Butler Sun Solutions SOLAR PV WAND User manual

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
SOLAR PV WAND™
WATER HEATING SYSTEM
PICTORIAL INSTALLATION GUIDE
Butler Sun Solutions Inc.
525 Stevens Avenue West
Solana Beach CA 92075
The Butler Sun Solutions, Inc. Solar PV and™ water heating system is a state-of-the-
art solar water heating system that augments your existing water heater. This system can save
over 2,400 pounds of CO
2
production per year compared to a conventional water heater, making
hot water from clean sunlight. It is like having an oil well on your roof producing 2.5 barrels of
oil per year (but without the pollution from burning the oil!).
The Solar PV and™ system has been designed for easy installation by either a
professional contractor or a do-it-yourselfer. This guide is designed to lead you through the
installation of the system in a simplified manner. It includes a pictorial summary of the
installation steps, followed by explanations of each step. e hope you enjoy bathing and
washing with hot water provided by the sun!
Dr. Barry Butler, CEO of Butler Sun Solutions, Inc.

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
Contents
PICTORIAL SUMMARY OF INSTALLATION STEPS ............................................................. 3
STEP 1. FAMILIARIZE AND PLAN ...................................................................................... 5
STEP 2. SOLAR PANEL MOUNTING ................................................................................... 7
STEP 3. PO ER IRE ROUTING, CONDUIT, & ROOF PENETRATION ....................... 8
STEP 4. CONNECT CONDUIT FROM PV ARRAY BOX TO OVER–TEMPERATURE
BOX ............................................................................................................................. 8
STEP 5. INSTALL PV AND™ INTO HOT ATER TANK .............................................. 9
STEP 6. INSTALL MIXING VALVE (IF REQUIRED BY LOCAL CODE) ....................... 13
STEP 7. CONNECT PO ER CABLE & TANK-TOP OVER- SENSOR ............................ 15
STEP 8. CONNECT PO ER, VERIFY OPERATION & CLEAN UP ................................ 16
APPENDIX 1. TOOLS OF THE TRADE ............................................................................... 17

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
PICTORIAL SUMMARY OF INSTALLATION STEPS

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
STEP 1. FAMILIARIZE AND PLAN
Step 1A: Open the boxes, lay out all of the parts, and be sure that you can identify them all.
Look over the packing list to verify everything is included. The actual appearance of the parts
may be different from the diagram below, but will have the same functionality.
-
Step 1B: Determine where you intend to put the solar collectors on the roof. The ideal
orientation of the solar panels for maximum annual energy delivery is tilted at your latitude angle
towards true South, with no shading of the collectors. Also, plan how you will route the power
wires from the collectors to the top of the existing hot water tank. The power wires (in conduit)
end near the PV panels at the PV array NEMA Disconnect Box. This NEMA box has
connections to the PV panels and should be placed near the array where the pigtail wires will
reach all of the panels. It should also be located where the cover can be raised and the
disconnect pullout can be reached to shut off the PV array. The polarized connectors provided
should be used to connect each panel. The roof cables should be protected from direct sunlight.
Plan for the components needed for this conduit at this time. Finally, plan where the over-
temperature protection NEMA Disconnect Box will be mounted near the water heater tank,
allowing for ease of access to the disconnect pullout, which disconnects the and from the PV
array.
The electrical schematic showing all of the parts is shown below. The yellow shaded area is the
PV panel array which we provide or has been purchased separately. The green shaded area is
what is normally provided with the kit. The 2-#6 THHN and 1#18 THHN wire and conduit to
house the wire are not provided with the standard kit and must be purchased at a local hardware
store.
The parts list is as follows:

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
Part Number Part Name Number
Supplied
Description
6 X PV-250 PV Panels ith Mounting
Hardware
6 PV Panels 250 with Pigtail
Connectors
#278 PV Array Disconnect Box
ith 15 PV Panel
1 NEMA 3R Enclosure: Rainproof,
60A, 220V, Disconnect Panel Box
& Electrical Pigtails
#279 Over-Temperature Protection
Box for PV and
™
1 NEMA 3R Enclosure: Rainproof,
60A, 220V, Disconnect Panel Box,
ith Temperature Sensor, Pigtail
to and Connector & Controls
#277 PV and
™
1 1,500 (50A and 30VDC)
Immersion Resistance heater with
50A Connector

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
STEP 2. SOLAR PANEL MOUNTING
Step 2A: Determine how the panels will be mounted, based on the type of roof you have: flat or
pitched, composition shingle, wood shakes, concrete tile, or clay tile. For flat roofs you need a
tilt kit. You should follow local codes for attaching the solar panels to the roof.
Step 2B: If you did not get a complete kit with PV mounting rails, you can get them from a
number of manufacturers. Typical mounting systems for flat roof tilt mount and flush roof
mounting are shown below. If you are including the PV panels for this solar hot water system
with a grid-tied PV power system, you can just extend the existing racks to include the PV panels
for this system.
Unirac System The IronRidge PV mounting rail
The racking system must support the solar panels to meet Housing and Urban Development
Guidelines, which include:

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Pictorial Installation Guide: PV Wand™ Hybrid Water Heating System
• Gravity Loads of 4 psf
• Wind Loads of 25 psf from 125mph wind
• Snow Loads of 4 psf from deep snow
• Structural ies to roof to prevent wind lifting up the panels, with corrosion-resistant
bolts and screws
• Lightning Grounding for both the rack and panels
Step 2C: As you install each PV panel, connect it to the power cable connectors. The
connectors are polarized so they cannot be connected backwards. Ideally, cables and connectors
should be tie-wrapped to the mounting frames to secure them and keep them out of the sun and
off the roof surface. The circuit diagram for the system is shown below.
STEP 3. POWER WIRE ROUTING, CONDUIT, & ROOF PENETRATION
Step 2A: The power wire conduit is often routed through an attic or crawl space. Typically, the
conduit penetrates through the roof below the solar panels. In some cases it is possible to avoid a
roof penetration by routing it around the eaves. If you must make a roof penetration, doing it
properly will save costs in repairs later. Flashing found at your local building supply store will
most likely meet local roofing codes. Commercial “Roof Jack” flashing is designed to prevent
rain water from entering the house and vermin from using the penetration as a pathway. Make
sure that the flashing is fitted and sealed to the roof properly with roof tar or other proper sealant.
STEP . CONNECT CONDUIT FROM PV ARRAY BOX TO OVER –
TEMPERATURE BOX

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Before any wiring is done, be sure that the disconnect pullouts are removed from both NEMA
boxes. That way all wire connections will be isolated from the power source. Route the power
wires 2-#6 THHN and 1-#18 THHN in conduit from the PV array disconnect box to the over-
temperature protection box near the top of the water tank, installing the THHN wires in conduit
to meet the NEC (National Electric Code). At the water tank, leave the 50A 30VDC connector
disconnected at this time.
STEP 5. INSTALL PV WAND™ INTO HOT WATER TANK
Step 5A: The ideal way to install the PV and™ is into an unused port on the top of the hot
water tank. On tanks with such an extra port, simply remove the existing plug and install the PV

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and™. If no extra port is available, you will have to see if the and will fit in the cold water
outlet port.
To determine if there is a sacrificial anode on the hot water outlet, follow these steps:
If you find the anode under the hot water outlet, you will need to put the PV and™ into the
cold water inlet port. Proceed to Step 5B to verify that the sacrificial anode is good, then to Step
5E for cold water inlet port insertion instructions.
If you do not find any obstructions, clean the threads with a wire brush or a ¾” NPT (National
Pipe Thread) tap. Once the threads are cleaned out you may be ready to put the PV and™ in
place after you complete the Step 5B.
Step 5B: Check the sacrificial anode in the tank. If the tank is only a few years old this may not
be necessary. If the tank is more than five years old, it is a must. Replacing a bad anode will
add another five to seven years to your tank’s life. A good LED flashlight will allow you to see
the anode condition within the tank. If you have one, it is handy to use an inspection scope such
as the one shown in the following figure. The pictures to the left in the picture below show
anodes in various states of usage. The one on the far left is new, the one in the center is well
used but still providing protection to the tank, and the one on the right is down to just the central
wire. If the anode is showing the central wire, it should be replaced. If it is down to just the
wire, you might consider replacing the tank since the anode has stopped providing any protection
and the tank may be compromised.
1. Remove the flexible pipe from the hot water
outlet to the house
2. Look down into the hot water nipple on the
tank (you may have to remove rubber heat trap
parts)
3. Determine if the anode is below the nipple by
probing with a wire or screwdriver as shown in the
photo to the left
4. If you find that an anode is present, do not
remove the nipple, as you may damage it. Just
reconnect it