State Deluxe Systems User Manual
Instruction Manual
RESIDENTIAL SOLAR WATER HEATING SYSTEMS
DELUXE SYSTEMS
WITH SINGLE WALL HEAT EXCHANGER
FOR POTABLE WATER HEATING ONLY
CUS
LISTED
Solar Water Heater
™
Solar Collector
SRCC OG-100
™
Solar Water Heating System
SRCC OG-300
ALL TECHNICAL AND W ARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE W A TER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLA TE ON THE W A TER HEA TER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1PRINTED 0311 318281-002
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use, and servicing of this water
heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to
warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this
manual. It is very important that the meaning of each safety message is understood by you and others who install,
use, or service this water heater.
This is the safety alert symbol. It is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous
DANGER
WARNING
CAUTION
CAUTION
situation which, if not avoided, will result in death
or injury .
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or injury .
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury .
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, could result in property
damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety
message, and how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed in the act.
Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To prevent
the possibility of injury under these conditions, we recommend the hot water faucet be opened for several minutes at
the kitchen sink before using any electrical appliance which is connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water begins to flow. Do not
smoke or have any open flame near the faucet at the time it is open.
IMPORTANT DEFINITIONS
• Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of
plumbing and electrical installation of these appliances. This would include a thorough understanding of the
requirements of the National Electrical Code and applicable local electrical and plumbing codes (and tools
necessary to confirm proper installation and operation of the water heater) as they relate to the installation
of electric water heaters. The qualified installer must have a thorough understanding of the water heater
Instruction Manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of
plumbing and electrical installation of these appliances. This would include a thorough understanding of the
requirements of the National Electrical Code and applicable local electrical and plumbing codes (and tools
necessary to confirm proper installation and operation of the water heater) as they relate to the installation
of electric water heaters. The service agency must have a thorough understanding of the water heater
Instruction Manual.
2
GENERAL SAFETY
3
INTRODUCTION
Thank You for purchasing this water heating system.
Properly installed and maintained, it should give you years
of trouble free service.
Abbreviations Found In This Instruction Manual:
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturers Association
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratories Inc.
• SRCC - Solar Rating and Certification Corp.
SYSTEM DESCRIPTION
This Solar Water Heating System consists of four main
parts — the solar collectors, the solar pump station, the
solar storage tank, and the plumbing for the heat transfer
fl uid.
The solar pump station uses a pump to circulate a heattransfer fl uid through the “collector loop”. This collector
loop includes the solar collectors, the fl uid lines or “line-
set” and a heat exchanger. The collector loop is a “closed
loop”, meaning there is no contact of the heat transfer fl uid
with your potable water or with the atmosphere. The collector loop contains only a small volume of heat-transfer fl uid
which is non-toxic and freeze-protected to -30°F (Freeze
tolerance limits are based upon an assumed set of environmental conditions). Though freeze protection may not be
necessary in all areas, the heat-transfer fl uid also contains
corrosion inhibitors which protect the system components,
has an elevated boiling point, and is suitable throughout
North America.
When exposed to sunlight, the solar collectors get hot.
As the heat-transfer fl uid passes through the collectors,
it absorbs the heat and then travels down the line-set to
the tank. The hot fl uid passes through the heat exchanger
and heat is transferred to the potable water. After giving up
its heat to the potable water, the cool heat-transfer fl uid is
pumped back to the solar collectors to be heated again.
Hot potable water is stored in the solar storage tank.
The auxiliary or back-up electric-heating guarantees hot
water even under poor solar conditions (at night or when
very cloudy). The minimum acceptable temperature setpoint is specifi ed in local plumbing codes.
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 recommend
leaving the backup heater turned on and set to 120° F to
provide adequate hot water.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section of this manual first and
then the entire manual carefully. If you don’t follow the
safety rules, the water heater will not operate properly . It
could cause DEA TH, SERIOUS BODIL Y INJURY, AND/
OR PROPERTY DAMAGE.
This manual contains instructions for the installation,
operation, and maintenance of the solar water heater.
It also contains warnings throughout the manual that
you must read and understand. All warnings and all
instructions are essential to the proper operation of
the water heater and your safety. READ THE ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
2. The installation must conform with these instructions
and the local code authority having jurisdiction and the
requirements of the power company. In the absence of
local code requirements follow NFPA-70, the National
Electrical Code (current edition), which may be
ordered from: National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02169.
3. If after reading this manual you have any questions or
do not understand any portion of the instructions, call the
local utility or the manufacturer whose name appears on
the rating plate.
4. Carefully plan your intended placement of the water heater
and collectors. INSTALLATION OR SER VICE OF THIS
WATER HEATER REQUIRES ABILITY EQUIVALENT
TO THA T OF A LICENSED TRADESMAN IN THE FIELD
INVOL VED. PLUMBING AND ELECTRICAL WORK ARE
REQUIRED.
Examine the location to ensure the water heater complies
with the “Facts to Consider About the Location” section
in this manual.
5. For California installation this water heater must be
braced, anchored, or strapped to avoid falling or moving
during an earthquake. See instructions for correct
installation procedures. Instructions may be obtained
from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.
6. Massachusetts Code requires this water heater to be
installed in accordance with Massachusetts 248-CMR
2.00: State Plumbing Code and 248-CMR 5.00.
7. The solar energy system described by this manual, when
properly installed and maintained, meets the minimum
standards established by the SRCC. This certification
does not imply endorsement or warranty of this product
by SRCC.
4
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE............................2
Important Defi nitions .................................................2
GENERAL SAFETY .................................................................3
INTRODUCTION .....................................................................4
System Description ...................................................4
Preparing for Installation ............................................4
TABLE OF CONTENTS ...........................................................5
SYSTEM DIAGRAM/TYPICAL INSTALLATION ......................6
SYSTEM COMPONENT PART ...............................................7
STORAGE TANK INSTALLATION ...........................................7
Local Codes ..............................................................7
Temperature-Pressure Relief Valve .......................7-8
Closed System/Thermal Expansion ...........................8
Locating the Solar Water Heater ...............................8
Water Piping ...........................................................8-9
Installation in Residential Garages.............................9
Filling the Solar Water Heater with Water ..................9
Wiring of Element .................................................9-10
Thermostat ..............................................................10
Temperature Regulation ..........................................10
Temperature Settings .........................................10-11
Temperature Adjustment .........................................11
Tank Sensor ............................................................11
Draining ..............................................................11-12
Element ...................................................................12
Element Replacement .............................................12
Anode ......................................................................12
Water Heater Sounds ..............................................12
SOLAR COLLECTOR INSTALLATION .................................13
Collector Location ...................................................13
General Considerations ..........................................13
Collector Orientation ..........................................14-15
Spanner Mounting ..............................................15-17
Attaching Collector to Mounting Brackets ...............18
Collector Piping .......................................................19
Collector Piping Detail .............................................20
Sensor Mounting at Collector ..................................20
Piping Through the Roof .........................................20
Piping Insulation ......................................................20
PUMP STATION INSTALLATION ..........................................21
Pump Station ...........................................................21
Safety Instructions ...................................................21
Safety Equipment ....................................................22
Wall Mounting the Solar Pump Station ...................22
Plumbing Confi guration ...........................................23
Function ..................................................................23
Flowmeter ...............................................................24
Start-up and Operation of the Solar Pump Station ..24
Leak Detection ........................................................24
Flushing ...................................................................25
Preparation of the Heat Transfer Fluid ...............24-25
Filling .......................................................................25
Draining ....................................................................25
PUMP STATION CONTROL INSTRUCTIONS ......................26
Control Instructions .................................................26
Operation and Function ......................................26-31
TROUBLESHOOTING .....................................................32-34
SYSTEM MAINTENANCE .....................................................35
REPAIR PARTS .....................................................................36
HEAT TRANSFER FLUID PROPERTIES .............................37
SOLAR RATING / MODELS / WARRANTY.......INSERT SHEET
5
SYSTEM DIAGRAM/TYPICAL INSTALLATION
10
6
VACUUM RELIEF
VALVE
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A CLOSED
WATER SYSTEM
INSTALL PER
LOCAL CODES
1 1
8
2
Discharge Pipe
(DO NOT CAP
OR PLUG)
Metal
Drain
Pan
3
10
At Least 2” Greater Than The
Diameter Of The Water Heater.
11
5
4
9
7
6” Maximum Air Gap
Flow Direction
Piped To An
Adequate Drain
NOTE: SEE SYSTEM COMPONENT
TABLE FOR DESCRIPTIONS
INSTALL VACUUM
RELIEF IN COLD
WATER INLET LINE AS
REQUIRED BY LOCAL
CODES.
INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER HEATER
IS INSTALLED IN A CLOSED WATER
SYSTEM.
Figure 1.
6
INSTALL SUITABLE METAL DRAIN
PANS UNDER HEATERS TO PREVENT
DAMAGE DUE TO LEAKAGE. REFER
TO WATER HEATER LOCATION, SEE
“LOCATING THE SOLAR WATER
HEATER” SECTION.
SYSTEM COMPONENT PART
Item Component Function
1 Solar collector Absorbs the sun’s heat energy and transfers this to the heat transfer
fl uid circulating through the collector.
2 Solar storage tank Stores potable water heated by solar generated heat or installed
back-up electric resistance element.
3 Heat exchanger (Not Shown) Transfers the heat from the collector loop to the potable water in the
solar storage tank.
4 Expansion tank Allows for the expansion and contraction of the heat transfer fl uid as
it heat and cools.
5 Temperature and Pressure relief
valve
6 Air vent Purges air from the collector loop fl uid during the installation.
7 Drain valve Used to drain the heat transfer fl uid from the collector loop.
8 Mixing valve Used to temper hot water from the solar storage tank with cold inlet
9 Solar pump station Controls the fl ow of heat transfer fl uid from the collectors to the tank/
10 Temperature sensor Tank and collector sensor work together to turn the circulating
11 Cold Water Cut-Off Valve Isolates the tank from incoming water supply.
Required by plumbing code to automatically open and dump water if
the storage tank exceeds 150 PSI of pressure or 210° F in temperature.
water to maintain appropriate temperature hot water delivered from
the system.
heat exchanger. For a detailed description of the solar pump station
see page 20.
pump(s) on and off at preset temperature differentials.
STORAGE TANK INSTALLATION
Never operate the electrical heating element without being
certain the solar water heater is completely filled with water.
If any air is left in the top of the tank, the heating element
will burn out.
LOCAL CODES
The installation of this solar water heater must be in
accordance with these instructions and all applicable local
codes and electric utility requirements. In the absence of
local codes, install in accordance with the latest edition of the
National Electrical Code (NFPA-70).
TEMPERATURE-PRESSURE RELIEF VALVE
For protection against excessive pressures and temperatures
in this water heater, install temperature-pressure protective
equipment required by local codes, but not less than a
combination temperature-pressure relief valve certified by
a nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment or
materials, as meeting the requirements for Relief Valves for
Hot Water Supply Systems, the latest edition of ANSI Z21.22.
This valve must be marked with a maximum set pressure not
to exceed the marked hydrostatic working pressure of the
water heater (150 lbs./sq. in.).
Install the temperature-pressure relief valve directly into the
fitting of the water heater. Position the valve downward and
provide a discharge pipe that must terminate a maximum
of six inches above a fl oor drain or external to the building.
In cold climates, it is recommended that the discharge pipe
be terminated at an adequate drain inside the building. Be
certain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in size
under any circumstances. Excessive length, over 15 feet, or
use of more than two elbows can cause restriction and reduce
the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
temperature-pressure relief valve and the tank. Do not
connect tubing directly to discharge drain unless a 6” air
gap is provided. To prevent bodily injury, hazard to life
or damage to property, the temperature-pressure relief
valve must be allowed to discharge water in quantities
should circumstances demand. If the discharge pipe is not
connected to a drain or other suitable means, the water flow
may cause property damage.
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the
temperature-pressure relief valve, or have any reducing
couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain
or external to the building. In cold climates, it is recommended
that the discharge pipe be terminated at an adequate drain
inside the building.
7
• Shall not have any valve between the relief valve and tank.
When installing the temperature-pressure relief valve, use
two or three turns of Teflon® tape or other suitable thread
sealer around the threaded end of the valve.
Figure 2.
The temperature-pressure relief valve should be manually
opened once a year. Caution should be taken to ensure that
(1) no one is in front of or around the outlet of the
temperature-pressure relief valve discharge line, and (2)
the water manually discharged will not cause any bodily
injury or property damage because the water may be
extremely hot.
If after manually operating the valve, it fails to completely
reset and continues to release water, immediately close
the cold water inlet to the water heater, follow the draining
instructions, and replace the temperature-pressure relief
valve with a new one.
If the temperature-pressure relief valve on the appliance
weeps this may be due to thermal expansion. The water
supply serving this solar water heater may have a check
valve installed. Contact the water supplier or local plumbing
contractor on how to control this situation. Do not plug the
temperature-pressure relief valve.
CLOSED SYSTEM/THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will grow. As the volume
of water grows, there will be a corresponding increase
in water pressure due to thermal expansion. Thermal
expansion can cause premature tank failure (leakage). This
type of failure is not covered under the limited warranty.
Thermal expansion can also cause intermittent temperaturepressure relief valve operation: water discharged from the
valve due to excessive pressure build up. The temperaturepressure relief valve is not intended for the constant relief
of thermal expansion. This condition is not covered under
the limited warranty.
A properly-sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of
thermal expansion. Contact a plumbing service agency or
your retail supplier regarding the installation of a thermal
expansion tank..
LOCATING THE SOLAR WATER HEATER
If you have a choice of where to install the solar water heater,
these ideas may help you decide.
1. Put the solar water heater indoors as close as possible
to where you use the most hot water. This water heater
is not intended for outdoor installation.
2. It is handy to have a floor drain, tub or sink nearby.
That will make it easy to drain water from the water
heater. It is also a good place to end the drain line of
the temperature-pressure relief (T & P) valve.
3. The solar water heater or the pipes and the connections
may , in time, leak. Put the solar water heater in a place
where a water leak will not damage anything.
4. You must not put the water heater in an area where
it might freeze You must turn off the electricity to the
water heater before you drain it, to protect the heating
elements.
5. Make sure that you are able to reach the drain valve
and all access panels when the water heater is in place.
This will make it easy to service the water heater.
6. The water heater must be level before you begin the
piping.
WATER HEATERS EVENTUALLY LEAK. The installation
of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow
of water will not cause damage to the area adjoining the
water heater or to lower floors of the structure. When such
locations can’t be avoided, a suitable metal drain pan should
be installed under the water heater. Such a pan should be
no greater than 1 1/2 inches deep, have a minimum length
and width of at least two inches greater than the heater
dimensions and must be piped to an adequate drain.
This solar water heater, as all water heaters, will eventually
leak. Do not install without adequate drainage provisions
where water flow will cause damage. Note: normal
condensation from a solar water heater may appear to be
a leaking tank.
WATER PIPING
This solar water heater is design certified to be used with a
potable water system. When connecting water piping with
solder joints use only lead free solder.
The indirect coil in this unit is a single wall and may only be
used in a closed loop - fi ll only with a mixture of propylene
glycol containing corrosion inhibitors (such as Dowfrost™)
(50% by volume maximum) and distilled or de-mineralized
water. Never fi ll with a toxic liquid. Use of any heat transfer
fl uid other than that specifi ed or failure to operate the heat
exchanger in a closed loop will void the warranty, and may
result in poor performance, equipment damage, or risk to
health and safety.
This solar water heater shall not be connected to any
heating systems or component(s) previously used with a
non-potable water heating appliance.
8
If this solar water heater is also used for space heating
applications, all piping and components connected to the
solar water heater shall be suitable for use with potable
water.
This appliance has been design certified as a solar water
heater complying with Standards for Safety - UL174 for
the U.S. and can/csa-c22.2 No 110 F379.1 and F379.2
for Canada. The particular application of this appliance
described (above paragraph) may be subject to review and
approval by local code officials.
T oxic chemicals such as used for treatment of boilers or nonpotable water heating appliances shall never be introduced
into a potable water space heating system.
a. Look at the top cover of the solar water heater. The
hot and cold connections are marked there.
b. A non-metallic dip tube is supplied to carry cold water
from the tank top to the bottom. Be sure that it is in
the cold water inlet.
c. If using copper tubing, solder tubing to an adapter
BEFORE you attach the adapter to the cold water
inlet. DO NOT solder the cold water supply pipe
directly to the cold water inlet connection. It might
harm the dip tube.
d. The cold water supply line must have a shut-off valve
and union.
4. Use a union to connect the hot water supply pipe to the
solar water heater’s hot water outlet.
Operating an empty or partially filled solar water heater will
result in damage to the tank.
If a solar water heater is installed in a closed water system;
such as one having a back flow preventer, check valve or
water meter with check valve in the cold water supply line,
means shall be provided to control thermal expansion.
Contact the water supplier or local plumbing contractor on
how to control this situation.
INSTALLATION IN RESIDENTIAL GARAGES
The solar water heater must be located and/or protected so
it is not subject to physical damage by a moving vehicle.
Figure 3.
The solar water heater will work better if you keep the hot
water runs short. You will also get hot water faster and with
less heat loss.
The illustration shows the correct valves and fittings that you
will need to install the solar water heater. Threaded (3/4”)
water connections are supplied through the tank top.
Figure 4.
1. Buy the fittings that you need to connect the pipes.
Remember that you have to connect both the hot and
cold water pipes.
2. Apply a light covering of pipe joint compound to each
outside thread before making connection.
3. Connect the cold water supply pipe to the cold water inlet
of your solar water heater as follows:
FILLING THE SOLAR WATER
HEATER WITH WATER
1. Close the solar water heater drain valve. The drain valve
is on the lower front of the solar water heater.
2. Open the cold water supply to the solar water heater.
NOTE: THIS V AL VE MUST BE LEFT OPEN WHEN THE
SOLAR WATER HEATER IS IN USE.
3. Fill the solar water heater until a constant flow of water
runs out an opened hot water faucet. This will let out
air in the solar water heater and the piping. Close the
faucet after all air has been purged and the water comes
out with constant flow.. You must not turn the electricity
on until the solar water heater is full of water. IF ANY
AIR IS LEFT IN THE TOP OF THE SOLAR WATER
HEATER THE TOP HEATING ELEMENT WILL BURN
OUT IMMEDIATELY.
4. Check all the new water piping for leaks. Fix as
needed.
WIRING OF ELEMENT
Determine voltage and wattage from the rating plate
attached to the solar water heater. All external wiring,
connection, and overcurrent protective devices must be
provided and installed in accordance with the latest edition
of the National Electrical Code, local codes, and local utility
requirements. The solar water heater must be electrically
“grounded” by the installer. A green ground screw has been
provided on the solar water heater’s junction box.
The grounding electrode conductor shall be of copper,
aluminum, or copper clad aluminum. The material shall
be resistant to corrosion, and shall be of one continuous
length without a splice or joint.
Rigid metal conduit, intermediate metal conduit, or electrical
metallic tubing may be used for the grounding means
if conduit or tubing is terminated in fittings approved for
grounding.
9
Figure 5.
BLACK
RED
BLACK
ELEMENT
RED
F
C)(66
F
(60 C)
F
C)(49
Flexible metal conduit or flexible metallic tubing shall be
permitted for grounding if all the following conditions are
met:
1. The length in any ground return path does not exceed
6 feet.
2. The circuit conductors contained therein are protected
by overcurrent devices rated at 20 amperes or less.
3. The conduit or tubing is terminated in fittings approved
for grounding.
Never use this solar water heater unless it is completely
full of water.
SOLAR WATER HEATERS EQUIPPED FOR ONE TYPE
VOLTAGE ONLY. This solar water heater is equipped
for one type of voltage only. Check the rating plate near
the bottom access panel for the correct voltage. DO NOT
USE THIS SOLAR WA TER HEA TER WITH ANY VOL T AGE
OTHER THAN THE ONE SHOWN ON THE MODEL
RATING PLATE. Failure to use the correct voltage can
cause problems which can result in DEATH, SERIOUS
BODILY INJURY OR PROPERTY DAMAGE. If you have
any questions or doubts consult your electric company.
If wiring from the fuse box or circuit breaker box was aluminum for the old tank, replace it with copper wire. If you wish
to reuse the existing aluminum wire, have the connection
at the solar water heater made by a competent electrician.
THERMOSTAT
Each thermostat is factory preset at 120°F to reduce the
risk of scald injury. This setting has proven by experience
to be most satisfactory from the standpoint of operational
costs and household needs.
Solar water heaters installed in Florida require the
thermostat(s) to be set at 125°F. If you wish to adjust the
settings, see the “Temperature Adjustment” section of this
installation manual on page 11.
TEMPERATURE REGULATION
HOTTER WATER CAN SCALD: Solar water heaters are
intended to produce hot water. W ater heated to a temperature
which will satisfy clothes washing, dish washing, and other
sanitizing needs can cause scalds resulting in serious
personal injury and/or death. Some people are more likely
to be permanently injured by hot water than others. These
include the elderly, children, the infirmed, or physically
handicapped. If anyone using hot water in your home fits
into one of these groups or if there is a local code or state
law requiring a certain temperature water at the hot water
tap, then you must take special precautions. Please see
Figure 7 and Table 2 for information regarding thermostat
settings. In addition to using the lowest possible temperature
setting that satisfies your hot water needs, some type of
mixing device, such as a mixing valve should be used at the
hot water taps used by these people or at the solar water
heater. Mixing valves are available at plumbing supply or
hardware stores. Follow manufacturers instructions for
installation of the valves. Before changing the factory
setting of the thermostat, read the T emperature Adjustment
section. KEEPING THE THERMOST A T SETTING A T 120°F
WILL REDUCE THE RISK OF SCALDS. Never allow
small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person
unattended in a bathtub or shower.
TEMPERATURE SETTINGS
Figure 6.
Contact your local utility to arrange for a professional
electrician.
NOTE: This residential solar water heater will not supply
sanitizing hot water for dishwashers.
The thermostat is factory set at its lowest position which
approximates 120°F and is adjustable if a different water
temperature is desired. For best system savings this
temperature should not be changed. Read all warnings in this
manual and on the solar water heater before proceeding.
10
HIGH LIMIT
CONTROL
RESET
BUTTON
ADJUSTABLE
THERMOSTAT
WITH
HIGH LIMIT
Figure 7.
Water
Temperature °F
110
116
116
122
131
140
149
154
(U.S. Government Memorandum, C.P .S.C., Peter L. Armstrong, Sept. 15,1978)
Time for 1st Degree
Burn
(Less Severe Burns)
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
Time for Perma-
nent Burns 2nd &
3rd Degree (Most
Severe Burns)
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 seconds
TABLE 2.
TEMPERA TURE ADJUSTMENT
To adjust the temperature setting:
1. Turn “OFF” the electrical power to the water heater, at
the junction box.
HAZARD OF ELECTRICAL SHOCK! Failure to turn
“OFF” electric power to the solar water heater will result
in the possibility of DEA TH, SERIOUS BODILY INJURY
OR PROPERTY DAMAGE.
2. Take off the access panel and fold away the insulation.
3. Turn the water temperature dial clockwise ( ) to
increase the temperature, or counterclockwise ( ) to
decrease the temperature.
4. Fold the insulation back in place and replace the access
panel.
5. Turn “ON” the power supply.
RESET
BUTTON
Figure 8.
A non-adjustable high temperature limit control operates
before steam temperatures are reached. The high limit is
in the same area as the upper thermostat and must be reset
manually when it activates. BECAUSE THE HIGH LIMIT
ACTIVATES ONLY WHEN ABNORMALLY HIGH WATER
TEMPERATURES ARE PRESENT, IT IS IMPORTANT
THAT A QUALIFIED SERVICE AGENT BE CONTACTED
TO DETERMINE THE REASON FOR OPERATION
BEFORE RESETTING.
TANK SENSOR
The surface mount tank sensor should be attached to the
sensor stud behind the lower door by placing the hole in
the sensor over the stud provided and securing in place
with a nut. The end of the tank sensor shall be connected
to the red wires in the opening with wire nuts (with no
regard for polarity). The other ends of the red temperature
sensor extension extend from the top of the tank and shall
be connected to the controller in the tank sensor position.
DRAINING
It is recommended that the storage tank be drained and
fl ushed every 6 months to remove sediment which may
build up during operation. The water heater should be
drained if being shut down during freezing temperatures.
To drain the tank, perform the following steps:
1. Turn off power to the water heater.
2. Open a nearby hot water faucet until the water is no
longer hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to
an adequate drain or external to the building.
5. Open the water heater drain valve and allow all of the
water to drain from the tank. Flush the tank with water
as needed to remove sediment.
6. Close the drain valve, refi ll the tank, and restart the
heater as directed in this manual.
If the water heater is going to be shut down for an extended period, the drain valve should be left open.
IMPORTANT: Condensation may occur when refi lling the
tank and should not be confused with a tank leak.
If the solar water heater is to be shut off and exposed to
freezing temperatures, it must be drained. Water, if left in
the tank and allowed to freeze, will expand and damage
the solar water heater.
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1. T urn “OFF” the electrical supply to the solar water heater.
Make sure the electrical supply to the solar water heater
is turned OFF. Failure to heed this will result in the
possibility of DEATH, SERIOUS BODILY INJURY OR
PROPERTY DAMAGE.
2. Open a nearby hot water faucet until the water is no
longer hot, then turn off the cold water supply and open
the drain valve, leaving the hot water faucet open.
3. The drain valve must be left open during the shut-down
period. Once the solar water heater is drained close the
hot water faucet.
ELEMENT
In some water areas, scale or mineral deposits will build up
on heating elements. This build up may cause a rumbling
noise. Follow the element replacement directions to remove
the elements from the tank. Soaking in vinegar and scraping
will remove the mineral deposit. Be careful not to bend the
element.
ELEMENT REPLACEMENT
Replacement elements must (1) be the same voltage and
(2) no greater wattage than listed on the model and rating
plate affi xed to the solar water heater .
1. Turn OFF the electrical supply to the solar water heater.
Make sure the electrical supply to the solar water heater
is turned OFF. Failure to heed this will result in the
possibility of DEATH, SERIOUS BODILY INJURY OR
PROPERTY DAMAGE.
2. Drain the solar water heater. Follow the directions for
draining.
3. Take off the access panel and take off the access panel
and remove the insulation. Disconnect the wires from the
heating element terminals.
4. Use an element wrench to remove the element and gasket.
Y ou should always use a new gasket when you replace the
element.
5. Install new element.
6. Reconnect the wires as they were.
7. Fill the tank , following the filling directions on page 9. Fill
the tank completely with water, BEFORE you turn on the
electric supply .
ANODE
Each water heater contains at least one anode rod, which
will slowly deplete (due to electrolysis) prolonging the life
of the water heater by protecting the glass-lined tank from
corrosion. Adverse water quality , hotter water temperatures,
high hot water usage, hydronic heating devices, and water
softening methods can increase the rate of anode rod
depletion. Once the anode rod is depleted, the tank will
start to corrode, eventually developing a leak.
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water. IMPOR T ANT : Do not remove this rod
permanently as it may void any warranties. A special anode
rod may be available if water odor or discoloration occurs.
NOTE: This rod may reduce but not eliminate water odor
problems. The water supply system may require special
filtration equipment from a water conditioning company to
successfully eliminate all water odor problems.
Artificially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease
the life of the water heater tank.
The anode rod should be inspected after a maximum of
three years and annually thereafter until the condition of
the anode rod dictates its replacement. NOTE: artificially
softened water requires the anode rod to be inspected
annually.
The following are typical (but not all) signs of a depleted
anode rod:
• The majority of the rod’s diameter is less than 3/8”.
• Significant sections of the support wire (approx. 1/3 or
more of the anode rod’s length) are visible.
If the anode rod shows signs of either
or both it should be replaced. NOTE:
Whether re-installing or replacing the
anode rod, check for any leaks and
immediately correct if found.
In replacing the anode:
1. Turn off power supply to the water
heater.
2. Shut off the water supply and
open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons
of water from tank. (Refer to
“Draining and Flushing” for proper
procedures). Close drain valve.
Figure 9.
4. Remove old anode rod.
5. Use T eflon® tape or approved pipe sealant on threads
and install new anode rod.
6. Turn on water supply and open a nearby hot water
faucet to purge air from water system. Check for any
leaks and immediately correct any if found.
7. Restart the water heater as directed in this manual.
See the Storage Tank Repair Parts section for anode
rod location.
TEFLON® is a registered trademark of E.I. Du Pont De
Nemours and Company.
Hydrogen gas can be produced in a hot water system that
has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of bodily injury under
these conditions, open the hot water faucet for several
minutes at the kitchen sink before any electrical appliances
which are connected to the hot water system are used (such
as a dishwasher or washing machine). If hydrogen gas is
present, there will probably be an unusual sound similar
to air escaping through the pipe as the hot water faucet is
opened. There must be no smoking or open flame near
the faucet at the time it is opened.
WATER HEATER SOUNDS
1. The solar water heater is equipped with an immersion
heating element for fastest recovery. If the solar water
heater occasionally makes noises this is not a defect or a
safety hazard.
2. Lime or scale has accumulated on the heating element
causing a hissing sound. Element scale removal can be
accomplished by using vinegar or by scraping.
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