Rudd RES120-64BC Installation Manual
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.
®
AP14990-2 (08/10)
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
RHEEM
RS80-32BP RS80-32BC
RS80-32BP-2E RS80-32BC-2E
RS80-32BP-2G RS80-32BC-2G
RS80-32BP-TG RS80-32BC-TG
RS80-40BP RS80-40BC
RS80-40BP-2E RS80-40BC-2E
RS80-40BP-2G RS80-40BC-2G
RS80-40BP-TG RS80-40BC-TG
RS80-48BP RS80-48BC
RS80-48BP-2E RS80-48BC-2E
RS80-48BP-2G RS80-48BC-2G
RS80-48BP-TG RS80-48BC-TG
RS120-64BP RS120-64BC
RS120-64BP-2E RS120-64BC-2E
RS120-64BP-2G RS120-64BC-2G
RS120-64BP-TG RS120-64BC-TG
RUUD
RUS80-32BP RUS80-32BC
RUS80-32BP-2E RUS80-32BC-2E
RUS80-32BP-2G RUS80-32BC-2G
RUS80-32BP-TG RUS80-32BC-TG
RUS80-40BP RUS80-40BC
RUS80-40BP-2E RUS80-40BC-2E
RUS80-40BP-2G RUS80-40BC-2G
RUS80-40BP-TG RUS80-40BC-TG
RUS80-48BP RUS80-48BC
RUS80-48BP-2E RUS80-48BC-2E
RUS80-48BP-2G RUS80-48BC-2G
RUS80-48BP-TG RUS80-48BC-TG
RUS120-64BP RUS120-64BC
RUS120-64BP-2E RUS120-64BC-2E
RUS120-64BP-2G RUS120-64BC-2G
RUS120-64BP-TG RUS120-64BC-TG
RICHMOND
RMS80-32BP RMS80-32BC
RMS80-32BP-2E RMS80-32BC-2E
RMS80-32BP-2G RMS80-32BC-2G
RMS80-32BP-TG RMS80-32BC-TG
RMS80-40BP RMS80-40BC
RMS80-40BP-2E RMS80-40BC-2E
RMS80-40BP-2G RMS80-40BC-2G
RMS80-40BP-TG RMS80-40BC-TG
RMS80-48BP RMS80-48BC
RMS80-48BP-2E RMS80-48BC-2E
RMS80-48BP-2G RMS80-48BC-2G
RMS80-48BP-TG RMS80-48BC-TG
RMS120-64BP RMS120-64BC
RMS120-64BP-2E RMS120-64BC-2E
RMS120-64BP-2G RMS120-64BC-2G
RMS120-64BP-TG RMS120-64BC-TG
ECOSENSE
RES80-32BP RES80-32BC
RES80-32BP-2E RES80-32BC-2E
RES80-32BP-2G RES80-32BC-2G
RES80-32BP-TG RES80-32BC-TG
RES80-40BP RES80-40BC
RES80-40BP-2E RES80-40BC-2E
RES80-40BP-2G RES80-40BC-2G
RES80-40BP-TG RES80-40BC-TG
RES80-48BP RES80-48BC
RES80-48BP-2E RES80-48BC-2E
RES80-48BP-2G RES80-48BC-2G
RES80-48BP-TG RES80-48BC-TG
RES120-64BP RES120-64BC
RES120-64BP-2E RES120-64BC-2E
RES120-64BP-2G RES120-64BC-2G
RES120-64BP-TG RES120-64BC-TG
2
Safety Information
!
FOR YOUR RECORDS
Model Numbers . . . . . . . . . . .2
Introduction . . . . . . . . . . . . 3, 4
subtext
Safety Precautions . . . . . . . 5, 6
Preface
1) Introduction . . . . . . . . . . . .4
2) System Description and
Operational Principle . . . 8
3) Installation Requirements -
General . . . . . . . . . . . . . . 9
4) Installation Requirements -
Specic . . . . . . . . . . . . . 10
5) Start Up Procedures . . . . . 20
6) Three Modes of System
Operation . . . . . . . . . . . 21
7) Isolating the Major
Components and
Shut Down Procedures . 23
8) Summer Vacation
Recommendations . . . . 23
9) Maintenance and
Troubleshooting . . . 24-25
10) Solaray System Component
Parts . . . . . . . . . . . . 26-27
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.
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.
Figures. . . . . . . . . . . 28-31
If You Need Service . . . . . . .32
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 troublefree 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
4
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 heating element..
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 heating element 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 heating element 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
heating element so hot water is available in the
morning.
IMPORTANT SAFETY INFORMATION.
!
R
E
S
E
T
R
E
S
E
T
TURN OFF
POWER
BEFORE
SERVICING
90°F150°F
125°F
(66°C)
(52°C)
(32°C)
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 water heater’s thermostat. 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.
Time/Temperature Relationship in Scalds
!
D A N G E R
HOT
BURN
Water temperature over 125°F 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.
!
DANGER: Burns from Hot Water and
Steam - Use extreme care when opening
relief valves, charging closed loop, and
filling storage tank.
The electrical element booster thermostat has
been factory set at 50°C (120°F) to reduce the
risk of scald injury. Adjusting the thermostat to a
higher setting is not recommended. Hotter water
increases the potential for Hot Water Scalds.
Temperature Time To Produce a Serious Burn
120°F More than 5 minutes
125°F 1½ to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1½ seconds
155°F 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 thermostat setting to prevent contact
with “HOT” water.
NOTICE: Mixing valves should be installed to reduce
the point of use water temperature by mixing hot and
cold water in branch water lines. Contact a licensed
installer or the local plumbing authority for further
information.
The temperature of the water in the water heater can be
regulated by setting the temperature dial of the adjustable
surface mounted thermostat located behind the jacket access panel.
This thermostat controls the
Reset button
Thermostat
dial pointer
Thermostat
protective
cover
water heater’s heating element only. (A separate thermostat should be utilized in
monitoring the temperature
from the collector).
To comply with safety regulatio ns the thermostat is
factory set at 120° F or less
where local codes require.
!
DANGER: Hotter
water increases the
potential for Hot
Water SCALDS.
5
IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING.
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.
Be sure to read and understand the entire Use and Care Manual before attempting to install or
operate this water heater. It may save you time and cost. Pay particular attention to the Safety
Instructions. Failure to follow these warnings could result in serious bodily injury or death.
Should you have problems understanding the instructions in this manual, or have any questions,
STOP, and get help from a qualified service technician, or the local utility.
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
6
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.
Section 1: Introduction
Solar water heating systems are climate and site
specic 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
efciently 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.
Your solar water heating system has been designed
to meet exacting SRCC OG-300 certication
requirements. The components found in your system
have been selected for their proven reliability,
longevity and performance in your specic region of
the country.
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
specic 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 specic 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 Section
10.
7
Section 2: 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 efciently
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 specically
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 Sections 8.1 and 8.2).
8
Section 3: Installation Requirements- General
3.2 The solar collector must be located in a
3. The contractor shall obtain all required permits and
approvals.
3.1 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.
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 Pathnder can be used for
solar site analysis.
3.3 Before the installation the contractor shall
inspect the condition of the roof and notify the
homeowner of any existing roof damage or
necessary repairs.
3.4 The homeowner and contractor shall conrm
the location of all roof and ground mounted
components in advance of the installation.
9
Section 4: Installation Requirements- Specific
4. 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
4.1 Collector Tilt
Optimal annual efciency 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
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