Rudd RSO120-64BP Installation Manual

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Use & Care Manual

With Installation Instructions for the Installer

Open Loop-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 heating system; 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.

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

RSO80-40BP
RSO120-64BP

It is very important that all persons
who are expected to install, operate
or adjust this water heating system
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 heating system 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.

AP15640 (01/10)

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Safety Information

Safety Precautions . . . . . . . . . . 2,3

Preface . . . . . . . . . . . . . . . . . . . . .5

Introduction . . . . . . . . . . . . . . . 6

System Description and

Operational Principle . . . 7

Installation Requirements -

General . . . . . . . . . . . . . . 8

Installation Requirements -

Specic . . . . . . . . . . . . . . 9

Basic Mounting Figures . 11-14

System Operating

Instructions . . . . . . . . . . 19

Three Modes of System

Operation . . . . . . . . . . . . 20

Isolating Major Components/

Shut Down Procedures . 21

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 Control System: _________________________________

Serial Number of Solar Control System: _________________________________

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.

Summer Vacation

Recommendations . . . . . 21

Maintenance and

Troubleshooting . . . . . . 22

Pumped Solar System

Component Parts . . . . . . 24

Single Tank Diagram . . . . . . 26

Double Tank Diagram . . . . . 28

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

2

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:

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DANGER

that will result in death or serious
injury.

WARNING

could result in death or serious injury

and/or damage to property.

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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

D A N G E R

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HOT

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.

BURN

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

Temperature Time To Produce a Serious Burn

120°F (49°C) More than 5 minutes
125°F (51°C) 1½ 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 1½ 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.

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DANGER: Households with small children, disabled,

or elderly persons may require a 120°F or lower
thermostat setting to prevent contact with “HOT”
water.

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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.

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 t h e jacket acc e s s
panel.

Reset button

Thermostat
dial pointer

Thermostat

protective

cover

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DANGER: Hotter water increases the potential for

Hot Water SCALDS.

This thermostat controls the
water heater ’s heating ele­ment only. (A separate ther­mostat should be utilized in
monitoring the temperature
from the collector).

To comply with safety regu­lations the thermostat is fac­tory set at 120° F

(49 °C)
or less where local codes
require.

3

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

44

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Preface

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 water­heating 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.

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, pump valves and fittings.

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 heater or 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 heater 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 heater 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 element so hot
water is available in the morning.

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

5

Preface

Let us rst offer two words of grateful
appreciation.Thank You! We sincerely

appreciate your business. The manufacturer
also wishes 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 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
uid through the collector.

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

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.

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 a solar
collector with a single 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
Figures 16a, 16b, 17a, and 17b. A description
of each component and its function is found in
Section 10.

6

Section 2: System Description And Operational Principle

2) The key components in the solar water heating
system include:

1. Solar collector.

2. Solar storage tank.

3. Digital controller.

4. Expansion tank.

5. Pressure gauge.

6. Mixing valve.

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 transferred to the
water circulating through the solar collector.
The system pump efciently circulates this
heated uid through the collector piping and
into the 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 pre-heater to your solar

storage tank or back-up water heater.

(3) Bypass the solar collector and run

100% on utility power.

Section 6 provides instructions for setting the

system for automatic operation in each of these

three modes.

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 freeze conditions.

(See Section 7).

7

Section 3: Installation Requirements-General

3. Permits

The contractor shall obtain all required

permits and approvals.

3.1 Regulations, Codes, Ordinances and

Standards

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.

3.2 Location

The solar collector must be located in a

structurally sound area of the roof that will be
un-shaded 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.

3.3 Roof Inspection

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 Conrmation

The homeowner and contractor shall conrm

the location of all roof and ground mounted
components in advance of the installation.

8

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. (See
Figures 1 & 2) 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. Figure 3 and Table 1
show 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 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

Figure 3 - Staggard Mount Collector Spacing

hottest summer months.

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

9

4.2 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). 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.

the mounting hardware as detailed in Figures
5–10 located at the end of this section. (Note:
The drawings in this manual detail mounting
hardware for the series collector.)

4.3.1 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.

Figure 4 - Collector Orientation

To ensure proper water drainage 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 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.

4.3 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

4.3.2

In selecting mounting hardware and
fastener 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.

4.3.3 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.

4.3.4 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.

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