1
Instruction Manual for Domestic
Solar Water Heating System
This Manual Contains:
Installation Instructions
Operating Instructions
Maintenance Procedures
Safety Precautions
PLEASE READ THIS ENTIRE MANUAL BEFORE BEGINNING
INSTALLATION OR ATTEMPTING TO OPERATE THIS SYSTEM
All Safety Precautions are posted as WARNINGS or CAUTIONS in text boxes.
Numbers:
SUN HoM DB-8040
SUN HoM DB-8042
SUN HoM DB-8048
SUN HoM DB-8064
SUN HoM DBSA-8040
SUN HoM DBSA-8042
SUN HoM DBSA-8048
SUN HoM DBSA-8064
SUN HoM DBSA-12063
SUN HoM DBSA-12064
SUN HoM DBSA-12072
SUN HoM DBSA-12080
Figure 1. Tank System Assembly, DB type Figure 2. Tank System Assembly, DBSA type
1
INSTALLATION
This product is designed for use in indirect
domestic solar water heating systems – other
applications, made without written factory
approval, will void the warranty.
The design and installation of solar water heating
systems should only be undertaken by qualified
individuals. Solar water heating systems involve
components and operating principles not found in
standard household plumbing installations. Often,
high operating temperatures, alternate fluids and
unusual plumbing techniques are an integral part
of solar systems. Failure to understand good
design and installation practices can affect the
health and safety of the system user. Poor
practices will also reduce system performance.
This systems described in this manual are equipped
with electrical heating elements in the storage tank.
This qualifies them as solar electric storage water
heaters and as such must be installed in accordance
with federal and local codes. The location chosen for
the system should be as close as possible to the
faucets most frequently used, and the piping should
be insulated.
HEAT EXCHANGER LOOP AND SOLAR
CONNECTIONS:
The DB type systems are equipped with a wrap
around, vented double wall heat exchanger that
provides positive leak detection.
have an external side arm, thermo-syphon heat
exchanger that is not double walled. Both type heat
exchangers are of copper and brass construction. To
prevent dissimilar metals corrosion, use only copper
and/or brass panels, piping, and fittings in the solar
loop.
Flow rates through the solar heat exchange loop are
recommended to be no more than 4 gpm to limit the
effects of erosion corrosion. The system employs a
TACO 008 or 009 Bronze circulator pump to move
the heat collection fluid from the heat exchanger to
the collector. Table 1., shows the flow rate curves for
these pumps. If the distance from the pump to the
top of the collectors is sufficient to keep the flow at or
below 4 gpm then no flow control is required. If not it
may be necessary to install flow metering devices in
the collector loop. Only a licensed, certified
contractor should do this.
This system is a DRAINBACK type using a high
strength, high temperature polymer drainback
DBSA systems
2
Table 1. Taco Pump Curves
reservoir with a capacity of 8.4 gallons. The
recommended heat transfer fluid (HTF) for these
systems is DISTILLED WATER. The drainback
configuration insures that there is no fluid present in
the solar collectors when the pump is turned off
thereby removing the need for anti-freeze solutions.
In the event the installer wishes to further insure the
safety of the system against freezing, a gallon of
propylene glycol can be added to the heat transfer
reservoir before the distilled water is added. See
“Parts Number List”, page 17, for recommended
Brand.
Adding propylene glycol IS NOT REQUIRED.
At the owner’s or installer’s request the manufacturer
can supply the proper additive. If this option is
selected then a regular method of checking the heat
transfer fluid for PH level must be implemented to
insure the protection of the heat transfer piping and
components. (See System Fluid Check, page 15.)
WARNING: Many heat transfer fluids are
TOXIC. Be absolutely sure of the fluid being
introduced into the drainback reservoir before it
Damage to the heat transfer loops can occur when
temperatures exceed 180
incorporated in this system has a high limit preset at
the factory to 1700F. Increasing this setting will void
the warranty on the system. Do not operate the solar
system if water temperature exceeds 170
temperatures exceed 170
and perform “Water is to HOT” troubleshooting
checks on page 18.
0
F. The solar controller
0
0
F shut off the solar system
F. If
2
p
3
POTABLE WATER CONNECTIONS:
Be sure to make all potable water connections prior
to installation of the solar components. Follow the
steps below to insure proper sequence. With the
exception of the tank drain valve, all potable water
connections are located on the top of the water
heater. Locate and identify connections before
proceeding with the installation.
WARNING: DO NOT Connect potable water
lines to the To and From connections to the
solar collector. Serious injury and damage can
occur. DO NOT introduce heat transfer fluids to
potable water lines
1. “COLD” Connect the cold water supply to the
connection marked “COLD” on the top of the
water heater tank. Install a shut off valve in the
cold water line near the water heater. See
Figures 1 and 2.
2. “HOT” Connect the hot water line to he
connection marked “HOT” on top of the water
heater tank. See Figures 1 and 2.
WARNING: The manufacturer’s warranty does
not cover any damage or defect caused by
installation, attachment or use of any type of
energy saving devices (other than those
authorized by the manufacturer) into or onto or
in conjunction with the water heater system.
The use of unauthorized energy saving devices
may shorten the life of the water heater and
may endanger life and property. The
manufacturer disclaims any responsibility for
such loss or injury resulting from the use of
If it is more convenient, the COLD connection on top
of the water heater can be used as the HOT water
outlet. If connections are used in reverse, remove
the dip tube and gasket from COLD outlet. Discard
the gasket. Install close a nipple in HOT connection
and insert the dip tube into the close nipple. HOT
connection can then be used as regular COLD
connection.
CAUTION: The water heater should not be
located in an area where leakage of the tank or
connections will result in damage to the area
adjacent to it or to lower floors of the structure.
When such areas cannot be avoided, it is
recommended that a suitable catch pan,
adequately drained, be installed under the
water heater. See Figure 1. and 2.
NOTE: Catch
an must conform to local codes
3. “Temperature and Pressure (T&P) Relief
Valve” Install the T&P Relief Valve in the marked
opening on top of water heater. See Figure 1. and 2.
The pressure rating of the relief valve must not
exceed the working pressure rating of the water
heater tank as marked on the tank’s rating plate
(150 psi for standard glass-lined tank). If other
components in the system have a lower working
pressure, the T&P relief valve should be selected
accordingly. The BTUH Rating of the relief valve
must not be less than the input rating of the water
heater (1 watt = 3.412 BTUH).
Refer to Figures 1. & 2. for the following. Install the
T&P relief valve in the 3/4" NPT fitting provided and
marked for the purpose on the water heater. The
outlet of the relief valve should be directed to a
suitable open drain, so that the discharge water
cannot contact live electrical parts and to eliminate
potential water damage. The discharge line must be
no smaller than outlet of the relief valve. Material for
the discharge line shall be of the type used for hot
water distribution. The valve and the line must drain
fully by gravity. The end of the discharge line should
terminate within 6 inches of an open drain, should
not be concealed and should be protected from
freezing. No valve or restriction of any type shall be
installed between the relief valve and tank or in the
discharge line. Follow all local codes.
CAUTION: For protection against excessive
pressure and temperature, install temperatureand-pressure protective equipment required by
local codes, but not less than a combination
temperature-and-pressure relief valve certified as
meeting the requirements of ANSI Z21.22-1979,
by a nationally recognized
4. FILL the TANK. Refer to Figures 1 & 2 for this
procedure. After making sure the Drain Valve is
closed, open the Shut Off Valve in the cold water
line. Open hot water faucet in the highest location in
the dwelling and keep it open until water flows from it
in a steady stream.
CAUTION: Hydrogen gas can be produced in a
water heater that has not been used for a long
period of time (generally two weeks or more).
HYDROGEN GAS IS EXTREMELY FLAMMABLE. To
dissipate such gas and to reduce the risk of injury,
it is recommended that the hot water faucet be
opened for several minutes at the kitchen sink
before using any electrical appliance connected to
the hot water system. If hydrogen is present, it
usually sounds like air escaping through the pipe
as the water begins to flow. Do not smoke or use
an open flame near the faucet at the time it is open.
testing laboratory.
3
pplying p
A
A
,
A
4
ELECTRICAL CONNECTIONS:
WARNING: The water heater should not be installed in an area where flammable liquids are
stored, or where vapors from combustible
liquids might be ignited by the arc drawn within
the water heater's thermostat when it cycles.
All connections for power to the electric element are
to be made to the junction box on top, front of the
tank. A separate branch circuit from the electrical
distribution panel that uses copper conductors, an
overcurrent protective device and suitable
disconnecting means must be provided by a
qualified electrician. (Refer to Table 2) All wiring
must conform to local codes or National Electrical
Code NFPA No. 70 -1981.
WARNING: The presence of water in the piping
and water heater does not provide sufficient
conduction for a ground. Non-metallic piping,
dielectric unions, flexible connectors, etc., can
cause the water heater to be electrically
isolated.
The branch circuit wiring should include either:
1. Metallic conduit or metallic sheathed
cable approved for use as a grounding
conductor and installed with fittings
approved for the purpose.
2. Non-metallic sheathed cable, or metallic
conduit or metallic sheathed cable not
approved for use as a grounding
conductor, shall Include a separate
conductor for grounding. It should be
attached to the ground terminals of the
water heater and the electrical distribution
box.
CAUTION: Tank MUST BE FULL OF WATER
BEFORE power is turned on. Heating element
WILL BE DAMAGED if energized for even a
short time while tank is dry, thus voiding the
limited warranty for the electric element.
Adjusting the Thermostat: The Thermostat is set at
the factory to 120°F. This setting is satisfactory for
average household use. If water of different
temperature is required
to the desired temperature.
set indicator on thermostat
NOTE: Households with small children, elderly
people or invalids may require lower
temperature settings to prevent accidental
contact with “HOT” water.
Adjustments to the temperature setting of the
electrical element can be made through the access
panel located on the front panel of the water heater
tank.
CAUTION: Make certain Power to water heater is
OFF prior to opening access panel for any
reason. Power is removed by throwing the
breaker su
There is a Hot Water SCALD Potential if the
thermostat is set too high.
TIME /TEMPERATURE RELATIONSHIPS IN SCALDS
Temperature Time to Produce Serious Bum
120°F. More than 5 minutes
125° F. 11/2 to 2 minutes
130°F.
135°F.
140°F. Less than 5 seconds
145° F
150°F.
155°F. About 1 second
If adjustment of the tank thermostat is necessary,
turn off the power to the water heater. (Throw the
breaker) Remove jacket access panel and insulation
exposing thermostat. The thermostat protective
cover should not be removed. With a small
screwdriver, set thermostat dial pointer to desired
temperature. Replace the insulation and jacket
access panel. Turn on the power to the water
heater.
ower.
bout 30 seconds
bout 10 Seconds
Less than 3 seconds
bout 11/2 seconds
Table courtesy of Shriners Burn Institute
RESET
Button
Thermostat Dial
Pointer
Thermostat
Protective
Cover
CAUTION: HOTTER Waterincreases risk of SCALD injuries.
4
5
COMBINATION Thermostat-High Limit Control
This water heater is equipped with a combination
"Thermostat-High Limit Control" which is located
above the heating element. If for any reason the
water temperature becomes excessively high, the
"High Limit Control" breaks the circuit to the heating
element. Once this switch opens, it must be
manually reset. However, THE CAUSE OF THE
OVER TEMPERATURE CONDITION MUST BE
CORRECTED FIRST.
To Reset — Press the "Red" reset button in toward
the tank.
!!! DANGER !!! Changing the
setting of the electric backup element does
not reduce the temperature which the solar
energy can raise the water too. This can only
be done by changing the high limit setting
on the solar controller or by the installation
of an approved tempering valve in the HOT
water line to the house.
The final step in the electrical installation procedure
is to plug in the solar controller which is done at the
end of the solar equipment installation and after the
Drainback tank has been filled. Do Not plug in the
controller prior to this.
WATER HEATER TANK SERVICE:
It is recommended that a few gallons of water be
drained from the water heater every two months.
This will flush lime and sediment deposits from the
bottom of the water heater and lengthen the water
heater's service. To flush the tank:
1. first attach a hose to the 3/4" hose connection
on the Drain Valve.
2. Place hose so that water is directed to a drain
where it will not cause damage.
3. Open the Drain Valve and allow several gallons
to purge.
4. Close Drain Valve
The water released by this valve CAN BE HOT.
CAUTION:
Electric Element
Wiring Diagrams
ROBERTSHAW THERMOSTATS
THERM-O-DISC THERMOSTATS
5
(
)
g
6
Watt Load
1500" 15 15 15 12 14 14 6.1
2000 20 15 15 10 14 14 8.2
2500 30 15 15 10 14 14 10.2
3000 30 20 15 8 12 12 12.3
3500 — 20 20 — 10 12 14.3
4000 — 25 20 — 10 10 16.4
4500 — 30 25 — 10 10 18.4
5000 — 30 30 — 10 10 20.5
5500 — 35 30 — 8 10 22.5
6000 — 35 30 — 8 8 24.6
Recommended Over
Current Protection
Rating
120 V 208 V 240 V 120 V 208 V 240 V
Copper Wire Size AWG Based on
N.E.C. Table 310-16
60°C.
Approx.
Recovery
Gal. Per
Hour@ 100°
F. Rise
Branch Circuit Sizing Guide based on N.E.C. NPPA No. 70-1981.
•Wattages less than 1500 watts may be wired 14 gauge with 15
amp protection.
TABLE 2
SOLAR COLLECTOR 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 un-shaded by
any permanent obstacle between 9:00 a.m. and
3:00 p.m. on any day of the year.
Collector Tilt
Optimal annual efficiency 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.
The solar collectors in a two collector staggered
mount installation must be spaced far enough apart
to prevent winter shading. Figure 4 and Table 1
show the correct spacing between collectors to
prevent shading on December 21, when the sun is
at its lowest angle.
Basic Mounting Procedures
The solar collectors in your SUN HōM solar System
can be mounted in either a vertical or horizontal
orientation on the roof (Figure 3). Because the
freeze protection method is Drainback it is strongly
recommended the collector always be mounted in
vertical orientation. It is still important to slope the
collectors just slightly to allow for complete drainage
during off mode. The required slope is at least 1/4"
vertical rise 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 flat roof surface. Use Solar
Energy Inc. 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 limited attic access,
mounting the collectors nearer the roof
peak pro-
vides for additional attic workspace.
Figure 3.
Fi
ure 4.
6
7
TABLE 3.
LATITUDE 25°N 30°N 35°N 40°N 45°N 50°N
COLLECTOR TILT 35° 40° 45° 50° 55° 60°
Figure 4 Dimensions
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 DEFINED IN FIGURE 4. AND ARE DESIGNATED IN INCHES
Fig. 5
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 Solar
Strut 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-
12. (Note: The drawings in this manual detail
mounting hardware for the SunEarth, Inc., Empire
series collector. Drawings for Imperial series
collectors are available upon request).
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 roofing
material. There should be at least 1 1/2" 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 SunEarth, Inc. anodized aluminum
"Solar Strut" 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, the use of
galvanized fasteners is prohibited.
Preserving the integrity of the roof membrane is
the most important roofing consideration. Ensure
that all roof penetrations required to plumb and
mount the solar collector are properly flashed and
sealed in accordance with standard roofing
practices. Tremco "POLYroof" is the recommended elastomer for sealing roof penetrations. Henry Co. 204, 208 or 209 roof mastic or
Dow Corning Glazing Sealant also are acceptable
sealants.
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 specific mounting procedures.
Consult your local building department.
7
8
8
Fig. 6
Fig. 8
Fig. 7
Fig. 9
9
Fig. 12
Fig. 10
9
CAUTION: NEVER TOUCH COLLECTOR LOOP
PIPING WITH BARE HANDS.
Collector Loop Pipe Insulation
The collector loop cold supply and hot return lines
must be well insulated with a high quality flexible
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. The specified insulation material
is Rubatex Insul-Tube 180 or equal.
Fig. 11
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 ultra-violet (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. Rubatex
UV Protective Coating or its equal is the required
coating material.
10
Piping in new solar installations can be covered
with dirt, grease, solder flux or other impurities that
over time affect the quality of the distilled water
heat transfer fluid (HTF). A thorough cleaning is
required before charging the system. Carefully
review the cleaning procedures in "Charging The
System".
Figures 13 & 14
Collector Plumbing
Solar Energy Inc. requires the use of all copper and
brass fittings in the collector loop plumbing.
Couplings rather than unions should be used to join
the collectors to avoid leaks and fluid loss. Use only
lead-free solder. Use of 50/50 lead solder is
expressly prohibited. Use of galvanized steel,
CPVC, PVC, or any other type of plastic pipe is
prohibited. The minimum size for To an From
collector piping is 5/8” OD copper.
Fig. 15
All vertical piping between the storage tank and the
collector shall be supported at each story or at
maximum intervals of ten (10) feet. Copper
plumbers tape or tube strap is required. The pipe
insulation may not be compressed or crimped by
the strapping material.
Fig. 16
10
11
THIS IS A DRAINBACK SYSTEM. ALL PLUMBING
TO AND FROM COLLECTORS AND THE
COLLECTORS THEMSELVES MUST BE SET SO
THEY WILL DRAIN COMPLETELY WHEN THE
PUMP IS OFF.
It is not recommended that collectors be mounted
with the parallel flow tubes in the horizontal
position. In the event this is the only option, the
collectors must slope downward toward the
collector inlet by no less than ¼” per foot. The To
and From Collector plumbing lines should also
slope ¼” per foot from the collectors back to the
tank.
The installation of all horizontal and vertical piping
may not reduce the performance or rating of any
structural member or fire rated assembly. Adhere to
all applicable local codes and ordinances.
Fig. 17
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 flanged portion of the
sensor to the SunEarth, Inc. collector header pipe,
as close as possible to the collector outlet, 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 InsulTape or equal). See Figure 17 for collector sensor
installation detail.
Low Voltage Wiring:
The low voltage wiring used to connect the collector
sensor 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. The system comes pre-wired for the
tank sensor.
Interconnect Plumbing:
Piping to and from the solar collector array is called
the interconnect plumbing. Because the SUN HoM
system is a Drainback Type it requires minimal
plumbing. The main Issue in Drainback systems is
that the interconnect plumbing must slope from the
collectors back to the drainback reservoir with no
change in the slope that would cause water to stay
in the lines when the pump is not running.
From the two collector interconnect fittings on the
tank system assembly only ¾” hard copper piping
should be used. The proper unions are supplied
with the system. Measure the distance from the top
of these two fittings to a point inside the attic spaces
that is 1¼” above the level of the top of the bottom
cord of the roofing trusses. Cut two pieces of hard
copper tubing to this length. Sweat the unions
provided with the system to two pieces of copper
tubing. Using Rubatex pipe insulation cut two
pieces the length of the distance from top of the
unions to the ceiling where the tubes will penetrate.
Install the Rubatex and insert the two pieces of
tubing into holes cut directly above the To and
Return Collector fittings on the tank system
assembly. Refer to Figure 1 and 2 for the location of
these fittings.
From these two pieces of copper tubing, soft copper
tubing can be run in the attic spaces to the point
where the piping must transition through the roof.
The entire length of the piping should be insulated.
Do not attempt to install a tank sensor.
11
12
Charging the System:
Once the components are plumbed you are ready
to charge the collector loop. This is done at the
Drainback tank on the tank system assembly. It is
recommended that the collector loop be flushed to
insure all solder fluxes and any other contaminants
are not present when the final distilled water charge
is put in. A pre-charge of regular tap water can be
run through the collector loop for several minutes
prior to the final operating charge being installed. If
there is evidence of sever contamination in the
piping, tri-sodium phosphate(TSP) can be added to
the tap water charge.
If a pre-flush is determined to be needed the
Drainback Tank should be filled with regular tap
water to the FILL Line on the side of the tank. At
this point ¼ to ½ cup of TSP can be added if
necessary. When ready, plug in the controller. The
pump should be turned on and off several times at
5 minute intervals to flush the system piping. The
pump can be turned off and on with the manual
switch located inside the controller front panel.
When this is completed drain the solar loop using
the System Drain Valve below the pump (On DBSA
systems the System Drain Valve is behind the
shroud). When the tank is fully drained use a hose
to continue flushing out the drainback tank for 5
minutes. Turn off the hose and let the system drain
fully. Make sure the controller is set back to the
automatic position. Unplug the controller when
finished.
After flushing and the drainback tank is completely
drained, fill the drainback tank to the Fill Line on the
side of the tank with pure clean distilled water. If the
election is made to add a gallon of propylene glycol
to the system, leave room for this when filling the
tank. Use of inhibited propylene glycol, plain
water or a concentration of these two fluids as
the Heat Transfer Fluid (
strictly prohibited.
If propylene glycol is added to the solar loop a
method of checking the heat transfer fluid for PH
must be implemented. See “Service” and “System
Parts List” Sections in this manual for instruction.
Flat plate collectors can reach temperatures over 3000F
under the right conditions. Always be cautious when
working around flat plates that are exposed to sun
light. Water passing through tube incorporated in the
This completes the system installation procedure.
HTF) in this system is
OPERATING INSTRUCTIONS
Refer to Figures 1 and 2 or the system schematics
at the end of this manual for references in operating
this system.
System Start Up:
Drainback type systems are the simplest of the
active type systems to start up. At this point all that
remains is for the controller to be plugged into an
outlet. A red light (First one on the left) on the front
of the controller should indicate power is present. If
not check to see power is present at the outlet.
If sufficient solar energy is present the system will
begin to operate automatically. When the collector
is hotter than the tank by 12
One light (Center one) on the controller will come
on indicating that power is supplied to the pump.
Water is lifted by the pump to the collector where it
picks up heat and is returned to the drainback tank.
The drainback tank supplies the water to the heat
exchanger where it gives up heat energy to the
water heater tank and is then sent back to the
collector by the pump. This cycle continues as long
as the collector is hotter than the tank. In “DB” type
systems the heat exchanger is wrapped around the
steel water heater tank so heat energy is
transferred by conduction through the tank wall to
the water. In “DBSA” type systems the solar heated
fluid is sent to a “Side Arm” heat exchanger located
out side the tank jacket. In this type heat exchanger
the solar heat fluid passes around the outside of a
bundle of vertical tubes that have the potable water
inside them. The heat causes the potable water to
rise where it moves back into the main tank. When
this happens, cold water flows in from the bottom
where it is heated. This is called a thermo-syphon
cycle and it will continue was long as long as heat
is available from the collectors.
With the pump running, check all lines, fittings and
joints for leaks. If leaks are present, unplug the
controller, wait for the HTF to drain back and then
make repairs. To start up again, plug in the
controller.
0
F or more the Number
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13
Explanation of Major Components and Their
Function.
COLLECTOR:
The SunEarth collectors in your SUN HoM system
are flat plate type. They are designed to maximize
the capture of solar energy in the temperature
ranges required for domestic hot water. Flat plate
collectors accomplish this by employing the green
house effect. The glass covering permits up to 90%
of the visible sunlight to enter the collector. When
the light passes through the glass it’s frequency is
changed slightly to a lower energy level. When the
light strikes the absorbing surface of the flat plate
inside the light is absorbed as heat. The
combination of the glass frequency change and the
solar absorbing surface of the plate capture the
maximum amount of energy. As the absorber plate
heats up it begins to radiate energy as infrared (IR)
or heat radiation. Glass is essentially opaque to IR
wavelengths so the heat is trapped increasing the
temperature.
TANK SYSTEM ASSEMBLY:
Unlike most other solar systems your SUN HoM
Drainback system comes pre plumbed and wired as
a complete assembly. This is called the Tank
System Assembly or TSA. The TSA contains the
water heater tank, the heat exchanger, pump
controller, drainback tank, tank sensor, drain valve,
system drain valve and the wiring and piping to
make all connections. The TSA, the collectors and
the interconnect piping make up the complete
system.
TANK SYSTEM ASSEMBLY: (cont.)
• Pump: The system is equipped with a single
TACO 009 or 008 Bronze circulator pump. It
uses 115V regular AC power which is supplied
from the controller. When heat is available in
the collector the pump is energized to lift the
heat transfer fluid (distilled water) through the
interconnect piping to the collectors where it
gains heat. The water then returns to the
drainback tank, then to the heat exchanger
where it heats the potable water. The cycle
continues until the collector can no longer
contribute heat energy.
• Controller: The controller is powered by 115V
house current and is the device that determines
if solar energy is available. The controller,
through the sensors, constantly measures the
temperature of the water heater tank and the
collector, comparing them to see if the collector
is hotter then the tank. When the collector
reaches a 12
0
F higher temperature than the
water heater tank the controller energizes the
pump. As stated above the pump will continue
to run until the differential temperature (the
difference between the collector and the tank)
drops to 4
0
F. When this happens the pump is
turned off and the heat transfer fluid drains back
into the drainback tank.
• Sensors: The system contains 2 sensors, one
at the outlet of the collector and one on the
bottom of the water heater tank. The controller
uses these 2 sensors to measure tank and
collector temperatures. They are simple
thermistor (thermal resistors) type sensors that
have an inverse reaction to temperature. As the
temperature goes, up the resistance goes
down. The controller is calibrated to read this as
temperature changes. As the collector heats up
the resistance goes down and at the right point
the controller turns on the pump. The reverse
happens when the collector cools off.
• Water Heater Tank: This is standard glass lined
steel tank that is constructed just like any other
water heater. The only difference is that it has a
heat exchanger wrapped around the outer steel
or it has extra ports to make connections to. In
the DBHE series systems the heat exchanger is
a copper coil wrapped around the lower half of
the tank before it is insulated. In the DBSA
series, the tank has side ports and the heat
exchanger is external to the tank. In either
system the heat exchanger is used to transfer
solar heat energy to the potable water.
• Heat Exchanger: An all copper device used to
transfer solar heat to the potable water. See
“System Start Up” section above for more detail
on how this works.
• Temperature and Pressure Relief Valve: This
device is inserted into the water heater tank for
safety. It is located on top of the tank. The T&P
relief valve is preset to open and discharge if
either a high pressure or high temperature
situation occurs in the water heater. All water
heaters regardless of whether they are solar
power or not, must have this safety device
which is required by national building codes.
There is no T&P valve required in the collector
loop as it is a non-pressurized type.
• Isolation Valve: Also called “Shut Off Valve”,
this valve is installed in the cold water service
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14
line to the water heater. It is used to isolate the
system for maintenance, repairs and service.
THIS VALVE SHOULD ALWAYS BE OPEN IF
ELECTRIC POWER IS ON TO THE HEATING
ELEMENT IN THE WATER HEATER TANK.
Other types of solar water heating systems
have collector isolation valves. Since this
system employs Drainback freeze protection.
the system does not have collector loop
isolation valves.
• Drainback Tank: This is a vented reservoir tank
attached to the side of the water heater tank
that holds the collector loop heat transfer fluid
(HTF). (The vent is in the cap supplied with the
system) This system uses distilled water for the
HTF. When the pump is turned on water is
drawn from the drainback tank and supplied to
the collectors. When the water returns it enters
the drainback tank through a copper dip tube
that is inserted into the top of the drainback
tank. This copper dip tube is a very important
part of the systems and cannot be replaced by
a simple tube. It has been pre-cut and drilled to
perform a precise function. It is extremely
important for the water to enter the
drainback tank below the water level in the
tank. If it does not, serious damage or injury
can occur.
• Freeze Prevention: The system uses the
principle of draining water from the collectors to
prevent freezing. No other valves, control
functions or devices are required to prevent
freezing of the collectors. When the pump is deenergized the water in the collector loop drains
back to the Drainback Tank thereby preventing
collector freeze damage. Proper installation is
key to insuring this type freeze protection
works.
• Heat Transfer Fluid: This is the liquid added to
and stored in the Drainback Tank. Distilled
water is the recommended fluid. Use of potable
tap water is prohibited. As described earlier,
propylene glycol can be added at a ratio of 8:1,
(8 parts water to one part propylene glycol).
This is not required.
SERVICE:
START UP PROCEDURE: At this point the water
heater tank should already be filled and on line for
hot water. This includes the electric element
connections.
1. Fill the Drainback Tank to the level indicated on
the side of the cover.
2. Insure all connections, both plumbing and
electrical have been made. Plumbing
connections include the To and From piping to
the collector. The electrical connection is the
sensor wire from the collector sensor to the
controller.
3. Plug in the controller.
If sufficient solar energy is available the pump
should come on right away.
DO NOT TEST THE RETURN LINE FOR HEAT BY
TOUCHING IT WITH YOUR BARE HAND.
This is the end of the start up procedure.
SHUT DOWN PROCEDURE: Depending on the
requirement, not every step needs to be followed.
1. Unplug the controller.
2. If required, attach a hose to the System Drain
Valve. See Figures 1 and 2.
3. Open the System Drain Valve and drain HTF to
a container if it has the propylene glycol
additive. If not discharge the HTF to a drain or
ground.
SYSTEM HTF CAN BE HOT. USE CAUTION!!!
This is the end of the shut down procedure
If the
follow these steps only after the Shut Down
Procedure for the solar system has been
completed.
1. Disconnect electric power to the water heater.
2. Close the Shut Off Valve.
3. If the water heater tank needs to be drained:
4. Open the drain valve.
5. Open the T&P relief valve to allow the tank to
To recharge the water heater tank follow the
instructions contained in the Installation section.
water heater tank is to be shut down
(Throw the breaker.)
Attach a hose to the Drain Valve on the bottom
of the water heater.
vent. The T&P valve can be opened by lifting
the lever on top to the vertical position.
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15
OPERATIONAL CHECK: If hot water is being
supplied the system is obviously producing it. It may
not be clear whether the heat is being supplied by
the electric element, or by the solar collectors.
Follow this procedure to check for solar system
operation.
1. During bright sunlight check to see if the
Number “1” indicator light on the controller is
on. (This is the center red light in the lower right
hand corner.) If it is the pump should be
running and the drainback reservoir should be
warm or hot to the touch. This step only shows
the controller and pump are working.
2. Check to see the pump is not running at night. If
it is consult the troubleshooting guide. When
finished locating problem and repairs have been
made, repeat this step.
3. In the morning, disconnect power to the electric
backup element in the water heater. (DO THIS
BY THROWING THE BREAKER).
4. At the end of the day check to see if quantities
of hot water are available.
During summer months it may be possible to
completely turn off power to the back up element.
This is done by throwing the breaker. This is
recommended only after it is determined the solar
systems is supplying hot water.
SYSTEM FLUID CHECK: A periodic inspection of
the system to check the HTF level is recommended.
Every month the level should be checked to see it is
within 2” of the Fill Line. If the level drops simply
add distilled water to bring it back up to the Fill Line.
If the option of adding propylene glycol to the HTF
is elected, a monthly check of the PH of the HTF is
required. Using PH strips such as those used for
swimming pools, or by using a digital PH meter are
acceptable methods for performing the PH check. If
the PH drops below “7”, follow the Shut Down
Procedure and drain the HTF. Then, repeat the
Start Up Procedure. (See also Charging
Procedure.)
MAINTENANCE:
WATER HEATER TANK: Once each year it is
recommended that the water heater tank be purged.
To do this, follow the steps below.
1. Disconnect power to the electric element.
(DO THIS BY THROWING THE CIRCUIT
BREAKER)
2. Attach a hose to the Drain Valve on the
bottom of the water heater tank.
3. See Figures 1 and 2. Open the Drain Valve
slowly to allow water under line pressure to
purge the tank for a few minutes.
4. Close the “Shut off Valve”.
5. Let the system set for 10 minutes, This
allows the sediment to fall back to the
bottom of the tank.
6. Now open the T&P relief valve to allow
sediment particles to drain out by gravity.
7. Let this continue until the discharge at the
end of the hose is clear water. When
finished follow the next series of steps
exactly.
1. Close the T&P Valve.
2. Close the Drain Valve and remove the
hose.
3. Open the system Shut Off Valve.
4. Open a hot water faucet in the highest part
of the home.
5. Wait until a stream of clear water runs for
several minutes with no air escaping.
6. Return power to the backup element.
SOLAR SYSTEM MAINTENANCE: Drainback type
systems are the most trouble free systems
available. The only maintenance required is to
check and insure the level and PH of the heat
transfer fluid in the Drainback Tank are kept within
proper limits. See “SYSTEM FLUID CHECK” under
SERVICE.
COLLECTOR MAINTENANCE: Collectors operate
best when the glass is clean and unobstructed. If
they become dirty wash them with mild soapy water
and rinse. Remove any branches or leaves that do
not naturally fall off or are blown away by the wind.
Collectors installed at the proper angle anywhere in
the continental United States should not have either
of these problems. Dust and dirt build can be a
problem in dry desert climates where there is little
rain to wash the glass.
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16
TROUBLESHOOTING:
Follow the chart below for problem identification and
resolution:
SYMPTOM CHECK REPAIR
No hot water
Pump “On”
light is lit,
pump does
not run.
Pump and
controller
work but no
hot water.
Water is too
HOT.
Check to see
power is on to
backup element
Perform solar
system
operational
checks
If election is made
to operate on
“Solar Only”
Check HTF level
in drainback tank
Unplug pump
power line from
controller and
plug into 115V
extension cord
Check for
sufficient sun
light.
Check to insure
proper flow in
solar loop.
If solar loop is
working properly
but sunlight is not
available then
check electric
backup element.
Check high limit
setting on solar
controller.
If solar supplied
water is at
preferred
temperature
Re-engage
power. If power is
on replace
element.
If pump does not
function, replace
it. If controller is
not working,
Check sensors
and replace if
necessary. If
controller does
not work, replace
it.
Check to insure
sufficient sunlight
has been
available.
If low, add
distilled water.
If pump runs,
replace controller,
if not replace
pump cartridge or
capacitor.
If no sun light is
available, reapply
power to electric
backup element.
If HTF water is
not flowing call
solar contractor
who installed the
system for service
Replace electric
element.
Reduce setting if
too high.
Install optional
tempering valve
between cold and
hot lines on water
heater.
SYMPTOM CHECK REPAIR
Check for
NO lights on,
on controller
Unsure of
system
performance.
Additional Troubleshooting procedures for solar
systems can be found at the Florida Solar Energy
Center web site:
http://www.fsec.ucf.edu/solar/apps/sdhw/trouble.htm
SYSTEM PARTS LIST:
System Part Number:
Each SUN HoM system is identified by a system
part number, i.e.: DBSA
DrainBack Type Heat Exchanger type:
“DBSA” stands for Side Arm Heat Exchanger
The first two or three number designators, (i.e.: 80
or 120) stand for the tank size in gallons. The
second two number designators indicate collector
square footage, (i.e.: 40).
The table below indicates collector type based on
the square footage number. Collectors are
manufactured and supplied by SunEarth, Inc.
Designator BRAND Sq. Ft. Part # NO.
40 Empire 40 EP-40 1
42 Empire 21 EP-21 2
48 Empire 24 EP-24 2
63 Empire 21 EP-21 3
64 Empire 32 EP-32 2
72 Empire 24 EP-24 3
80 Empire 40 EP-40 2
thermostat failure
on electric
element.
Check to insure
unit is plugged in.
Call system
80-40. The letters refer to:
“DB” only means Heat Exchange Tank
If bad replace it.
If plugged in
replace unit or
call technician
installer.
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17
Parts Number List:
All parts available through SolarDirect.com, or
Solar Direct, 5919 21
Florida 34203. Ph: 941-359-8228
Water Heater Tank: RUUD, RSPE-80-1 for DBSA
models, RSPER-HE-1 for DB models.
Collectors: See table above.
Pump: TACO 009B or 008B Circulator
Drainback Tank: Solar Energy, Inc., DB-Tank
Controller: Goldline, GL-30 LC.
Sensors: Goldline, SB sensor.
Propylene Glycol: Dow Frost (R)
Other parts have multiple options for replacement.
st
Street E, Bradenton,
LIMITED WARRANTY:
This system is covered under Limited Warranty by
Solar Energy, Inc. Its coverage only extends to the
limits of coverage of materials and workmanship of
system components that are not covered by
Warranty from or by the OEM manufacturer of the
individual components. Individual Warranties for the
components are supplied with the system when it is
delivered. Please consult the individual warranty
cards before making a claim to Solar Energy, Inc.
Limits of Coverage: Solar Energy, Inc. will
replace or repair any part in the system for a period
of five (5) years from the date of initial purchase
subject to the following Terms and Conditions.
1. The part does not have a Warranty supplied by
another company that covers the part.
2. The part was installed in the initial assembly.
3. The part became defective as result of normal
use.
This Limited Warranty does not extend any
Warranty, written or implied by others with
respect to time or limits of coverage. This
Limited Warranty does not cover valves.
How To File a Claim:
A Warranty Card is supplied with the system when it
is sold. THIS CARD MUST BE FILLED OUT AND
RETURNED AT THE TIME OF SALE. The
Warranty Card has two sections. Fill out both
sections and separate the two halves. Mail the half
that has the address on the back side and keep the
other for your records.
When filing a claim with Solar Energy, Inc., use the
system serial number on the retained part of the
Warranty Card. If a claim does not have this
number it will NOT BE HONORED. If it is an
emergency and the part is needed right away, you
may call the company at 1-941-359-8228 to file a
claim. The original system serial number must be
available at the time the claim is made. All other
claims should be sent by mail.
This system is provided by:
Solar Direct
5919 21st Street East
Unit A
Bradenton, Florida 34203
Phone: 800—333- 9276
FAX: 941-359-8228
http://www.SolarDirect.com
“The solar system described by this manual,
when properly installed and maintained, meets
the 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.”
For Service Call:
17
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