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INTEGRATED SOLAR
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ASDX-80-48C

INTEGRATED SOLAR ASDX-65-40P, ASDX-80-E-32PX2, ASDX-80-E-40C, ASDX-65-40C, ASDX-65-48C Installation, Operation And Maintenance Manual

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VERSION 2012.3.2
TABLE OF CONTENTS
DRAINBACK HEAT EXCHANGE SOLAR SYSTEM ................................................ 2!
SYSTEM CONCEPT AND OPERATION DESCRIPTION .......................................... 3!
OPERATION OF A DRAINBACK SYSTEM .............................................................. 4!
GENERAL CONSIDERATIONS ................................................................................ 5!
SOLAR COLLECTOR INSTALLATION .................................................................... 6!
SOLAR STORAGE TANK ....................................................................................... 11!
DRAINBACK TANK INSTALLATION ..................................................................... 17!
COMPLETING THE INSTALLATION ...................................................................... 20!
BASICS ABOUT THE DRAINBACK SYSTEM'S OPERATION .............................. 22!
WHEN TO CALL FOR SERVICE ............................................................................ 25!
DRAINBACK/HEAT EXCHANGER SYSTEM WARRANTY ................................... 26!
TROUBLE SHOOTING GUIDE ............................................................................... 28!
2
DRAINBACK HEAT EXCHANGE SOLAR SYSTEM
Introduction
Integrated Solar’s "DBHX" Drainback/Heat Exchange method of freeze protection is the most reliable and safest type of system to use. The drainback system is a positive approach to prevent freezing and scaling of the solar collectors, and to prevent overheating/stagnation of the collector fluid in high temperatures and low usage situations. The drainback tank contains a closed loop of water which circulates through the collector(s) and transfers the energy to the storage tank located in the non-freezing environment of the house. The drainback tank contains all of the water necessary to fill the collector loop while the differential control operates the circulating pump. Gravity drains the water out of the collector(s) and piping when the pump is off. The collector fluid is stored in the insulated and protected drainback tank.
There are numerous advantages of a drainback system:
1. Beneficial in all climates
2. Power is not required for the drainback freeze protection to work.
3. Deep and prolonged freezes can be tolerated repeatedly.
4. The collector fluid will not stagnate in high temperature/low usage situations.
5. The closed loop protects collector fluid passages in hard water areas.
The key to a successful drainback system is proper installation. Proper installation requires the collector supply and return lines be installed with sufficient slope to drain back to the tank. Failure to observe this simple rule will circumvent the freeze protection offered by this system concept. The ideal installation is to mount the collectors in a vertical orientation with the transfer module lower than the collectors.
This manual refers to the following system model numbers:
Single Tank Systems Dual Tank Systems w/Electric Using Solar Tank Water Heater for backup With backup element ASDX-65-E-40P
ASDX-65-40P ASDX-80-E-40C ASDX-65-40C ASDX-80-E-32PX2 ASDX-65-48C ASDX-120-E-40PX2 ASDX-80-40P ASDX-80-40C Dual Tank Systems w/Gas ASDX-80-32PX2 Water Heater for backup ASDX-80-48P ASDX-50-G-24C ASDX-80-48C ASDX-50-G-32P ASDX-120-40PX2 ASDX-65-G-40P ASDX-80-G-40C
Systems w/existing Electric ASDX-80-G-32PX2 Water Heater for storage ASDX-120-G-40PX2 and backup
ASDX-50-24C Systems w/Tankless Gas ASDX-50-32P Water Heater for backup ASDX-80-TLG-40C
3
SYSTEM CONCEPT AND OPERATION DESCRIPTION
A diagram of a typical Drainback system is shown in Figure 1.1. A detailed list of Integrated Solar’s supplied components and typical installer supplied components is provided in the related sections of this document.
Collector circuit can be all ¾” copper tubing; if using PEX use only where shown in diagram.
Drainback System Conceptual Drawing Only
Figure 1.1
SRCC Disclaimer Statement
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 SRCC.
4
OPERATION OF A DRAINBACK SYSTEM
The operation of a Drainback System is simple. Whenever the collector sensor reaches a temperature 16"! to 24º F higher than the water at the bottom of the storage tank, the control turns on the pumps. The first pump circulates the water stored in the drainback (DBHX) storage tank through the solar collector. The water increases in temperature and is returned to the drainback storage tank, bathing the copper coil heat exchanger in solar heated water. The second pump circulates water from the storage tank through the copper coil heat exchanger which transfers the heat from the collector to the storage tank. This process continues until the collector temperature sensor is within 4º F of the storage tank temperature sensor, or the storage tank reaches the pre-set high temperature limit, at which time, the control unit turns the pumps off. The water in the collector loop then drains back into the insulated DBHX tank where it remains until the collector temperature again reaches 16" to 24º F higher than the storage tank.
Freeze protection is automatic. When the control has turned the pumps off, the water in the collector loop drains back into the DBHX storage tank. If freezing conditions occur, there is no water in the collectors or piping to freeze and, therefore, no damage occurs.
Overheating and stagnation of the collector fluid is also automatically avoided, because the water in the collector loop also drains back into the DBHX storage tank when the hot water storage tank is fully heated
The primary advantage of the drainback system is that it is fail safe and can be used anywhere. Loss of power does not disable the freeze protection, nor does any other probable malfunction.
The key to the installation of a drainback system is to provide the proper pitch in both the supply and return lines that connect the collector array and the DBHX reservoir tank. The water will drain back through the pump, but to do so, air must go up the return line. Proper sloping in all lines and the collector array, with the avoidance of water traps in the supply line, are required to provide the drainback feature.
5
GENERAL CONSIDERATIONS
All installations must conform to local building code requirements especially for penetrating structural members and fire-rated assemblies.
The design and installation of the system must not impair emergency movement of the building occupants.
Do not install the collectors on a roof which already needs repairs. Keep a safe distance from roof vents, chimneys, skylights, etc.. Take special precautions to prevent damage to tile, shake and slate roofs.
Be sure the collector(s) are not shaded by external obstructions more than the specified period allowed in the site design
The location, orientation, and position of the collector(s) relative to nearby objects and surfaces shall be such that water run-off from the collector surface is not impeded. In climates where snow may collect on the roof, excessive build-up of snow on lower portions of the collector glazing shall not be permitted to occur. Collectors should be mounted as close to the peak as practical on smooth roof surfaces like metal roofs and as close to the lower edge as practical on rougher roof surfaces like asphalt shingles.
Penetrations of the building through which piping or wiring is passed shall not reduce or impair the function of the enclosure. Structural components penetrated by solar system components must meet applicable codes. Penetrations through fire-rated assemblies shall not reduce the building’s fire resistance required by local codes, ordinances, and applicable standards. Penetrations through wall or other surfaces shall not allow intrusion by insects and/or vermin. Required roof penetrations shall be made in accordance with applicable codes and also by practices recommended by the National Roofing Contractors Association. Be sure any caulking and/or sealant is recommended for use on the surface(s) to which it is applied.
Building materials adjacent to solar components should not be exposed to elevated temperatures. Insulation in the sides and back of the collectors protect adjacent materials from heat produced by the collector, pipe insulation must be installed to protect materials from the heat of the collector loop piping. Insulation around the drainback tank and pipe insulation serve to protect adjacent materials from the heat of the solar heated water. Be sure to position the drainback module so that the pumps are not too close to walls or other building materials, and so that the pumps are isolated from public traffic areas.
Filled Weights of Integrated Solar components
AS406C Collector 89 lbs AS406C Collector 92 lbs AS408P Collector 120 lbs. AS408C Collector 121 lbs. AS410P Collector 146 lbs. AS410C Collector 151 lbs. AS412P Collector 174 lbs. AS412C Collector 179 lbs. DBHX08 Drainback Module 117 lbs. DBHX12 Drainback Module 164 lbs.
Temperature and Pressure Ratings of Integrated Solar components
All Collectors Maximum Operating Temperature 230" F. Maximum Operating Pressure 30 PSI (in drainback loop) Test Pressure 150 PSI Drainback Modules Maximum Operating Temperature 230" F. Maximum Operating Pressure 30 PSI (in drainback loop) Maximum Operating Pressure 125 PSI (in Heat Exchanger loop)
6
SOLAR COLLECTOR INSTALLATION
Locate all collectors for accessibility and check the proposed roof area for compatibility. Collectors must be located for a southerly orientation. The best location for the solar collectors is one that provides a day-long shadow-free view of the southern sky.
Determine which manifold ends of the collector or array are to be used for the inlet and outlet connections; the inlet at the bottom and the outlet at the top. The inlet and outlet must be at diagonally opposite corners of the collector or array, to insure balanced flow. The collector outlet side should be the side closest to the tank to minimize the return pipe length. Consider the best access to the roof and internal access for attic work. Plan routes to be used and prepare the clearances. Plan the piping runs for the least number of bends and fittings while maintaining a minimum 1/4" per foot slope in horizontal runs.
Collector Sizing and Location
The Architectural Series collector array is typically made up of one or two collector panels plumbed together. It is possible to plumb up to a maximum of five collectors together for a residential Domestic Hot Water (DHW) application. It is recommended that the array be mounted with the waterways in the vertical position (up the slope of the roof) in all cases. Collectors mounted horizontally may not drain properly.
Select the collector array location and determine the inlet roof penetration. Locate the rafters to which the array will be mounted and mark with a chalk line.
From the inlet pipe location, strike a horizontal line a minimum of 10 feet. Make certain there are no dips or sags in the roof which may prevent the collector from draining. To insure complete drainage for the solar energy system, the vertical collector array must be installed with a minimum vertical drop towards the inlet of 1/4" per foot of collector header. Lay out the collectors at the proposed location and place a 2 foot (min.) level on the collector near one edge of the glazing and parallel with the ends. Orient the collector array so that the bubble indicates the proper slope. Make certain there is no trap in the collector supply pipe from the roof jack to the collector.
7
Mounting the collectors
Collectors can be mounted either parallel to a pitched roof surface, or, using a Panel Tilt Kit, on a flat roof or on a pitched roof at a steeper angle than the roof slope. Any alternate mounting method must be capable of maintaining tilt and azimuth to design conditions.
To mount collectors parallel to a pitched roof, use kit #ASZ1 or #AS1 for a single collector, Kit #ASZ2 or #AS2 for 2 collectors side by side, or Kit #ASZ3 or #AS3 for 3 collectors side by side. Figure 2.1 shows several acceptable methods for attaching the Solar Strut to the roof structure; local codes may dictate which method to use. CAUTION: NEVER LAG INTO THE ROOF SHEATHING ONLY.
For barrel or “S” shaped concrete tiles, remove one tile at each penetration point and attach a hanger bolt, threaded rod or “J” hook as shown in Figure 2.1. Use a long enough fastener so that it extends above the top (“peak”) of the tile. Drill a hole in the tile so the fastener can extend up through the tile when it is replaced. The strut should be above, not touching, the top of the tile. See Figure 2.2. Although the tile is not the waterproof portion of the roof, it’s still a good idea to seal where the fastener extends through the tile with an appropriate sealer.
For metal roofs, use fasteners recommended by the roof manufacturer to attach the Solar Strut.
To mount collectors using the Architectural Series Tilt Kit, first determine the length of the riser needed to achieve the desired angle for the installation. Use one Panel Tilt Kit per collector. Use Kit #ASTKXX5 (where “XX” is the riser length) if you wish to attach the 5” base shoes directly to the roof as shown on the left hand side of Figure 2.3. Use Kit #ASTKXX3 if you wish to attach the 3” shoes to Solar Strut as shown on the right side of Figure 2.2 (for multiple collectors, the Solar Strut method is usually easier). Attach the 5” shoes or the Solar Strut to the roof in one of the ways shown in Figure 2.1. CAUTION: NEVER LAG INTO THE ROOF SHEATHING ONLY.
All collector installations must allow for a 2" minimum clearance between the back of the collector and the roofing material.
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Figure 2.1
Methods of attaching to the roof structure
Figure 2.2
Mounting above concrete tile
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