Heat transfer Superstor sb series User manual

SB SERIES

WITH BACK-UP

HEAT EXCHANGER

SE SERIES

WITH BACK-UP

ELECTRIC ELEMENT

• Installation • Operation • Maintenance

The solar energy system described in 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.

E113265

Installation Manual

CONTENTS

Part 1 – Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Definitions

Local Installation Regulation

Water Temperature Adjustment

Part 2 – General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Preface

Introduction

System Description

Specifications

General Solar Panel Orientation

General Solar Panel Installation

Collector Loop Pipe Insulation

Collector Piping

Collector Sensor Placement

Part 3 – Solar Water Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Installation Check List

Solar Water Heater Location

Inspection of the SuperStor Solar Water Heater

Potable Water Piping

Solar Heat Exchanger Piping

Tank Sensor Placement

Solar Heat Exchanger Piping to Collector Panel

Boiler Back-Up Heat Exchanger Connection

Boiler Tank Control

Circulator Sizing

Boiler Back-Up Heat Exchanger (SB Models only)

Electrical Connection

Thermostat Adjustment

Combination “Thermostat and High Limit Control (ECO)”

Charging the System

Commissioning the System

Part 4 – Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25

Shut Down Procedures

Vacation Shut Down

Estimate Life of Components

Part 5 – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-30

NOTICE

Heat Transfer Products, Inc., reserves the right to make product changes or updates without notice

and will not be held liable for typographical errors in literature.

Installation Manual

Be sure to read and understand this entire manual before attempting to install and operate your water

heater. Pay particular attention to the Special Attention Boxes located throughout this manual which

will alert the user of a hazard. Failure to follow these warnings could result in serious bodily injury or

death. Should you have a problem understanding the instructions in this manual or have any questions,

STOP, and get help from a qualified installer, service technician, local electric utility or supplier.

DEFINITIONS

LOCAL INSTALLATION REGULATION

Installation of the SuperStor Contender Solar Water Heater may be governed by individual local

rules and regulations for this type of product, which must be observed. Always use the latest edition

of codes. The installation, adjustment, service and maintenance of the SuperStor Contender Solar

Water Heater must be done by a licensed professional who is qualified and experienced in the instal-

lation, service and maintenance of solar hot water systems.

The system design of the SuperStor Contender Solar system is approved by the Solar Rating and

Certification Corporation (SRCC). Any deviation from the approved specified SRCC components for

this design may affect your ability to certify this system.

WATER TEMPERATURE ADJUSTMENT

If the SuperStor ContenderSolar Water Heater is going to have a set temperature above 120 F you

must use a rated anti-scald device to avoid severe burns or death from scalding temperature.

PART 1: PRODUCT AND SAFETY INFORMATION

SPECIAL ATTENTION BOXES

The following defined terms are used throughout this manual to bring attention to the presence of

hazards of various risk levels or to important information concerning this product.

nDANGER

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in

death or serious injury.

nWARNING

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

nCAUTION

CAUTION Indicates a potentially hazardous

situation which, if not avoided, may result in

minor or moderate injury.

CAUTION

CAUTION used without the safety alert symbol

indicates a potentially hazardous situation which,

if not avoided, may result in property damage.

nDANGER

Water temperature over 125 degrees F. can cause severe burns

instantly, or death from scalds. Children, disabled, and elderly

are at highest risk of being scalded. See instruction manual

before setting temperature at water heater. Feel water before

bathing or showering! Temperature limiting valves are available.

Installation Manual

PART 2: GENERAL INFORMATION

PREFACE

The SuperStor Contender Solar Hot Water Heating System will help to reduce the nation's depend-

ence on polluting fossil fuels. Designed to meet the certification requirements of SRCC-0G-300, The

SuperStor Contender Solar is, reliable, with a system performance that runs efficiently based on

your specific region in the country.

INTRODUCTION

The System performance varies as a function of the household hot water load. The ambient air tem-

perature , the roof pitch and orientation along with seasonal intensity will determine the efficiency

of you SuperStor Contender Solar System.

Your SuperStor Contender Solar System used a circulation pump that circulates the propylene gly-

col heat transfer fluid throughout the system. This fluid protects the collector piping from freezing

and keeps scale deposits from forming that could reduce the performance of the system. Proper

maintenance of the propylene glycol in the system can protect the solar water heating system to

minus 60° Fahrenheit.

This manual is intended to familiarize you with the proper installation and maintenance of your

SuperStor Contender Solar Water Heater System. This system must be installed by a licensed solar

or plumbing contractor in accordance with SRCC Standard OG-300 and all applicable national, state

and local codes. Failure to follow the procedures described in this manual can void the manufac-

tures' warranty.

SYSTEM DESCRIPTION

The system components required in the SuperStor Contender Solar Water Heating System include

the solar collector, The SuperStor Contender Solar Tank, circulator pump, differential solar control,

expansion tank, pressure gauge, mixing valve and non-toxic propylene glycol heat transfer fluid.

The solar collector is the engine of the SuperStor Contender Solar System. When the sun is shining,

the heat energy is absorbed by the solar collector and transferred to the HTF ( Heat Transfer Fluid)

circulating through the solar collector. The system pump efficiently circulates this heated fluid

through the collector's piping and heat exchanger. As the HTF passes through the heat exchanger,

the heat in the fluid is transferred by conduction to the potable water in your solar storage tank. This

process is continuously repeated during the average sunny day, the temperature rises.

SPECIFICATIONS

This solar water heater is designed for the production of domestic hot water from either a solar col-

lector, an electrical or boiler back up. The solar heat exchanger shall be located on the bottom sec-

tion of the tank to heat the entire water volume of the tank. The electrical or boiler back up shall be

located in the upper portion of the tank to provide back up heat if the solar collector is not provid-

ing enough heat to maintain the upper operating set point of the tank. This solar tank shall be

equipped with a control well located a third of the way from the bottom of the tank located near the

PART 1: PRODUCT AND SAFETY INFORMATION

(CONT’D)

nWARNING

Households with small children, disabled, or elderly persons may require a 120°F or

lower temperature setting to prevent scalding with of hot water.

Installation Manual

PART 2: GENERAL INFORMATION

(CONT’D)

coil to monitor the heat input, this is the best location for a water heater with a differential tempera-

ture controller.

The system components should carry temperature and pressure ratings equivalent to the design of

the solar collector. The ratings for the solar collectors should be verified against the solar collector

manufacturers specifications, depending on the climate where the system is installed. The system

temperatures for the collector and storage tank can be read from the system controllers. Typical tank

operating temperatures can range from the cold supply of 40-80F up to 175F which represents the

high limit of the tank. This will vary depending on the climate where the system is installed. The col-

lector temperature sensor should be 5-20 F above the tank sensor during normal charging opera-

tion. During idle periods, when there is no sun, the collector will read the ambient temperature and

when there is full sun upward to 250° F. The system can be operated down to ambient temperatures

of –60°F using proper concentrations of glycol. Freeze tolerance limits are based upon an assumed

set of environmental conditions. Refer to the DOWFROST Specification sheet in the back of this man-

ual for recommended concentrations.

The differential controller uses 10k ohm thermistors or 1k RTDs, depending on the contoller model,

to monitor the temperature difference between the collector and the SuperStor Contender Solar

Water Heater The controller turns on when the collector is 12–20° F above tank temperature and

turns off when the differential drops to 4° F.

GENERAL SOLAR PANEL ORIENTATION

Part of the performance of your solar water heater for optimal efficiency is based on the correct ori-

entation of the solar panels. The collector should be mounted as close to the storage tank as possi-

ble to minimize heat loss in the piping runs. In North America, collectors should be oriented due

south, however may be within 40–60 degrees of due south. Optimal tilt is +/– 10° from the latitude

of the site. The

solar collector

must be locat-

ed in an area

of the roof that

will be und-

shaded for the

majority of the

day (from

9:00–3:00) all

year round.

Adjacent

buildings and

trees should

be checked for

possible win-

ter shading.

You must con-

sult your solar

panel installa-

tion manual

for recom-

mended

mounting and

positioning of

the panels.

LONGAXISOFROOFFACESDUESOUTH

LP-199-O

REV. 8/20/07

Fig. 2-1

Installation Manual

PART 2: GENERAL INFORMATION

(CONT’D)

GENERAL SOLAR PANEL INSTALLATION

The Contractor shall obtain all required permits and approvals for installing the solar system. The

installation shall conform to all federal, state and local regulations governing solar water heating sys-

tem installations. The contractor shall adhere to sound building safety and trade practices. Special

consideration must be given to building code requirements for the penetration of structural mem-

bers and fire rated assemblies. Before the installation, the contractor shall inspect the condition of

the roof and notify the homeowner of any existing roof damage or necessary repairs. The most

important structural consideration is to securely anchor the solar collector and the solar strut mount-

ing hardware to the structural members of the roof with stainless steel hanger or lag bolts as detailed

in figures below. Consult with the panel manufactures installation manual for proper guidelines in

your application. Preserving the integrity of the roof membrane is the most important roofing con-

sideration. 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 mastic or Dow

Corning Glazing Sealant are also acceptable.

This detail is an example of a typical solar roof mount application. All equipment should be

installed in accordance with all local codes and best practices as identified with National Roofing

Contractors Association (NRCA) or other qualified body.

COLLECTOR LOOP PIPE INSULATION

The collector loop cold supply and hot return lines must be well insulated with a high quality flexi-

ble closed cell insulation to minimize heat loss. The wall thickness of the pipe insulation should not

be less than ¾". 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 mate-

rial is Rubatex Insul-Tube 180 or equal.

To the extent possible, slide the insulation material over the pipe without cutting or taping. All butt

Installation Manual

PART 2: GENERAL INFORMATION

(CONT’D)

joints must be sealed with contact adhesive. The use of rigid polyethylene pipe insulation is prohib-

ited. The temperatures generated by your collector in the summer months or under stagnation con-

ditions can melt this type of material.

Any above ground exterior pipe insulation is subject to 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 equal is the required coating material.

COLLECTOR PIPING

Collector piping requires the use of all copper and brass fittings in the collector loop. Cast iron is also

acceptable because it is a glycol loop. Couplings, rather than unions should be used to join the col-

lectors to avoid leaks and fluid loss. Use only lead-free solder. Engelhard Silvabrite 100 or equal is

required. Use of 50/50 lead solder is expressly prohibited. Use of galvanized steel, CPVC, PVC or any

other type of plastic pipe is prohibited.

Piping in new solar installations may have dirt, grease, solder flux or other impurities that over time

affect the quality of the glycol HTF. A thorough cleaning is required before charging the system with

glycol.

All vertical piping between the storage tank and the collector shall be supported at each story or at

maximum intervals of ten feet (10'). Copper plumbers tape or tube strap is required. The pipe insu-

lation may not be compressed or crimped by the strapping material.

The installation of all horizontal and vertical pip-

ing may not reduce the performance or rating of

any structural member or fire rated assembly.

Adhere to all applicable local codes and ordi-

nances.

COLLECTOR SENSOR PLACEMENT

The collector sensor must be located on the hot

water return line as close to the collector as pos-

sible. Some collectors have insertion areas to

measure temperatures more accurately at the

collector manifold.

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 collector header pipe 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 thorough-

ly wrapped in electrician's tape.

The low voltage wiring used to connect the sensors to the controller should be a minimum 18 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, Beldon Wire and Cable no. 8461

or equal.

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 Insul-Tape or equal).

HOT WATER

RETURN LINE

FOAM PIPE

INSULATION

LP-199-O

REV. 8/21/07

Fig. 2-2

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

Location:

• Sufficient room to service water heater

• Provisions made to protect area from

water damage

• Centrally located to fixtures

• Protected from freezing temperatures

• Area free of flammable vapors

Potable Water Supply:

• All related piping is free from leaks.

• Thermal Expansion tank installed

• Water heater and fixtures have been

properly purged of air.

Relief Valve:

• Temperature and Pressure Relief Valve

properly installed and discharge line

runs to open drain.

• Discharge line is not exposed to freezing

temperatures.

• Discharge line is constructed of copper.

Wiring; SE Models:

• Power supply voltage agrees with the

water heater rating plate.

• Branch circuit wire fusing or circuit

breaker properly sized.

• Electrical connections tight and unit

properly grounded.

Wiring; SB Models:

• Water heater control is secure in control

well.

• Boiler back-up control is wired back to

the boiler control or relay center.

Solar Heat Exchanger to Solar Panel; SE

and SB Models:

• Anti-Freeze if required, is added and is

rated as non-toxic with copy of MSDS

sheet for homeowner.

• Solar Heat Exchanger is completely

purged of air.

• Expansion tank and pressure

temperature gauge are operating

properly.

• Solar control shows circulators

operating properly on the solar panels.

Boiler Heat Exchanger; SB Models Only:

• Heat Exchanger is completely purged of

air.

• Expansion tank and pressure

temperature gauge are operating

properly.

• Boiler control is operating circulator for

the boiler back-up heat exchanger.

Anti-Freeze Fluid:

• Make sure freeze protection fluids are

certified as non-toxic.

• Glycol percentage must be calculated

per local area freeze level.

• Provide glycol MSDS sheet to end user.

INSTALLATION CHECK LIST

SOLAR WATER HEATER LOCATION

Choose a location for your solar water heater centralized to the piping system. You must also locate

the SuperStor Contender Solar Water Heater and related domestic piping where it will not be

exposed to freezing temperature. All piping should be insulated. The Solar Water Heater should be

installed so there is access to the element and thermostat for future service. If you do not provide

minimum clearances, it might not be possible to service the water heater without removing it from

the space. The solar water heater should also be placed in a location where T&P discharge or a leak

will not result in damage to the surrounding area. If you do not have this location requirement avail-

able, you must use an auxiliary catch pan.

Installation Manual

INSPECTION OF THE SUPERSTOR SOLAR WATER HEATER

Inspect the SuperStor Contender Solar Water Heater for possible damage. Check markings on the

rating plate to be certain of the power supply (Solar Electric Only) corresponds to that for which the

water heater is equipped.

POTABLE WATER PIPING

The design and installation of the SuperStor Contender Solar Water Heating System should be done

by qualified individuals. It is important that good design and installation practice be followed to

assure that your system will operate properly. Failure to follow installation guidelines for your

SuperStor Contender Solar Water Heater System could cause component failure and possible safe-

ty issues.

It is mandatory that all plumbing be done in accordance with all local and state codes or warranty

will be void. It Is also necessary on all mechanical connections to use both thread tape and pipe

dope. The potable water piping is located on the side of your SuperStor Contender Solar Water

Heater and marked Hot and Cold. It is recommend that unions or flexible copper connectors be used

so heater can be easily serviced. Install a shut-off valve in the cold feed near the Solar Water Heater

to isolated the tank for future service (See Figure 3-1).

Provide clear access to the storage tank, pump, expansion tank, mixing valve, time clock and other

key components. The components on the potable side of the system may require future service or

maintenance, so it is recommended that the connections be made with brass unions. You must use

copper and brass fittings in plumbing the solar storage tank and expansion tank. The use of galva-

nized fittings, nipples, di-electric unions, CPVC, PVC or other plastic pipe is prohibited.

Hard copper connections to the city cold water supply line and home hot water feed lines are rec-

ommended.

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

TO OPEN DRAIN,

LINE SHOULD BE AT

LEAST 3/4" ID AND

PITCHED FOR PROPER

DRAINAGE.

DIAMETER OF WATER HEATER

PLUS 2" MINIMUM

MAXIMUM 2"

CLEARANCE

6" MIN.

CLEARANCE

6" MIN.

CLEARANCE

24" MIN.

ZERO

CLEARANCE

RECOMMENDED SERVICE

CLEARANCE

AUXILIARY CATCH PAN

LP-200-K

REV. 5/24/07

LP-200-H

REV. 6/4/07

nWARNING

Do not introduce heat transfer fluids into any fittings on the heater except those clearly

marked for that purpose and must be classified as non-toxic. See HTF specification in

the back of this manual.

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

TO ELECTRICAL

DISTRIBUTION PANEL

PREVENTER

SHUT-OFF VALVE

BACKFLOW

TANK

EXPANSION

GAUGE

TEMP/PRESSURE

MIXING VALVE

COLD

ANTI-SCALD

SUPPLY

WATER

ACCESS COVER

SOLAR HEAT *

EXCHANGER SUPPLY

DRAIN VALVE

SOLAR HEAT *

TEMP AND PRESSURE

RELIEF VALVE

THERMOSTAT/ELEMENT

EXCHANGER RETURN

TO SUITABLE OPEN DRAIN

DISCHARGE LINE

OUTLET

HOT WATER

RELIEF VALVE

SOLAR SENSOR

AUXILIARY CATCH PAN

POTABLE WATER HEATING SYSTEM

NON-POTABLE HEAT TRANSFER FLLUID SHALL BE CONNECTED TO THE SOLAR HEAT EXCHANGER ONLY. NEVER INTRODUCE

ANTI-FREEZE SOLUTION INTO ANY OTHER CONNECTION OTHER THAN THE SOLAR HEAT EXCHANGER.

* THESE CONNECTIONS ARE FOR THE NON-POTABLE HEAT TRANSFER FLUID LOOP. DO NOT MAKE POTABLE WATER CONNECTIONS

TO THESE FITTINGS. DO NO INTRODUCE NON-POTABLE HEAT TRANSFER FLUIDS INTO ANY OTHER TANK FITTING. ANTI-FREEZE,

LP-200-O

REV. 8/27/07

Fig. 3-1

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

The gaskets in standard water heater flex hose connectors can become brittle and compressed over

time and begin leaking on the water heater. If not detected in a timely manner, even a drip or leak

may cause serious damage to the tank's electrical components or in extreme cases, may cause the

tank to leak from the outside in.

SOLAR HEAT EXCHANGER PIPING

Set the primary balance of the system components down following the piping detail in this manual.

Run ½" type M or greater copper pipes to and from the collector following the direction or supports,

penetrations and other relevant items.

Only copper, cast iron and brass are to be allowed in the collector piping loop due to transient oper-

ating temperatures that may reach as high as 300°F. PEX, PVC, CPVC and other polymers are

expressly prohibited in the piping network.

When making a connection to the heat exchanger, use Teflon Tape and joint compound to prevent

leaks. The connections to the heat exchanger are 1" NPT. Do not apply heat directly to the heat

exchanger thread connection when sweating fittings.

Line pressure and temperature gauge shall be installed in the collector supply and return lines to

allow for a simple diagnostic check of proper system operation. On a sunny day, the hot water return

line should be approximately 5°-12° warmer than the water in the collector supply line. Compare the

temperature readings in the two line thermometers . The ¾" cold water supply line to the SuperStor

Solar Storage Tank must be insulated with a minimum 7/8" x 1/2" pipe insulation to a minimum dis-

tance of 5' behind the storage tank, or to the wall if closer than 5'.

TANK SENSOR PLACEMENT

Make sure the sensor is secured inside the well located in the lower section of the water heater..

Secure the sensor by packing Rubatex insulation behind the sensor. This will also help the sensor

react to temperature change.

Freeze protection fluid must be used to protect the system from freezing and must be rated as non-

toxic. Use a mixture most appropriate for your climate. Do not use a higher glycol to water concen-

tration than necessary, as this will adversely impact heat transfer efficiency. See the DowFrost Data

Sheet in the back of this manual for recommended concentrations. A copy of the MSDS sheet must

be left with the end user of the Solar System. See “EMERGENCY OVERVIEW” as part of the

DowFrost Data Sheet in the back of this manual. The collector loop must be charged with a mixture

of heat transfer fluid and distilled or deionized water. The use of regular tap water as a mixing agent

is prohibited. Scheduled maintenance must be established to monitor and maintain the proper PH

level of the heat transfer fluid in the system to protect the heat exchanger and other components in

the system.

SOLAR HEAT EXCHANGER PIPING TO THE COLLECTOR PANEL

Listed below are the components needed for installation of the SuperStor Contender Solar Water Heater.

1. Solar Collector

Absorbs the sun's energy and transfers this energy into the the heat exchanger located on the bot-

tom of the SuperStor Solar Water Heater .

2. Solar Air Release Vent*

This air vent is used in the solar system to allow air contained in the system to be released.

The air vent valve must be designed to work in high temperatures( as high as 350°F) with a glycol

medium. (This is typical of solar heating systems.)

*Remove and cap the solar air release vent after commissioning the system.

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

3. Solar Collector Sensor

This sensor is to wired to the solar controller and automatically turns on the circulator pump when

the differential set point is reached between the solar water heater and the solar collector.

4. Tank and Heat Exchanger Temperature and Pressure and Gauge.

The Temperature and Pressure Gauge on the solar piping will show the user the actual temperature

and pressure being supply and returned to the solar collector.

5. Check Valve

The Check Valve helps minimize the convective heat loss at night when the system is not operating.

If a check valve is not installed, most of the heated energy stored during the day would be trans-

ferred back up into panel and lost.

6. Collector Array Isolation Valve (Valve #6)

Valve #6 & 11 (for Solar Collector Isolation) to isolate the solar collector loop from the solar water

heater.

7. Pressure Relief Valve (for Solar System Isolation)

Will release the pressure in the Solar Loop when it exceeds 150 PSI. If the valve opens and releases

fluids, than it is recommend that you contact your contractor immediately.

8. System Fill Valve (Valve #8)

Used to fill the system with HTF fluid and also eliminate air form the system.

9. Expansion Tank

Pre-charged with air to allow for the expansion as the HTF fluid gets expansion and contraction with

heating and cooling.

10. Drain Valve (Valve #10)

Used to charge the collector loop with glycol, purge air form loop and drain the Solar water heater

heat exchanger of fluid.

11. Collector Array Isolation Valve (for system fill) (Valve #11)

When closed is used to direct the flow of the fluid to pressure the entire Solar system with HTF fluid

and eliminate air from your Solar system.

12 Ball Valve (for circulator) (Valve #12)

Used Isolate the Circulator Pump for service. Close both ball valves to isolate pump.

13. Circulator (Valve #13)

Circulates the HTF fluid form the Solar Collector into the Super Stor Solar Exchanger.

14. Drain Valve (Tank) (Valve #14)

Used to flush sediment which may accumulate on the bottom of the Super Stor Solar Water Heater

and also provide a means of draining the tank.

15. Tank Sensor

The Tank Sensor is wired to the solar controller to measure the temperature on the bottom of the

SuperStor Solar Water Heater in conjunction with the solar collector sensor which will turn the cir-

culating pump on and off at the solar control preset temperature differentials.

16. Solar Controller

The solar controller, turns on or off circulator depending on the heat gained from the solar opera-

tion. The controller will also limit over heating in the SuperStor Solar Water Heater. Some controllers

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

have various options. The controller should always be set in the “auto” position so that it operates

the array auomatically when there is solar energy to be collected.

17. Solar Heat Exchanger

The Solar Heat Exchanger is designed to transfer heated energy rapidly from the solar collector into

the potable water. The Heat Exchanger has an integral finned tube design. The Heat Exchanger is

constructed in 90/10 copper nickel for superior corrosion resistance and long term reliability.

18. Hot Water Outlet

Each SuperStor Solar Water Heaters has a hot water dip tube outlet which draws water from the very

top of the heater. This helps to keep the heat trapped inside the highly insulated storage tank.

19. Temperature and Pressure Relief Valve

The Relief Valve must comply with standards for relief valves (ANSI Z21.22) by a nationally recog-

nized lab that maintains periodic inspections of production listed equipment. No valve of any type

should be installed between the relief valve and tank. Local codes govern installation of relief valves.

The outlet of the relief valve must be piped to suitable open drain so that the discharge water can-

not contact live electric parts to eliminate potential damage. Piping used should be approved for hot

water distribution.The valve discharge line must be no smaller than the outlet of the valve and must

be pitched downward from the valve to allow complete drainage of the relief valve and discharge

line. The end of the discharge piping should be not be threaded or concealed and should be pro-

tected from freezing. No valve of any type, restriction or reducer coupling should be installed in the

discharge line.

20. Anti-Scald Mixing Valve

Automatically blends the hot water and the cold water feed line to control the discharge tempera-

ture to an acceptable and safe temperature. This will also increase the amount of hot water that is

drawn from the SuperStor Solar Water by not allowing the incoming water to fully temper the hot

water stored inside the tank.

21. Back-Up Electric Element with Thermostat (SE Model)

The back electric element will only be activated when the desired minimum set point temperature

set on the back-up thermostat cannot be satisfied by the solar gain achieved from the solar collec-

tor.

22. Boiler Back-Up Heat Exchanger (SB Model)

The back-up boiler will only be activated when the desired minimum set point temperature set on

the back-up thermostat can not be satisfied by the solar input from the solar collector.

23. Boiler Back Up Aquastat

The Boiler Back Up Aquastat will activate the boiler to circulate the hot water generated from the

boiler into the Heat Exchanger located on the top section of the SuperStor Solar SB model. Once the

controller is satisfied and has reached its desired set point, it will shut off the boiler. This Back-up

portion will only be activated if the solar gain achieved from the solar collector can not keep the tank

at the minimum desired temperature setting.

24. Ball valve (for cold water shut off) (Valve #24)

The cold water shut off valve should be used in the event of an emergency shut down.

nCAUTION

It is very important that you do the potable piping before you pipe into your solar

system. Failure to do so may damage your water heater.

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

BALL

CIRCULATOR

(SEE NOTE 7)

TANK (9)

EXPANSION

(SEE NOTE 7)

TEMPERATURE/PRESSURE GAUGE

(7)

BALL VALVE CIRCULATOR

GAUGE

PRESSURE

VALVE

PRESSURE REDUCING

PREVENTER

AIR SEPARATOR

BACKFLOW

DRAIN VALVE (14)

ISOLATION

SOLAR AIR RELEASE VENT

MAKE-UP

DRAIN

WATER

VALVE

(17) SOLAR HEAT EXCHANGER

(1)SOLAR COLLECTOR

RELIEF VALVE

OUTLET

WATER

HOT

VALVE (11)

(10)DRAIN VALVE

COLLECTOR

(SEE NOTE 7)

(8)FILL VALVE

BALL VALVE(12)

CIRCULATOR

AUXILIARY CHATCH PAN

SOLAR(16)

RELIEF VALVE (19)

TEMPERATURE AND PRESSURE

HEAT EXCHANGER

BALL VALVE

(4)

MIXING VALVE

(20)

VALVE

DRAIN

(18)

UNION

ARRAY

ANTI-SCALD

COPPER DISCHARGE LINE

TO SUITABLE OPEN DRAIN

(23) THERMOSTAT

(5)CHECK VALVE

(3)SOLAR COLLECTOR SENSOR

(15)

HEATING ZONE

CIRCUIT

TANK SENSOR

TO SPACE

(13) CIRCULATOR

HOT WATER

COLD

PRESSURE

SUPPLY

WATER

(6)

(11)

ISOLATION VALVE

COLLECTOR ARRAY

CONTROLLER

OUTLET

BALL VALVE (12)

TEMPERATURES.

)

VALVE

(24)

(22)

BALL VALVE

BOILER BACKUP

(2)

NOTES:

1. THIS DRAWING IS MEANT TO SHOW A SYSTEM PIPING CONCEPT ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING

BY LOCAL CODES.

2. ANTI-FREEZE, NON- POTABLE HEAT TRANSFER FLUID SHALL BE USED FOR THE SOLAR HEAT EXCHANGER CIRCUIT ONLY. NEVER NTRODUCE

ANTI-FREEZE SOLUTION TO ANY OTHER CONNECTION OTHER THAN THE SOLAR HEAT EXCHANGER.

3. IF THERE IS A CHECK VALVE ON THE COLD WATER FEED LINE, A THERMAL EXPANSION TANK SUITABLE FOR POTABLE WATER MUST BE SIZED

AND INSTALLED WITHIN THIS PIPING SYSTEM BETWEEN THE CHECK VALVE AND THE COLD WATER INLET OF THE SOLAR WATER HEATER.

4. AN ANTI-SCALD MIXING VALVE IS RECOMMENDED IF THE DOMESTIC HOT WATER SETTING IS ABOVE 120F.

5. A MINIMUM OF 12 DIAMETERS OF STRAIGHT PIPE MUST BE INSTALLED UPSTREAM OF ALL CIRCULATORS.

6. FOR ALL SE MODELS, MAKE SURE TANK IS FULLY PURGED OF AIR BEFORE POWER IS TURNED ON TO THE BACKUP HEAT SOURCE.

7. CIRCULATORS SHOWN IN THE HYDRONIC BOILER PIPING ABOVE SHOULD HAVE AN INTEGRAL FLOW CHECK OR ALTERNATELY USE A

STOCK PUMP WITH AN EXTERNAL

SPRING TYPE CHECK VALVE. (CIRCULATORS WITH INTEGRAL FLOW CHECKS ARE NOT TO BE USED IN SOLAR SYSTEMS DUE TO EXTREME

(6)

100% SOLAR OPERATION

VALVE POSITIONING DIAGRAM

VALVES SHOWN OPEN

CONTENDER SOLAR SB MODEL

WITH SOLAR COLLECTOR

SUPPLY

GAS

LP-200-B

REV. 11/2/07

Fig. 3-2

Installation Manual

PART 3: SOLAR WATER HEATER INSTALLATION

(CONT’D)

TEMPERATURES.

)

SUPPLY

COLD WATER