAKS ...................................................................................................................................................................................... 29

B. OTHER PROBLEMS ................................................................................................................................................................. 29

C. OPERATING SUGGESTIONS FOR THE USER ...................................................................................................................... 29

LP-200 REV. 3.25.14

NOTE: Failure to follow the procedures described in this manual WILL VOID the warranty.

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 heating installer/service technician. Have this solar water heating system serviced/inspected by a qualified service technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS SOLAR WATER HEATING SYSTEM SERVICED/INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If any component of the solar water heating system is exposed to the following, do not operate until all corrective steps have

been made by a qualified serviceman:

1. FIRE

2. DAMAGE

3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Be sure to disconnect electrical power from the solar water heating system before performing service. Failure to do so could result in an electrical shock, property damage, serious personal injury, or death.

PART 11 - SYSTEM PARTS LISTING....................................................................................................................................... 30

A. ESTIMATED COMPONENT LIFE ............................................................................................................................................. 30

B. WARRANTIES AND DISCLAIMERS ........................................................................................................................................ 30

MAINTENANCE NOTES .................................................................................................................................................................. 38

HTP CUSTOMER INSTALLATION RECORD FORM ...................................................................................................................... 39

INTRODUCTION

Your solar water heater has an internal solar heat exchanger for use with solar collectors. When there is not sufficient solar energy, the water heater utilizes a backup system to provide hot water. In SB Series water heater models, the tank has an extra heat exchanger that connects to a boiler. In SE Series models, the water heater has an electric heating element. (Refer to solar piping details in this manual for suggested piping applications of both models.)

Your solar system uses a circulation pump to circulate a propylene glycol/water heat transfer fluid solution (HTF) throughout a closed loop system. Closed loop propylene glycol systems provide freeze protection for 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.

Job site conditions will require your installation contractor to supply some or all of the following:

 Plumbing Connections  Piping and Insulation  Valves Between the Existing Domestic Water System and the Solar System

NOTE: Solar system performance and efficiency varies with factors such as: household hot water load, ambient air temperature, collector/roof pitch, collector orientation, and seasonal intensity.

PART 1 - GENERAL SAFETY INFORMATION

A. PRECAUTIONS

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the solar water heater rating label.

NOTE: OBTAIN ALL APPLICABLE PERMITS AND OBEY ALL LOCAL CODES.

LP-200 REV. 3.25.14

DO NOT USE THIS SOLAR WATER HEATING SYSTEM IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. Components MUST BE replaced if submerged. Attempting to operate a solar water heating system that has been even partially submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged solar water heating system could result in property damage, severe personal injury, or death.

NOTE: Damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

NOTE: Install all system components and piping in such a manner that does not reduce the performance of any fire rated assembly.

Improper installation or use may result in property damage. Such damage IS NOT covered by warranty.

NOTE: HTP DOES NOT WARRANT THIS WATER HEATER AGAINST FREEZE RELATED DAMAGE.

Only use this solar hot water system as intended and described in this installation manual. Any use other than described will void warranty and may lead to fire, property damage, personal injury, or death.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the water heater as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this water heater and related components near high heat sources.

NOTE: DAMAGE TO THE SOLAR WATER TANK, COLLECTOR, OR RELATED COMPONENTS CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. The limited warranty is voided when failure of water tank is due to a

corrosive atmosphere. (Refer to the limited warranty for complete terms and conditions).

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops

Adhesives used to fasten building products

ALL PIPING AND PLUMBING CONNECTIONS IN CLOSED LOOP SYSTEMS SHOULD BE MADE WITH COPPER PIPE ONLY. No less than ¾” I.D. copper tube of the type meeting local codes must be used for piping. Pipe runs must be solidly attached with proper clamping methods. Soldered connections should be secured with 95/5 lead-free solder. Use only pipe rated for 250oF minimum on both the collector return and supply piping.

B. LOCAL INSTALLATION REGULATION

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.

C. CHEMICAL VAPOR CORROSION

Table 1 – Chemical Contaminants

LP-200 REV. 3.25.14

Households with small children, disabled, or elderly persons may require a 120oF or lower temperature setting to prevent severe personal injury or death due to scalding.

Failure of the solar system due to freeze related damage IS NOT covered by warranty.

APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS

120oF

More than 5 minutes

125oF

1 ½ to 2 minutes

130oF

About 30 seconds

135oF

About 10 seconds

140oF

Less than 5 seconds

145oF

Less than 3 seconds

150oF

About 1 ½ seconds

155oF

About 1 second

Table 2

D. INSULATION BLANKETS

For installation of insulation blankets, refer to Solar Water Heating System Design and Installation Guidelines, SRCC OG-300.

E. DOMESTIC HOT WATER TEMPERATURE ADJUSTMENT

An ASSE 1017 rated mixing valve to avoid severe burns or death from scalding temperature IS REQUIRED PER SRCC OG-300.

F. FREEZE PROTECTION

NOTE: Consider piping and installation when determining heater location. Place heater in location not prone to freezing.

In order to meet health and safety regulations, solar system antifreeze fluid should be food grade polypropylene glycol, FDA rated as “generally recognized as safe” (GRAS). The recommended glycol is DOWFROST or equivalent. Using proper concentrations of glycol, solar systems can be operated at ambient temperatures as low as -60oF. Freeze tolerance limits are based upon an assumed set of environmental conditions. Refer to the specification sheet included with the glycol for recommended concentrations. A glycol/water mix must not exceed 50%, unless the manufacture specifies that a different ratio is recommended for use with solar water heaters. Glycol may need to be changed periodically (every 3-5 years) to prevent it from becoming acidic; please refer to the guidelines provided by the glycol manufacturer regarding replacement.

PART 2 – IMPORTANT INSTALLATION INFORMATION

A. SCOPE OF MANUAL

This manual pertains only to the installation and operation of the HTP SuperStor Ultra solar water heater. Details for the installation, operation, and maintenance of the complete solar water heating system, including, but not limited to: the solar collector(s), boiler, pump, system controller, valves, and other plumbing components, should be provided separately by their respective manufacturers.

NOTE: This manual is primarily a reference document for authorized persons, as the solar water heater is not permitted to be installed by non-authorized persons.

B. LOCAL STANDARDS AND AUTHORIZED PERSONS

Installation must be completed in accordance with local standards and regulations. Installation must also be completed by a qualified tradesperson who holds relevant industry licenses or certificates. The term

“authorized person(s)” refers to a suitably qualified professional. Unless otherwise specified, no part of the HTP solar water heater may be inspected, repaired, or maintained by anybody other than an authorized person.

C. TERMINOLOGY

Solar terminology differs from region to region. To avoid confusion, please note the following: Supply – The plumbing line running from the outlet of the collector to the tank (or heat exchanger).

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Return – The plumbing line running from the tank (or heat exchanger) to the inlet of the collector. This line incorporates the circulation pump.

D. SYSTEM DESIGN

PRESSURIZED CLOSED LOOP SYSTEMS

A closed loop system uses non-potable HTF and must be pressurized to less than 72.5 psi. Closed loop systems require an expansion tank to accommodate HTF expansion. The system should be designed to minimize stagnation after the tank temperature has been met; extensive stagnation may increase pH levels and glycol deterioration.

The expansion tank and plumbing must be properly sized so that the safety pressure relief valve will not activate except in the event of component failure or extreme conditions. The pressure release must be set at no more than 90 psi. (There may be exceptions in engineered designs for tall buildings.)

E. FLUID QUALITY

Water quality is very important. Water in direct flow through the solar collectors must first meet potable water requirements; any fluid circulated through the collectors should be non-corrosive to copper. In addition, water quality must meet the following requirements.

Hardness: Less than 7 grains Chloride levels: Less than 100 ppm pH levels: 6-8 TDS: Less than 2000 ppm Sodium: Less than 20 mGL

In order to meet health and safety regulations, glycol used should be food grade propylene glycol, FDA rated as “generally recognized as safe” (GRAS). If using a glycol/water mix, distilled water is preferred. If distilled water is unavailable, the water must meet the above

requirements. The glycol content of the liquid must not exceed 50%, unless the manufacturer specifies that a different ratio is recommended for use with solar water heaters. Glycol should be checked periodically to prevent it from becoming acidic. Please refer to guidelines provided by the glycol manufacturer regarding glycol maintenance.

F. CORROSION

Both copper and stainless steel are susceptible to corrosion when, amongst other factors, high concentrations of chlorine are present. NOTE: Leakage of the solar water heater due to corrosion caused by improper water quality IS NOT covered by product warranty.

G. FREEZE PROTECTION

Freeze protection must be implemented in any regions that may experience freezing conditions at any time throughout the year.

“Freeze tolerance limits are based upon an assumed set of environmental conditions. Extended periods of cold weather, including ambient air temperatures below the specified limit, may cause freezing in exposed parts of the system. It is the owner’s responsibility to

keep the system’s freeze protection levels maintained in accordance with the supplier’s instructions if the air temperature is expected to

approach the specified freeze tolerance limit.”

Closed loop systems: In areas with temperatures not falling below 23oF, a differential solar controller with freeze protection may be used (e.g. requiring pump to circulate if the manifold temperature approaches freezing). In an open loop system, a freeze valve (which opens to allow water to dribble out) could also be considered.

Closed loop systems: In areas with temperatures falling below 23oF, a propylene glycol/water mix should be used to provide freeze protection. Please refer to glycol manufacturer’s specifications about the temperature ranges the liquid can withstand. Only food grade propylene glycol, FDA rated as GRAS, should be used.

NOTE: HTP DOES NOT WARRANT THE SOLAR WATER HEATER AGAINST FREEZE-RELATED DAMAGE.

PART 3 - GENERAL SOLAR INFORMATION

A. SYSTEM DESCRIPTION

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. Basic components of the solar water heating system include: the solar collector(s), a solar water heater, a circulator pump, a differential

solar control, and an expansion tank. The types of solar systems in which the solar water heater can be installed include:

LP-200 REV. 3.25.14

Do not introduce HTF into any fittings on the heater except those clearly marked for that purpose.

All persons working on roofs should have completed a fall safety course and must be properly outfitted with appropriate safety equipment. Failure to follow this information could result in property damage, severe personal injury, or death.

Solar collectors should be covered at all times until installation is complete. Failure to follow this information could result in severe personal injury or death.

Pressurized Closed Loop Systems – These systems use a glycol/water mix as HTF, which protects the system from freezing. These systems operate at high pressures.

In systems using a glycol/water mix, 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 HTF 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 the 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 40-80oF on the cold supply line to the 175oF 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 250oF. Temperatures vary depending on installation climate.

Using proper concentrations of glycol, solar systems can be operated at ambient temperatures as low as -60oF. Freeze tolerance limits

are based upon an assumed set of environmental conditions. Refer to the manufacturer’s specification sheet for recommended

concentrations. Depending on the controller model, the differential controller uses 10k ohm thermistors or 1k ohm RTDs to monitor the temperature

difference between the collector and the solar water heater. The controller turns on when the collector is 12-20oF above tank temperature and turns off when the differential drops to 4oF.

B. SOLAR SYSTEM DESIGN

System design should be completed prior to installation. Solar collectors need to be installed correctly to ensure high efficiency and, most importantly, safe and reliable operation. Please seek professional advice for the design and installation of your solar heating system.

NOTE: Only authorized licensed contractors are permitted to install the solar collector.

C. SOLAR COLLECTOR INSTALLATION

NOTE: The solar collector instructions are general in nature. Reference the solar collector manufacturer’s instructions for more specific and detailed installation information.

The solar collector installation contractor shall obtain all required permits and approvals when 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 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 solar strut mounting hardware to the structural members of the roof with stainless steel hanger or lag bolts. Consult with the collector 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”.

LP-200 REV. 3.25.14

Never use dielectric unions or galvanized steel fittings in the collector loop. Doing so will lead to corrosion, property damage, and possible early water heater failure. Such damage IS NOT covered by warranty. Use only copper and brass fittings.

Figure 1 - Suggested placement of solar collectors Figure 2 – Sensor Placement

D. COLLECTOR ANGLE, PLANE, AND DIRECTION

1. COLLECTOR DIRECTION

The collector should face the equator. In the northern hemisphere, this is due south, and in the southern hemisphere, due north. Facing the collector in the correct direction and angle is important to ensure optimal heat output. A deviation of up to 15o from due south is acceptable, and will have minimal effect on heat output.

2. COLLECTOR ANGLE (TILT)

It is common for collectors to be installed at an angle that corresponds to the installation latitude. While adhering to this guideline, an angle of latitude +/- 10o is acceptable, and will not greatly reduce solar output. The solar collector should be installed at an angle of between 20 – 80o to ensure optimal operation.

For year-round domestic hot water, the collector should be tilted to an angle of equal to the latitude of the installation site. Add 15o to the latitude to optimize for winter performance (space heating). Subtract 15o from the latitude to optimize for summer performance (pool heating).

Given the formula above, a solar collector installed at 30oN latitude should face due south at an angle of 45o for wintertime advantage, and 15o for summertime heating.

Preventing Overheating To reduce summer heat output, angle the collector for optimal winter absorption. This is achieved by installing the collector at an angle of around 15o above the latitude angle (e.g. 45o at 30oN latitude). This angle corresponds closely to the angle of the sun in the sky during the winter months, thus maximizing winter output. Conversely, during the summer when the sun is high in the sky, the relative collector surface area exposed to sunlight is reduced, cutting overall heat production considerably (by about 15%). This option is ideal for installations where solar thermal is being used for space heating.

3. COLLECTOR PLANE (HORIZONTAL OR VERTICAL)

The collector could be installed vertically, but may be installed at an angle, such as sideways on a pitched roof. In vertical installations, collectors may be installed level, or with ¼” pitch towards the return port. See more detail in Part 2, Section D, Number 3.

E. COLLECTOR PIPING

Collector piping requires the use of copper and brass fittings in the collector loop. To avoid leaks and fluid loss, copper and brass ground joint unions should be used to join the collectors. Use only lead-free solder. Engelhard Silvabrite 100 or equivalent is the required soldering material. Use of 50/50 lead solder is expressly prohibited. Use of galvanized steel, CPVC, PVC or any other non-rated plastic pipe is prohibited.

Penetrations through walls or other surfaces shall not allow intrusion by insects and/or other vermin. Ensure that all structural penetrations are properly sealed with an elastomer, such as Tremco “POLYroof”.

Piping in new solar installations may have dirt, grease, solder flux, or other impurities that will affect the quality of HTF over time. Thorough cleaning is required before charging new solar installations with glycol.

Ensure that there are no dips or low points in solar piping that could trap fluid and possibly rupture in freezing conditions. Copper plumbers tape or tube strap is the required strapping material. The pipe insulation may not be compressed or crimped by the strapping material.

The installation of all piping may not reduce the performance or rating of structural members or fire rated assemblies and must adhere to all applicable local codes and ordinances.

LP-200 REV. 3.25.14

Zinc galvanized components should NOT be installed in direct contact with stainless steel or aluminum, as galvanic reaction between metals can cause premature oxidation of the zinc coating, as well as the steel and aluminum underneath.

F. COLLECTOR LOOP PIPE INSULATION

The collector loop supply and return lines must be well insulated with high quality, flexible, closed cell insulation to minimize heat loss. Wall thickness of pipe insulation should not be less than ¾". 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 HT/Armaflex or equivalent.

Whenever possible, slide the insulation material over the pipe without cutting or taping. All butt joints must be sealed with contact adhesive. HT/Armaflex should be sealed with Armaflex HT 625 adhesive. Use of rigid polyethylene pipe insulation is prohibited. 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 PVC pipe wrap or painted with two coats of high quality water-based acrylic resin coating as supplied by the insulation manufacturer. Foil tape should not be used as it will fail. The required coating material is Armaflex WB Finish or equivalent. Prior to applying finish, wipe insulation clean with denatured alcohol. Paint insulation with two coats of finish. Do not tint the finish.

G. 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 wells to measure temperatures more accurately at the manifold.

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 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 equivalent.

The sensor must be placed on the solar collector return line as close to the collector header as possible. Place the sensor wire over the rubber pipe insulation, under the insulation tape or PVC pipe wrap. Thoroughly wrap and weatherize the insulation with electrician's tape or insulation tape as provided by the manufacturer.

H. AVOID SHADE

Collectors should be located so that shading does not occur between 9 AM and 3 PM local time. Partial shading due to small objects such as antennas and flues is not of great concern.

I. LOCATION

To avoid long pipe runs, the collector should be positioned as close as possible to the storage tank. Storage tank location should therefore be considered part of the location requirements of the solar collector. The storage tank should be located as close as possible to the most frequent draw off points in the building.

J. LIGHTNING PROTECTION

To avoid lightning related damage or electrical safety issues, it is advisable to earth/ground the frame and copper circulation loop of the collector.

K. GALVANIC REACTION

Avoid using galvanized steel bolts. Use stainless steel components instead. If galvanized components ARE used, avoid direct contact between two metals by using rubber/plastic separators.

If roof surface is galvanized steel, refer to manufacturer’s corrugated roof installation guidelines.

L. WIND STRESS

When installing the solar collector(s), please consider the issue of wind resistance and the resultant stress on attachment points. Adhere to relevant building codes/regulations regarding installation of such objects.

It is the responsibility of the installation contractor to ensure that the frame mounting is of suitable strength. Where applicable, inspection by building department officer or equivalent should be completed to ensure the installation is in accordance with relevant regulations.

LP-200 REV. 3.25.14

To dissipate hydrogen safely, it is recommended that a hot water tap be turned on for several minutes at a sink, basin, or bath, but not a dishwasher, clothes washer, or other electrical or heat producing appliance. During this process, there must be no smoking, open flame, or electrical appliance operating nearby. Hydrogen discharged through the tap will sound like air escaping. Failure to dissipate hydrogen properly could result in explosion and fire, serious property damage, severe personal injury, or death.

M. SNOW LOAD

In areas prone to heavy snowfall, the solar collector(s) should ideally be installed at an angle of 50o or greater to help promote snow sliding off the collectors. In addition, it is advisable to raise the lower collector frame off the roof surface 6 – 8 inches or higher. Doing this places the collector above moderate snowfall accumulation and allows drifting snow to more easily slide out from under the collector, which helps ensure that snow does not cover the collector array.

Please refer to local regulations regarding snow loading precautions.

N. HAIL RESISTANCE

Solar collectors are surprisingly strong and able to handle significant impact stresses once installed. Testing and impact stress modeling proves that when installed at an angle of 40o or greater, collectors are able to withstand impact from hail larger than 1” in diameter. The ability of collectors to withstand hail impact is greatly influenced by the angle of impact, so installing the collectors at low angles does reduce their impact resistance.

O. STORAGE TANKS

It is recommended that the lever on the pressure and temperature relief valves (PTRV) on main pressure hot water storage tanks be operated once every 6 months to ensure reliable operation. It is important to raise and lower the lever gently, and be careful as the water released will be HOT. Failure to operate the PTRV on a regular basis could lead to failure of the component and the possibility of the storage tank exploding.

It is recommended, and may also be a local regulation, that, in order to expel water safely, the PTRV have a copper pipe connected and run to an appropriate drainage location. The PTRV and drain outlet pipe must not be sealed or blocked.

NOTE: If the water heater is left in an operating condition and not used for two weeks or more, a quantity of highly flammable hydrogen may accumulate in the top of the water cylinder.

P. THERMAL EXPANSION (CLOSED LOOP SYSTEMS)

As water is heated, it expands. This is known as thermal expansion. Thermal expansion can cause premature component failure. Such failures ARE NOT covered under product warranty.

An expansion tank, properly sized for your solar system, should be installed to control thermal expansion. Refer to expansion tank manufacturer’s specifications for proper sizing guidelines.

LP-200 REV. 3.25.14

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