Rheem RESG75-40BP, RUSG75-40BP, RMSG75-40BP, RESG75-48BP, SUSG75-40BP Use & Care Manual

http://waterheatertimer.org/Should-you-buy-solar-water-heater.html

Use & Care Manual

With Installation Instructions for the Installer

Pumped Solar Water
Heating Systems

The purpose of this manual is twofold: one, to
provide the installer with the basic directions and
recommendations for the proper installation and
adjustment of the water heater; and two, for the owner–
operator, to explain the features, operation, safety
precautions, maintenance and troubleshooting of the
water heater. This manual also includes a parts list.

It is very important that all persons who are expected
to install, operate or adjust this water heater read the
instructions carefully so they may understand how to
perform these operations. If you do not understand these
instructions or any terms within it, seek professional
advice.

Any questions regarding the operation, maintenance,
service or warranty of this water heater should be
directed to the seller from whom it was purchased. If
additional information is required, refer to the section on
“If you need service.”

Do not destroy this manual. Please read carefully and
keep in a safe place for future reference.

Recognize this symbol as an indication of

!

Important Safety Information!

California Proposition 65 Warning: This

!

product contains chemicals known to the State of
California to cause cancer, birth defects or other
reproductive harm.

I

S

G

E

N

D

®

AP15326-1 (04/11)

System Model Numbers

PLEASE VISIT OUR WEB SITE FOR NEW PRODUCT UPDATES, ANSWERS TO FREQUENTLY
ASKED QUESTIONS (FAQ) AND USEFUL INFORMATION ABOUT SOLAR WATER HEATING
SYSTEMS.

www.rheem.com

This Solar Water Heating system is for the models listed below:

RSG75-48BP

RUSG75-40BP

RUSG75-48BP

RSG75-40BP

RMSG75-40BP

RMSG75-48BP

RESG75-40BP

RESG75-48BP

SUSG75-40BP

SUSG75-48BP

SUSG75-48BC

SUSG100-64BP

2

Safety Information

!

System Model Numbers . . . . .2

For Your Records . . . . . . . . . .3

Introduction . . . . . . . . . . . . . . . . . 4

Safety Precautions . . . . . . . . . . .5-7

Installing the System

Introduction to Solar . . . . . . . 8

System Description and

Operational Principle . . . . . . . 9

Installation Requirements -

General . . . . . . . . . . . . . . . . . . 9

Installation Requirements -

Specic . . . . . . . . . . . . . . 10-20

Operating the System

Start Up Procedures . . . . . . .21

Three Modes of System

Operation . . . . . . . . . . . . 22-23

Use and Care of the
System

Isolating the Major Components
and Shut Down Procedures . 24

Summer Vacation

Recommendations . . . . . . . . 24

Maintenance and

Troubleshooting . . . . . . . 25-26

System Component Parts 26-27

System Schematics . . . . . 28-31

FOR YOUR RECORDS

Write the model and serial numbers here:

Model Number of Solar System Tank: ____________________________________

Serial Number of Solar System Tank: _____________________________________

Model Number of Collector Panel #1: ____________________________________

Serial Number of Collector Panel #1: _____________________________________

Model Number of Collector Panel #2: ____________________________________

Serial Number of Collector Panel #2: _____________________________________

Model Number of Solar System Pump: ___________________________________

Serial Number of Solar System Pump: ____________________________________

Model Number of Solar System Control: _________________________________

Serial Number of Solar System Control: _________________________________

You can find them on a label on the appliance.
Staple sales slip or cancelled check here.
Proof of the original purchase date is needed to obtain service
under the warranty.

READ THIS MANUAL

Inside you will find many helpful hints on how to use and
maintain your water heater properly. Just a little preventive care
on your part can save you a great deal of time and money over
the life of your water heater.

You’ll find many answers to common problems in the Before
You Call For Service section. If you review our chart of
Troubleshooting Tips first, you may not need to call for service
at all.

READ THE SAFETY INFORMATION

Your safety and the safety of others are very important. There
are many important safety messages in this manual and on your
appliance. Always read and obey all safety messages.

Customer Service

If You Need Service . . . . . . . 32

This is the safety alert symbol. Recognize this symbol as
an indication of Important Safety Information!

!

This symbol alerts you to potential hazards that can kill

or hurt you and others.
All safety messages will follow the safety alert symbol and
either the word “DANGER”, “WARNING”, “CAUTION” or
“NOTICE”.

These words mean:

!

DANGER

that will result in death or serious
injury.

WARNING

could result in death or serious injury

and/or damage to property.

!

CAUTION

may result in minor or moderate
injury.

NOTICE:

specified procedure or maintain
a specific condition.

An imminently hazardous situation

A potentially hazardous situation that

A potentially hazardous situation that

Attention is called to observe a

3

Introduction

!

Thank you for purchasing a solar water heating system. It is
one of the most effective and trouble-free systems available
today. In addition to reducing your water-heating bills, it
will help preserve precious natural resources by using free
energy from the sun.

As with an electric or gas water heater, your new solar water
heating system operates automatically to ensure you will
always have an ample supply of hot water. However, there
are simple steps you can take to increase both its efficiency
and service life.

This manual provides the manufacturers recommended
procedures for solar water-heating systems. The procedures
are essential for correct installation, troubleshooting and
maintenance.

Read each section of this manual thoroughly before
beginning work on the system.

CAUTION: Changes to the design or intended
use of the Solar Water Heating System will void the
manufacturers warranty. Installation,
troubleshooting, and maintenance must be
performed by a qualified technician.

This manual will help you get the most out of your solar

water heating system. Please read it carefully when the
installation is complete, and review it from time to time to
refresh your memory about the service requirements and
safety measures.

The Operation section of the manual contains important
information regarding the system procedures as well as
safety measures pertaining to the system. It is important
that you follow these guidelines to ensure safe, efficient and
trouble-free operation.

While the system requires very little maintenance, there
will be a periodic need for some upkeep. The Maintenance
section outlines those requirements for service, which you
may do yourself, as well as those procedures best performed
by a qualified service technician.

The Troubleshooting section contains steps you can take if
the system is not performing, as it should.

The solar energy system described by this manual, when
properly installed and maintained, meets the minimum
standards established by the Solar Rating and Certification
Corporation (SRCC). This certification does not imply
endorsement or warranty of this product by the SRCC.

The solar energy system described by this manual, when
properly installed and maintained, meets the minimum
standards established by the Florida Solar Energy Center,
in accordance with Section 377.705, Florida Statutes. This

certification does not imply endorsement or warranty of this
product by the Florida Solar Energy Center or the state of
Florida.

The components of the system include a water storage tank,
solar collector panels, expansion tank, pump valves and
fittings.

In locations which are subject to temperatures below 41°F,
a mixture of heat transfer fluid and water circulates through
the solar collector panels. This fluid is heated by the sun,
then circulated through a heat exchange, heating the potable
(drinking) water inside the storage tank. The heat transfer
fluid is a non-toxic, food-grade liquid, which provides freeze
protection for the closed loop heat transfer loop. It is colored
to differentiate the closed system fluid from the potable
water supply.

This circulation of the heat transfer fluid is accomplished by
a pump and sensors. These solar water heaters are referred
to as closed loop systems.

Your hot water is stored in a steel tank lined with porcelain
enamel and thickly insulated to help maintain the water
temperature throughout the day and night.

To ensure your hot water supply is never depleted, the
system is equipped with a backup thermostactic gas valve.
When there may be insufficient solar energy, you are still
assured of all the hot water you will need.

While your system is one of the most efficient available,
there are two simple steps you can take to increase your
water-heating cost savings.

Keep the use of the Backup Heater to a Minimum

You can save the most money on your water-heating bills by
using the backup thermostactic gas valve on your system as
little as possible. If the sun shines brightly between 10 am
and 3 pm, enough heat will normally be generated to keep
the water hot throughout the rest of the day and night.

However, on days when the sky is cloudy or when large
quantities of hot water are being used, we suggest that the
backup thermostactic gas valve be left “ON” overnight to
ensure adequate hot water the next morning.

Try to use Hot Water during Daylight Hours

When possible, schedule heavy hot water use, such as dish
washing, laundry and showers, in the middle of the day. If
hot water usage occurs while the sun is up, the fresh (cold)

water added to the storage tank is heated more quickly.

When water is used late in the day or at night, the fresh
water entering the tank will be heated by the thermostactic
gas valve so hot water is available in the morning.

4

IMPORTANT SAFETY INFORMATION.

!

!

!

READ ALL INSTRUCTIONS BEFORE USING.

DANGER!

WATER TEMPERATURE SETTING

Safety and energy conservation are factors to be considered when selecting the water
temperature setting of a water heater’s gas control. Water temperatures above 125°F can cause
severe burns or death from scalding. Be sure to read and follow the warnings outlined on the
label pictured below. This label is also located on the water heater.

Time/Temperature Relationship in Scalds

!

D A N G E R

HOT

BURN

Water temperature over 125°

can

cause severe burns

instantly or

death from scalds.

Children, disabled and elderly are
at highest risk of being scalded.

See instruction manual before
setting temperature at water
heater.

Feel water before bathing or
showering.

Temperature limiting valves are
available, see manual.

Notice: Mixing valves are available for reducing point
of use water temperature by mixing hot and cold water
in branch water lines. Contact a licensed plumber or the
local plumbing authority for further information.

F (52°C)

Water Temperature Time To Produce a Serious Burn

120°F (49°C) More than 5 minutes

125°F (51°C) 11/2 to 2 minutes
130°F (54°C) About 30 seconds
135°F (57°C) About 10 seconds
140°F (60°C) Less than 5 seconds
145°F (63°C) Less than 3 seconds
150°F (66°C) About 11/2 seconds
155°F (68°C) About 1 second

Table courtesy of Shriners Burn Institute

The chart shown above may be used as a guide
in determining the proper water temperature for your
home.

DANGER: Households with small children,
disabled, or elderly persons may require a 120°F
or lower gas control (thermostat) setting to prevent
contact with “HOT” water.

Maximum water temperatures occur just after the
burner has shut off. To find water temperature being
delivered, turn on a hot water faucet and place
a thermometer in the water stream and read the
thermometer.

The temperature of the water in the heater can be
regulated by setting the temperature dial on the
front of the gas control (thermostat). To comply
with safety regulations the gas control(thermostat)
was set at its lowest setting before the water heater

was shipped from the

110°F

100°F

90°F

80°F

45°F

Temperatures are approximate

120°F

130°F

140°F

150°F

160°F

factory.

The illustration at
the left details the
approximate water
temperature
for each mark on
the Gas Control
(Thermostat)
Temperature Dial.

DANGER: Hotter water increases the potential for
Hot Water SCALDS.

5

IMPORTANT SAFETY INFORMATION.

!

!

READ ALL INSTRUCTIONS BEFORE USING.

DANGER!

LIQUEFIED PETROLEUM (LP PROPANE OR BUTANE)
AND NATURAL GAS MODELS

LP and Natural gas have an odorant added to aid in detecting a gas leak. Some people
may not physically be able to smell or recognize this odorant. If you are unsure or
unfamiliar with the smell of LP or natural gas, ask the gas supplier. Other conditions,
such as “odorant fade”, which causes the odorant to diminish in intensity, can also hide or
camouflage a gas leak.

● Water heaters utilizing LP gas are

different from natural gas models. A
natural gas water heater will not function
safely on LP gas and vice versa.

● No attempt should ever be made to

convert the water heater from natural
gas to LP gas. To avoid possible
equipment damage, personal injury or
fire, do not connect the water heater to a
fuel type not in accordance with the unit
data plate. LP for LP units. Natural gas
for natural gas units. These units are not
certified for any other fuel type.

● LP appliances should not be installed

below grade (for example, in a basement)
if such installation is prohibited by
federal, state and/or local laws, rules,
regulations or customs.

● LP gas must be used with great caution.

It is heavier than air and will collect first
in lower areas making it hard to detect at
nose level.

● It is recommended that more than one

method, such as soapy solution, gas
detectors, etc., be used to detect leaks in
gas applications.

DANGER: If a gas leak is present or
suspected:

● Donotattempt to find the cause yourself.

● Donot try to light any appliance.

● Donot touch any electrical switch.

● Donot use any phone in your building.

● Leave the house immediately and make

sure your family and pets leave also.

● Leave the doors open for ventilation

and contact the gas supplier, a qualified
service agency or the fire department.

● Stay away from the house (or building)

until the service call has been made, the
leak is corrected and a qualified agency
has determined the area to be safe.

● Before attempting to light the water

heater, make sure to look and smell for
gas leaks. Use a soapy solution to check
all gas fittings and connections. Bubbling
at a connection indicates a leak that must
be corrected. When smelling to detect a
gas leak, be sure to sniff near the floor
also.

● Gas detectors are recommended in LP

& natural gas applications and their
installation should be in accordance
with the detector manufacturer’s
recommendations and/or local laws,
rules, regulations or customs.

6

!

WARNING!

For your safety, the information in this manual must be followed to minimize the risk of fire or
explosion, electric shock, or to prevent property damage, personal injury, or loss of life.

FOR INSTALLATIONS IN THE STATE OF CALIFORNIA

California Law requires that residential water heaters must be braced, anchored or strapped
to resist falling or horizontal displacement due to earthquake motions. For residential water
heaters up to 52 gallon capacity, a brochure with generic earthquake bracing instructions can be
obtained from: Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95814
or you may call 916-445-8100 or ask a water heater dealer.

However, applicable local codes shall govern installation. For residential water heaters
of a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable
bracing procedures.

SAFETY PRECAUTIONS

Have the installer show you the location of the circuit breaker and how to shut it off if
necessary. Turn off the circuit breaker if the water heater has been subjected to overheating,
fire, flood, physical damage or if the ECO fails to shut off.

● Read this manual entirely before installing

or operating the water heater.

● Use this appliance only for its intended

purpose as described in this Use and Care
Manual.

● Be sure your appliance is properly installed

in accordance with local codes and the
provided installation instructions.

● Do not attempt to repair or replace any part

of your water heater unless it is specifically
recommended in this manual. All other
servicing should be referred to a qualified
technician.

READ AND FOLLOW THIS SAFETY INFORMATION
CAREFULLY.

SAVE THESE INSTRUCTIONS

7

Installing the System

Preface

Let us rst offer two words of grateful
appreciation.Thank You! We sincerely
appreciate your business. We also wish 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.

Your solar water heating system has been
designed to meet exacting SRCC OG-300
certication requirements. The components
found in your system have been selected
for their proven reliability, longevity and
performance in your specic region of the
country.

Introduction to Solar Water Heating Systems

Solar water heating systems are climate
and site specic 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 system will
save on an annual basis.

Your solar system is known as a "forced
circulation" system because it utilizes a
mechanical pump to efciently circulate
the Dow Chemical Dowfrost HD propylene
glycol heat transfer uid (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
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 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
specic component parts.

This manual covers installations utilizing
two 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 specic component parts.
The placement of each component can be
seen in system schematic gures 16, 17,
18 & 19. A description of each component
and its function is found in the System
Component Parts section

8

System Decription and Operational Principle

The key components in the solar water heating
system include the 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 uid (HTF).

The solar collector is the heart of the system.
Simply stated, when the sun is shinning, heat
energy is absorbed by the solar collector’s all
copper absorber plate and tranferred to the
HTF circulating through the solar collector.
The system pump efciently circulates this
heated uid through the collector piping and
integral tank heat exchanger. As the HTF
passes through the heat exchanger the heat in
the uid 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.

When the solar collector absorber plate is
approximately sixteen 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 eight degrees, the controller
automatically turns the pump off.

Both single and double tank 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 instructions for setting
the system for automatic operation in each of
these three modes.

The Dowfrost HD HTF protects your 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 uids 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. Manufacturer’s collector
warranty specically excludes freeze damage
for any reason and absorber plate damage
resulting from the oxidation of the propylene
glycol HTF.

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 Summer Vacation Recommendations and
Procedures Section).

Installation Requirements - General

The contractor shall obtain all required permits
and approvals.

The installation shall conform to all federal,
state and local regulations, codes, ordinances
and standards governing solar water heating
system installations, and the contractor shall
adhere to sound building safety and trade
practices. Special consideration must be
given to building code requirements for the
penetration of structural members and re
rated assemblies.

The solar collector must be located in a
structurally sound area of the roof that will be
unshaded for the majority of the day all year
round. Adjacent buildings and trees should
be checked for possible winter shading. An
instrument such as the Pathnder can be used
for solar site analysis.

Before the installation the contractor shall
inspect the condition of the roof and notify the
homeowner of any existing roof damage or
necessary repairs.

9

Installing the System

Installation Requirements - Specific

The homeowner and contractor shall conrm the
location of all roof and ground mounted components
in advance of the installation.

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.

Figure 2 - Side Pitch Mounting

The solar collectors in a two collector staggered
mount installation must be spaced far enough apart
to prevent winter shading. Table 1 shows the correct
spacing between collectors to prevent shading on
December 21, when the sun is at its lowest angle.

Figure 1 - Reverse Pitch Mounting

Collector Tilt

Optimal annual efciency 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.

Figure 3 - Staggered Mount Collector Spacing

TABLE 1

LATITUDE 25°N 30°N 35°N 40°N 45°N 50°N

COLL. TILT 35° 40° 45° 50° 55° 60°

A B A B A B A B A B A B

FLAT 29 96 33 113 37 145 41 145 44 145 48 145
5° 1/12 25 83 29 93 33 113 37 132 41 133 44 141
9° 2/12 22 74 26 82 30 77 34 110 38 115 41 118

14° 3/12 17 66 22 72 26 82 30 92 34 95 38 98

18° 4/12 14 61 18 66 22 74 26 82 30 85 34 87
ROOF 23° 5/12 10 58 14 60 18 66 22 72 26 74 30 77
PITCH 27° 6/12 7 58 11 58 15 61 19 66 23 68 27 70

30° 7/12 4 58 8 58 13 58 17 62 21 65 25 66

34° 8/12 0 58 5 58 9 58 13 58 17 60 22 62

37° 9/12 0 58 3 58 7 58 11 58 15 58 19 58

40° 10/12 0 58 0 58 4 58 8 58 13 58 17 58

43° 11/12 0 58 0 58 2 58 6 58 10 58 14 58

45° 12/12 0 58 0 58 0 58 4 58 8 58 13 58

DIMENSIONS A AND B ARE DESIGNATED IN INCHES

10

Basic Mounting Procedures

The solar collector in your solar system can
be mounted in either a vertical or horizontal
orientation on the roof (See Figure 4). 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.
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 at roof surface.
Use "Solar Strut" tilt mount kits to rack the
collectors to the proper angle.

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 roong material. There
should be at least 3" of clearance between
the roof surface and the bottom of the
solar collectors.

In selecting mounting hardware and

fasteners it is extremely important to
avoid galvanic corrosion resulting from
the direct contact of incompatible metals.
Use of anodized aluminum 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.

Preserving the integrity of the roof

membrane is the most important roong
consideration. Ensure that all roof
penetrations required to plumb and
mount the solar collector are properly
ashed and sealed in accordance with
standard roong practices.

Figure 4 - Collector Orientation

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 roof
in accordance with these general principles:

The most important structural

consideration is to securely anchor the
solar collector and the 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
5–10. (Note: The drawings in this manual
detail mounting hardware for the series
collector.)

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
specic mounting procedures. Consult
your local building department.

11

Installing the System

Figures 5-10

Figure 5- Composition Shingle Mounting

ST STL SLIDING

NUT
ANODIZED ALUM
SOLAR STRUT

ST STL NUTS &
WASHERS

ST STL HANGER BOLT SET
IN SEALANT
* LE NGTH & DIA. VARY

WITH INSTALLATION

* DR ILL PILOT HOLE 3/4

OF BOLT DIA.

SOLAR COLLECTOR

MOUNTING

CLIP

SOLAR COLLECTOR

MOUNTING GROOVE

3/8" ST STL BOLT
W/ LOCKWASHER &
FLATWASHER

3" MIN.

CEDAR SHAKE OR SHINGLES ON
ROOF FELT OVER ROOF DECK
SHEATHING ON ROOF FRAMING
SYSTEM - BEAM OR RAFTER

SIDE VIEW

MOUNTING
CLIP

ROOFING SEALANT

12" X 12" LEAD
FLASHING

Figure 6- Shingle Roof Mounting

12

MOUNTING

GROOVE

SIDE VIEW

3/8" ST STL
BOLT W/ LOCK

-

WASHER &
FLATWASHER

ROOFING
SEALANT

12" X 12" LEAD FLASHING

HOLE 2X BOLT DIA. MIN.

CLAY OR CONCRETE TILE
ON BATTEN OVER ROOF-
ING FELT ON ROOF DECK
SHEATHING ON ROOF
FRAMING SYSTEM BEAM
OR RAFTER

MOUNTING

CLIP

Figure 7 - Tile Roof Mounting

SOLAR COLLEC

TOR

MOUNTING CLIP

ST STL HANGER BOLT
SET IN SEALANT
* LE NGTH & DIA. VARY

WITH INSTALLA-
TION

* DR ILL PILOT HOLE

3/4 OF BOLT DIA.

ST STL NUTS & WASH

-

ERS

ANODIZED ALUM

SOLAR STRUT

ST STL SLIDING

NUT

BLOCK BETWEEN RAFTERS FOR
HANGAR BOLT ATTACHEMENT
IF RAFTER SPACING DOES NOT
MATCH BOTH SPACING.

SOLAR COLLECTOR

MOUNTING CLIP

MOUNTING

GROOVE

SIDE VIEW

ST STL SLIDING NUT

ANODIZED ALUM

SOLAR STRUT

ST STL NUTS & WASHERS

ST STL HANGER BOLT SET
IN SEALANT
* LE NGTH & DIA. VARY

WITH INSTALLATION

* DR ILL PILOT HOLE 3/4

OF BOLT DIA.

MOUNTING

CLIP

3/8" ST STL BOLT

ROOFING
SEALANT

W/ LOCKWASHER
& FLATWASHER

12" X 12" LEAD FLASHING

CLAY OR CONCRETE TILE ON
BATTEN OVER ROOFING FELT
ON ROOF DECK SHEATHING
ON ROOF FRAMING SYSTEM
BEAM OR RAFTER

HOLE 2X BOLT DIA. MIN.

BLOCK BETWEEN RAFTERS FOR
HANGAR BOLT ATTACHEMENT
IF RAFTER SPACING DOES NOT
MATCH BOTH SPACING.

Figure 8 - Tile Roof Mounting

13

Installing the System

Figures 5-10

Figure 9 - Flush Mounting

14

Detail "D"

Figure 10 - Universal Tilt Mount

15

Installing the System

collector in the summer months or under stagna-
tion conditions can melt this type of material.

g.14

COLLECTOR PLUMBING - VERTICAL MOUNT

Installation Requirements - Specific - continued

Collector Loop Pipe Insulation

The collector loop cold supply and hot return
lines must be well insulated with a high quality
exible 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. Use 3/4" Armaex (or similar) exible
elastomeric closed cell thermal insulation.

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. Use
3/4" Armaex (or similar) exible elastomeric
closed cell thermal insulation.

Collector Plumbing

This solar heating system requires the use of all
copper and brass ttings in the collector loop
plumbing. Couplings rather than unions should
be used to join the collectors to avoid leaks and
uid loss. Use only lead-free solder.

Notice: Use of 50/50 lead solder is expressly
prohibited.

Notice: Use of galvanized steel, CPVC,
PVC, or any other type of plastic pipe is
prohibited.

Piping in new solar installations can be covered
with dirt, grease, solder ux 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 on page 19.

All vertical piping between the storage tank and
the collector shall be supported at each story
or at maximum intervals of ten feet (10'). (See
Figure 13, Collector Plumbing-Vertical Mount)
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 any structural member or re rated
assembly. (See Figure 14, Collector Plumbing­horizontal Mount) Adhere to all applicable
local codes and ordinances.

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 anged

Figure 13 - Collector Plumbing - Vertical Mount Figure 14 - Collector Plumbing - Horizontal Mount

16

portion of the sensor to the collector header pipe

Figure 15

COLLECTOR

SENSOR

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 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 15 for collector sensor installation
detail.

Low Voltage Wiring

The low voltage wiring used to connect the sensors
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.

Installing the Solar Storage Tank
and Expansion Tank

Refertotheinstallationmanualsforthestorage

tankandexpansiontank.

RefertoFigure16,SingleTankSystem

SchematicandFigures17,18,&19Double
TankSystemSchematiconpages28-31,forall
itemslistedas(No.##)throughoutthismanual.

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, 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 ttings
in plumbing the solar storage tank and expansion
tank. The use of galvanized ttings or nipples, di­electric 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 ex hose connectors can become brittle and
compressed over time and begin leaking on the
water heater. If not detected in a timely 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.

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. 19).

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. 22).

In a single tank system install a third thermometer
(No. 22) 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.

In plumbing the solar storage tank and expansion

17

Installing the System

Figure 18 TANK SENSOR

The circulation pump shall be the Grundfos
model UPS15-58FC/LC, 115 volt or equivalent.
The pump shall be pre-wired with a 6’ line
cord so that it can be plugged directly into
the 115 volt receptacle on the side of the
differential control. Isolation/Drain valves
(No. 6 & 7) must be installed on either side
of the circulating pump 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.

The expansion tank shall have a minimum 60
PSIG working pressure and have a total volume
of not less than 2.1 gallons. The expansion tank
shall be Watts Model ET-15 or equal (No. 11).

A high quality thermostatic mixing valve (No.

12) is a required component in all OG-300
certied systems and should be plumbed in line
with brass union connections for ease of future
repair or replacement. The specied 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.

The temperatures generated by your 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 xtures at a safe,
controlled temperature.

!

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.

he 3/4" cold water supply line to the solar

T

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'.

Tank Sensor Placement

Figure 20 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.

Figure 20

Thoroughly weatherize the wire connections in
accordance with the roof sensor detail above.
Replace the berglass insulation batting and
close the access cover.

A properly licensed contractor must make the
gas supply connection to the water heater or
solar storage tank.

The tank must be full of water before heater
is turned on. The water heater warranty does
not cover damage or failure resulting from
operation with an empty or partially empty tank.

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.

Tank Sensor

18

Charging the System

!

Proceed as follows:

WARNING: Under no circumstances can
any fluid other than Dowfrost HD be used,
alternate fluids could be hazardous to your
health.

Once the components are plumbed you are ready to
ll the solar storage tank with water and to charge
the collector loop with a mixture of heat transfer
uid (HTF) and distilled or deionized water. The

use of regular tap water as a mixing agent is
prohibited.

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

Table 5

Total Collector Loop Fluid Capacity In Gallons*

1 Collector System 4 Gallons

2 Collector System 5 Gallons

• Begin by lling the solar tank with water. Do
this by opening the cold water isolation ball
valve to the solar tank (No. 19). When the tank
is lled, inspect all threaded ttings and solder
joints for leaks.

• Fill and pressurize the solar collector loop with
water. Begin by connecting a washing machine
hose to the upper isolation/drain valve (No.

7) and ll the collector loop with water. The
isolation ball valve (No. 7) remains closed at
this point. While the hose is still connected to
the upper isolation/drain valve and the water is
running, open the lower isolation/drain valve
(No. 6) 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 isolation/drain valve. The
collector loop now has been subjected to city
pressure and the pressure gauge (No. 10) should
read somewhere in the range of 50 - 75 PSI
in most cases. Make a nal inspection of the
collector plumbing connections to ensure that
there are no leaks anywhere in the collector loop
piping.

• 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 ve minutes and carefully
check to ensure there is proper uid ow and
that all the air has been purged from the solar
collector glycol loop. An inexpensive ow
meter is recommended as an optional system
component. A ow meter allows you to monitor
and adjust the ow rate through the piping and
also to visually inspect the HTF uid quality.

Set the controller to the "off" position and
proceed to the next step.

• 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

19

Installing the System

charging process also will require a low ow
diaphragm pump (Flojet or equal) to ll and
pressurize the collector loop.

Connect the discharge side of the pressure
pump to the upper isolation/drain valve
(No. 7) Place the pump suction side hose in
the glycol solution. Close the isolation ball
valve (No. 7) and connect a second hose
to the lower isolation/drain valve (No. 6).
Place the other end of the hose in the empty
bucket.

Open the upper drain valve 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 drain valves (No. 6 & 7) faucets
now open, run the pressure pump until the
pinkish glycol mixture begins owing into
the empty bucket. Quickly switch the hose
from the empty/return bucket to the bucket
containing the glycol mixture. Continue to
circulate the uid using the pressure pump
until the bubbling has stopped and the air
has been purged.

signicant 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 uid quality.

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
efciency of the solution.

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 gures are examples only
and should not be regarded as specications. As
conditions are not within our control, we do not
guarantee that freeze damage may not occur at
temperatures other than shown.

20

• After charging the collector loop, shut
the lower drain valve (No. 6) 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 solar water heating system must be
charged and the uid quality maintained by
an experienced contractor. If the system is
drained during the winter, or you notice a

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.

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.

Operating the System

System Start - Up Procedures

Throughout the installation procedures outlined in
Installation Requirements- Specic, 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 uid
quality and pump performance.

Having completed these tasks it is time to start up
your solar water heating system.

When the glycol loop has been fully charged and

Collector Sensor (Hottest Point) Solar Collector

the pressure is around 25 psi (check the pressure
gauge,(No. 10), set the differential controller to
the "Automatic" setting. This will activate your
circulating pump. The controller allows you to set
the "on" differential.

Adjust the valve settings in accordance with
following section, Three Modes of System
Operation.

Differential Temperature
Thermostat

Optional Digital
Monitor

120V House Current

Thermostatic Gas Valve

Figure 21 - Components

"Storage" Sensor (Coldest Point)

21

Operating the System

Three Modes of System Operation

Both single and double tank systems are
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 or gas 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.

Single Tank Operating Instructions:

100% Solar Operation:

Turn off the thermostatic gas valve 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.

Solar Preheat

Leave the thermostatic gas valve to
your solar storage tank on and set the
tank thermostat to the lowest acceptable
temperature setting. The thermostatic gas
valve 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 thermostatic gas valve will
not come on. If you have a water heater
timer, you may preset the timer to turn the
thermostatic gas valve on and off at specied
times throughout the day if desired.

100% Utility Power

Leave the thermostatic gas valve to your
solar storage tank on and close the isolation
ball valves in the collector loop (Nos. 6
and 8). 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:

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 25). Valve handle
No. 24 must be in the horizontal position.
Valve handle No. 25 must be in the vertical
position. (See Figure 22a, 100% Solar
Operation)

Solar Preheat

Follow the instructions for the single tank
system for setting the thermostatic gas valve
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 and 25) must be placed in the
horizontal position. (See Figure 22b, Solar
Preheat)

100% Utility Power

Follow the instructions for the single tank
system above. All three way ball valves
above the heaters (Nos. 24 and 25) must
have the valve handles placed in the
horizontal position. (See Figures 22c, 100%
Utility Power and 22d, Valve Position
Diagram)

22

25

25

24

24

Figure 22a - 100% Solar Operation

25

Figure 22c - 100% Utility Power Operation

Hot Outlet

25

Figure 22b - Solar Preheat Operation

24

Cold Inlet

See Handle Above

24

Figure 22d - Valve Position Diagram - Two Tank System

23

Use and Care of the System

Isolating the Major Components and System Shut Down
Procedures

Your 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. 19). In the case of a storage
tank or tting 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. 6 and 8). If the pressure in this loop drops
or you nd 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 all necessary isolation ball valves to the off
position to service the solar storage tank or the
back up water heater.

Summer Vacation Recommendations and Procedures

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 dissipate
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. The
manufacturer recommends that you cover the
collectors if practical.

If you choose to drain the HTF in the collector
loop follow these steps:

Connect one end of a garden hose to the
isolation/drain valve (No. 6) and place the other
end in a ve gallon bucket. Open the valve and
gravity will drain the heat transfer uid into the
bucket. Repeat process using isolation / drain
valve (No. 7) . 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!

f the system is installed with an optional

I

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

Turn the controller to the “off” position (No. 4).

24

Maintenance and Troubleshooting

The following simple procedures are intended
to optimize the performance of your solar water
heating system and also to extend the life of the
primary components.

• Fluid Quality: It is extremely important to
monitor the quality of the Dowfrost HD HTF
on a periodic basis. The chemical composition
of the heat transfer uid 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 second most important component
in your system, at least from a longevity
standpoint, is often ignored and never seen.
We are referring to the sacricial "anode
rod" installed in your solar storage tank (No.

14). Typically constructed from magnesium,
anode rods are installed in "glass lined" water
heaters and storage tanks to inhibit corrosion.

As the name implies, the "sacricial" 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 fth year of
system operation, and every three to ve 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
signicantly extend the tank life.

• The solar storage tank also should be ushed
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, ush
the tank on a semi-annual basis. Turn the
thermostatic gas valve to the solar tank off
before ushing. Turn the controller to the off
position.

Open the ush valve on the bottom of the

storage tank (No. 18) and drain a sufcient
volume of water to eliminate the sediment.
After the procedure is complete make sure the
tank is completely full of water before turning
the thermostatic gas valve gas on. Turn the
controller to the "on" position.

• 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.

• Check the exterior pipe insulation annually
and patch or repair any exposed surfaces or
degraded areas. Repaint as necessary.

• In the unusual instance of collector glass
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.

• 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.

• If it’s been a sunny day and you don’t
have hot water, rst 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.

• 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. 20) 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

25

Use and Care of the System

Maintenance and Troubleshooting continued

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 nd a
defective 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.

22) in the collector loop piping to detect
night thermosiphoning.

• If the weather is poor and your gas solar
storage tank is not heating water, the pilot
may have to be lit. Refer to the storage
tank manual for lighting instructions and
diagnostic procedures.

System Component Parts

See Figures 16, 17, 18 & 19 for the location
of the specific components numbered below.

1) Solar Collector(s) (Rheem RS Series):
Absorbs the sun’s heat energy and
transfers this heat to the HTF circulating
through the collector. (Provided)

2) Collector Sensor (Stecca PT1000):
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. (Provided)

3) Tank Sensor (Stecca PT1000): Wired to the
system controller. Works in conjunction
with the collector sensor to automatically
turn your circulating pump on and off at
preset temperature differentials. (Provided)

4) Differential Thermostat (Stecca
Controller RHTR0301U): 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. (Provided)

5) Circulating Pump (Grundfos UPS15­58FC or equivalent): Circulates the HTF
through the collector loop. (Provided)

Never remove the Burner Access Door

unless absolutely necessary. This should
only be done by a qualied service
technician. A new burner access door
gasket must be installed on any burner
access door that has been removed.

If the pilot will not stay lit or you still

do not have hot water after one hour, the
thermocouple or thermostatic gas valve
may be defective. Contact your installation
contractor for service.

6) Isolation / Drain Valve (Unique 50613 or
equivalent): When closed in conjunction
with No. 7 will isolate the circulation
pump for repair or replacement. Used
to charge the collector loop with glycol,
purge air from the loop and drain the
heat exchange fluid. (Provided)

7) Isolation / Drain Valve (Unique 50613 or
equivalent): When closed in conjunction
with No. 6 it will isolate the circulation
pump for repair or replacement. Used
to charge the collector loop with glycol,
purge air from the loop and drain the
heat exchange fluid. (Provided)

8) Isolation Ball Valve (Cash Acme
20800-204 or equivalent): Used in
conjunction with component No. 7 to
isolate the solar collector loop from
the solar storage tank. (Provided)

9) Pressure Relief Valve (Cash Acme 09564­0125 or equivalent): Will release glycol
loop HTF at 75 PSI. If this valve opens
and the HTF fluid is expelled contact your
contractor immediately. This valve also can
be opened to drain the HTF from the charge
glycol loop for replacement. (Provided)

26

System Component Parts continued

10) Pressure Gauge (Winters PFQ804): Indicates
pressure in the collector loop. (Provided)

11) Expansion Tank (Arrow 12-A101):
Pre-charged with air to allow for the
expansion and contraction of the glycol
HTF as it heats and cools. (Provided)

12) Mixing Valve (Watts 1170USM2):
Automatically blends hot water from the
solar storage tank with incoming city cold
water to an acceptable set point. Note: A
mixing valve must be installed on every
solar water heating system. (Provided)

13) 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. (Provided)

14) 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. (Provided)

15) 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. (Provided)

16) Heat Exchanger: Transfers heat from the
solar collector loop to the potable water
in the solar storage tank. (Provided)

17) Thermostatic Gas Valve: The solar
storage tank is equipped with an auxiliary
thermostatic gas valve. The thermostatic gas
valve controls the water temperature in the
solar storage tank to ensure your hot water
supply is never depleted. When there may be
insufficient solar energy, you are still assured
of all the hot water you will need. (Provided)

18) Drain Valve: Used to drain the storage
tank and to flush sediment from the
tank on an annual basis. (Provided)

19) Isolation Ball Valve (Cold Water Supply
Line): When open allows potable water
to fill the solar storage tank or back-up
water heater. When closed isolates the
solar storage tank and back-up water

heater from the pressurized city cold
water supply line. (Not Provided)

20) 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 in the much
cooler solar collector and dissipate heat
unless prevented from doing so by a check
valve. Check valves are also referred to
as one way valves. (Not Provided)

21) Isolation Ball Valve (Hot Water): Used
in conjunction with component No.
19 to completely isolate the solar
storage tank for repair or replacement
as necessary. (Not Provided)

22) Tank / Line Thermometer(s): Will
read the temperature of the water and
the collector supply and return lines
on sunny days. (Not Provided)

23) Optional Time Switch: Allows you
to automatically or manually turn the
auxiliary thermostatic gas valve in the solar
storage tank on and off. (Not Provided)

24) Three Way Ball Valve: Used in
conjunction with component No.
25 to establish the proper mode of
system operation. (Not Provided)

25) Three Way Ball Valve: Used in
conjunction with component No.
24 to establish the proper mode of
system operation. (Not Provided)

26) Isolation Ball Valve: Used in conjunction
with component No. 21 to completely
isolate the back-up water heater for repair or
replacement as necessary. (Not Provided)

27) Temperature and Pressure Relief Valve:
See No. 13 above. (Provided)

28) Anode Rod: See No. 14 above. (Provided)

29) Cold Water Dip Tube: See No.
15 above. (Provided)

30) Drain Valve: See No. 18 above. (Provided)

31) Thermal Well (Tasseron 8TW4550
or equivalent): Not pictured. (Two
thermal wells provided)

27

System Schematics

SINGLE TANK SYSTEM SCHEMATIC*

Note: When two collectors are

required, plumb in parallel.

2

Pipe Insulation

1

Collector Return

Hot Water Supply Outlet to
Fixtures

23 -

Optional

Time Switch

Figure 16

12

21

13

16

14

22

15

18

22

22

19

4

17

8

3

6

Feed

7

5

Cold Water Supply Inlet

20

10

11

9

28

* Installation as shown does not reflect SRCC approval or certification.

Figure 17

DOUBLE TANK SYSTEM SCHEMATIC
with Gas or Electric Back up Tank

DOUBLE TANK SYSTEM

SCHEMATIC with Gas or

Electric Back up Tank *

Note: When two collectors are

required, plumb in parallel.

2

Pipe Insulation

1

Collector Return

Roof Jacks

Hot Water Supply
Outlet to Fixtures

23 -

Optional

Time Switch

22

12

26

27

28

29

30

Gas or Electric Back up Tank

24

21

Cold

25

16

14

15

13

18

19

Cold Water Supply
Inlet

22

Feed

4

20

17

9

8

10

3

11

7

5

6

Figure 17

* Installation as shown does not reflect SRCC approval or certification.

29

Figure 18

DOUBLE TANK SYSTEM SCHEMATIC
with Heat Pump Back up Tank

System Schematics

Note: When two collectors are

required, plumb in parallel.

Hot Water Supply
Outlet to Fixtures

DOUBLE TANK SYSTEM

SCHEMATIC with HEAT

PUMP BACK UP TANK*

22

12

2

Pipe Insulation

1

Collector Return

Roof Jacks

Cold Water Supply
Inlet

19

23 -

Optional

Time Switch

26

27

30

24

25

21

14

16

15

18

13

Feed

4

17

3

5

6

11

7

Heat Pump Back-up Tank

Figure 18

* Installation as shown does not reflect SRCC approval or certification.

22

20

9

10

30

DOUBLE TANK SYSTEM

SCHEMATIC with

TANKLESS BACKUP*

Note: When two collectors are

required, plumb in parallel.

2

Pipe Insulation

1

Collector Return

Roof Jacks

22

Hot Water Supply
Outlet to Fixtures

26

27

Tankless Back-up

26

24

12

21

16

14

13

15

18

25

19

3

Cold Water Supply
Inlet

Feed

4

17

7

5

6

22

20

9

10

11

Figure 19

Figure 19

DOUBLE TANK SYSTEM SCHEMATIC
with Tankless Back up

* Installation as shown does not reflect SRCC approval or certification.

31

IF YOU NEED SERVICE

1. Should you have any questions about your new water heater, or if it requires adjustment,
repair, or routine maintenance, it is suggested that you first contact your installer, plumbing
contractor or previously agreed upon service agency. In the event the firm has moved, or is
unavailable, refer to the telephone directory, commercial listings or local utility for qualified
service assistance.

2. Should your problem not be solved to your complete satisfaction, you should then contact the
Manufacturer’s National Service Department at the following address:

1241 Carwood Court
Montgomery, Alabama 36117
Phone: [phone].

When contacting the manufacturer, the following information will be requested:

a. Model and serial number of the water heater as shown on the rating plate attached to the jacket

of the heater.

b. Address where the water heater is located and physical location.
c. Name and address of installer and any service agency who performed service on the water

heater.

d. Date of original installation and dates any service work was performed.
e. Details of the problems as you can best describe them.
f. List of people, with dates, who have been contacted regarding your problem.

32