Sage Advance Corp Copper Cricket 1B User manual

95.0101

IMPORTANTNOTICE:PLEASEREADTHISPAGE.
Thesolarenergysystemdescribedbythismanual,whenproperlyinstalledand
maintained,meetsthestandardsestablishedbytheSolarRatingandCertification
Corporation(SRCC)andthestandardsestablishedbytheFloridaSolarEnergyCenter
(FSEC),inaccordancewithSection377.705,FloridaStatutes.Thiscertificationdoes
notimplyendorsementorwarrantyofthisproductbySRCC,byFSEC,orbytheState
ofFlorida.

TABLEOFCONTENTS PAGE
SYSTEMINFORMATION1
HOWDOESTHECOPPERCRICKET™WORK?2
FIGURE1.SchematicshowinghowtheCopperCricket™works3
FIGURE2.Diagramof the basicwaterconnectionsbetweentheauxiliarytank,solarstoragetank,
andtheSolarPad4
FIGURE3.Alternativediagramofthewaterconnections,showingoptionalby-passandoptional
3-valveisolation5
FIGURE4.Photographofthe3-wayvalves,showingthe"FLOW"and"FLUSH"positions5
TESTINGFORPROPERPERFORMANCE6
GENERALMAINTENANCE7
Cleaningtheglass7
SOLARPADANDTANKMAINTENANCE7
SolarpadandTankflush8
DE-SCALINGFLUSH8
Keepa record9
RE-ROOFING9
ABSENCEFROMHOME9
Winter:9
Summer:9
SOLARACCESS10
SAFETY10
A.LeakintheSolarPadheatexchanger:10
B.Leakinthesolarstoragetank.Ifyourtankhasnoisolationvalves10
C.Leakinthesolarstoragetank.Ifyourtankhasisolationvalves10
D.Leakintheauxiliarytankorthewaterconduitsconnectingthetanktothehouse
watersystem10
E.Ifindoubt,calla plumberorSageAdvance'sCustomerService(503)485-1947.10
FIGURE 5. Isolationofthesolarstoragetankusingthebrassnipple11

TABLEOFCONTENTSPAGE
IMPORTANTNOTES12
Donotopenthesealedplugsortheaccessvalveonthesolarloop.Severesteam
burnscouldresult12
Takeprecautionsnottodrill,saw,orpuncturethecopperpipesofthesolarloop.12
Hotwatercaninjurechildrenandpets,orkillgardenplantsandgrassifdirected
outside12
TEMPERATURERECORD13
ANNUALHEATEXCHANGERMAINTENANCERECORD14
THEINSTALLATIONPROCEDURES15
1.0OVERVIEW16
1.1HowtoUsethisInstallationManual16
1.2PreviewoftheInstallationProcess16
1.3SAFETYandImportantNotes17
1.4FunctionalRequirements17
2.0INSTALLATIONATTHESOLARSTORAGETANK19
2.1InstalltheSolarPadandthesolarstoragetank19
2.2ConnecttheSolarPadtotheThermosiphonPort19
2.3ConnecttheSolarPadtotheSolarstoragetank'sDrainPort20
FIGURE6.Partslaidoutforthehot waterhook-upbetweenthesolarstoragetankandtheheat
exchanger.21
FIGURE7.Installingthethermosiphondiptubeintothelowerelementport22
FIGURE8.Hotwaterconnectionbetweenthesolarstoragetankandtheheatexchanger22
FIGURE9.Partslaidoutforthecoldwaterhook-upbetweenthesolarstoragetankandtheheat
exchanger23
FIGURE10.Connectionof the coldwaterbetweenthesolarstoragetankandtheheatexchanger.23
FIGURE11.Heatexchanger3-wayvalvesshowingflowandflushpositions24
FIGURE12.Partsofthemixingvalve24
2.4ConnecttheSOLARSTORAGETANKtotheHouseWaterSystem25
2.5FillwithWater,PressureTest,andFlush25
FIGURE13.Basictwo-tankwaterhook-up26
FIGURE14.Waterhook-upwithoptionalby-passandisolationvalves27

TABLEOFCONTENTSPAGE
FIGURE15.AssemblyoftheT-PvalveandOverheatProtection(OHP)valve27
3.0INSTALLATIONONTHEROOF28
3.1InformationaboutMountingtheSolarCollectorontheRoof28
3.2LayingOuttheRooffortheSolarCollector28
3.3InstallingtheRoofJack28
3.4PreparingtheSolarCollector(s)forMountingontheRoof.29
3.5MountingtheCollectorontheRoof.29
FIGURE16. CopperCricketplanviewandrooflayout31
FIGURE17.CopperCricketeastelevationandrooflayout32
FIGURE 18. Mountingoptions(A)usingspannersundertherafters,or(B)4 X 4 blocksbetween
therafters32
FIGURE19.Connectingtwo CopperCricketsRedandBluePipesandVaporConnector33
3.6ConnectingtheSolarCollector(s)totheSolarPad34
FIGURE20.Placethethermometerwellsontheredandbluepipeswheretheyareeasilyread...35
4.0FLUSHANDPRESSURETESTTHESOLARLOOP36
4.1FlushingOuttheSolarLoop36
4.2PressurizetoTestforLeaks36
4.3PrepareforStart-up37
FIGURE21.DetailofCopperCricketportsandschematicdrawingof the fillingequipment37
5.0FILLANDSTARTTHECOPPERCRICKET38
5.1PreparetheSolarLiquid38
5.2FilltheSolarLoop38
5.3Sun-StarttheCopperCricket.39
5.4FinishingUp41
5.5InsulatePipesandSolarstoragetank41
5.6"NITE-STARTtm"Note41
6.0TESTINGFORPROPERPERFORMANCE42
6.1AboutTestingforProperPerformance42
6.2IftheRedandBluearebothhigh(above160°F),andYellowislow(below
100°F)43

TABLEOFCONTENTSPAGE
6.3Ifthedifference,Red-minus-Blue,isgreaterthan50°F,butlessthan90°F...43
6.4IfBlueishigherthanRed- 44
6.5IfRed,Blue,andYellowarealllow(60-100°F)ORIfRed-minus-Blueis
greaterthan90°F,ORifthefuseplugismelted- 44
6.6ReplacingtheFusePlug44
7.0RE-ROOFING45
APPENDIXA - METHANOLMATERIALSAFETYDATASHEET46
APPENDIXB - PROJECTEDLIFETIMEOFPARTS53
APPENDIXC - PARTSLISTANDAVAILABILITY54
APPENDIXD - SRCCRATINGCERTIFICATES55
APPENDIXE - 10YEARLIMITEDWARRANTY57
APPENDIXF - RECOMMENDEDTOOLSLIST58
APPENDIXG - SOLDERINGINSTRUCTIONS59
APPENDIXH - VACUUMVS.TEMPERATUREGRAPH60

SYSTEMINFORMATION
Pleaserecordthefollowinginformationimmediately.Itisessential
informationforanyservicecall.SageAdvanceCorporation'sphone:
[phone].
YourNamePhone( )
Installer'sNamePhone( )
PurchasedateStart-update
CopperCricket:1 or2 collectors?
Serialnumber(s)(l)(2)
SolarPadheatexchangerserialnumber
Collectorelevation(forexample30°or7/12 pitch)
Verticalheightfromtopofcollectortoheatexchanger(infeet)
Pipelengthfromtopofcollectortoheatexchanger(oneway,infeet)
Pipesizeandtype(forexample:3/4"copper,TypeM)
Storagetankcapacity(gallons)
Page1

HOWDOESTHECOPPERCRICKET™WORK?
TheCopperCricketisa passiveself-pumping,self-regulatingsolarhot waterheater.Itoperates
onthe"geyserpumping"principle.Unlessthehermeticallysealedsolarloophasbeenopenedandair
allowedin,theCopperCricketwilloperatewithoutattention,collectingsolarheatinthecollectorand
transferringittoyourhot watertank — withnoelectricpower,nopumps,nomovingorelectronicparts.
FollowthediagraminFigure 1 whileyoureadbelowtoseehowitworks.
SolarenergyabsorbedintheCOPPERCRICKETheatsandboilstheliquidintheRISERTUBES.
Theliquidisan"antifreeze"mixtureofmethanolandwater.Boilingmakesvaporbubbleswhichlifthot
liquidintotheHEADER(asina coffee percolator)wheretheliquidandvaporseparate.Hotliquidflows
onewaytoward theHEATEXCHANGER,andvaporflowstheotherwaytowardtheVAPOR
CONDENSER.Thesolarloop,filledonbothsidestothesamelevelastheVAPORCONDENSER,stays
inbalanceuntilthehot liquidfrom theHEADERbeginstobuildup.Thebuild-uppushesthehotliquid
downtotheHEATEXCHANGER,whereitgivesupitsheattotheSOLARSTORAGETANK,and
pushesthecooledliquidbackuptotheVAPORCONDENSER.AsthecooledliquidenterstheVAPOR
CONDENSER,itcondensesthehotvapor from theHEADER,andthecombinedflowreturnstothefoot
ofthecollector.SolarenergyagainheatsandboilstheliquidintheRISERTUBES-andtheCopper
Cricketchirpson!
TheCopperCricketisevacuatedsotheliquidintherisertubeswillboilassoonasit'swarm,
ratherthanwaitinguntilitreachesitsusualboilingpoint.Thevacuumismaintainedbythevapor
condenser,whichre-condensesthevaporafterithasdoneitsworkof lifting thehotliquidintotheheader.
HotwaterfromtheSolarPadheatexchangerrisesbyconvection(thermosiphons)intothesolar
storagetank.A plumbingschematicforthetankisshowninFigure2.
Page2

FIGURE1.Schematicshowing howtheCopperCricket™works.
Page3

FIGURE2.Diagramofthebasicwaterconnectionsbetweentheauxiliarytank,solar
storagetank,andtheSolarPad.
Page4

FIGURE3.Alternativediagramofthewaterconnections,showingoptionalby-pass
andoptional3-valveisolation.
OptionalOptional
By-PassValveIsolationValves
FIGURE4.Photographofthe3-wayvalves,showingthe"FLOW"and"FLUSH"
positions.
Page5

TESTINGFORPROPERPERFORMANCE
YourCopperCricketisworkingwellif the thermometerontheYELLOWsideofthewaterloop
(abovetheSolarPad)readsatleast80°Fonanysunnyorlightlyovercastday.Itwillread120°Formore
onhotdayswithstrongsun.Checkthistemperatureoccasionallyonsunnydaysbetween11a.m.and2
p.m.justtoassureyourselfthattheCopperCricketis"chirping".Recordyourreadingsonpage13.See
Figure2 forcolorcodes.
IftheYELLOWtemperatureislessthan80°Fona sunnyday,besurethetwo3-wayvalves arein
theirFLOWpositions.SeeFigure4 forFLOWandFLUSHpositions.
IfthereisanydoubtwhethertheCopperCricketisrunningwell,placethethermometeralternately
intheRED,BLUE,andYELLOWthermometerwellsontheSolarPad.Waitabouta minuteafteryou
insertthethermometerintoitswell,thenrecordthereadingonpage13.SubtracttheBLUEtemperature
fromthe RED temperature.Thedifferenceshouldbelessthan50°Fundernormalsunaroundnoon.Ifthe
differenceismorethan50°F,callyourCertifiedInstallerandtellher/himthereadingsandsunconditions;
orcallSageAdvanceCorporation(503)485-1947.
IftheCopperCricketisworkingfine (RED-BLUEtemperaturedifferenceislessthan50°F)butthe
YELLOWtemperatureisbelowtheBLUE,itmaybetimetoflushtheSolarPad.Seethemaintenance
instructionsonthenextpages.
Intheeventthatthesolarloopshouldstopfunctioning(improperinstallation,leakinthesolar
loop,etc.)a fusible pluginsidethecollectorwillmeltifthecollectortemperaturereaches283°F(139°C).
Whentheplugmeltsthesolarliquidisreleasedwithabout60psipressure.Youmayheara "whoosh"
lastinga fewminutes,seesteamemittingfromaroundthecollector'shood,orseesolarliquiddraining
fromthecollector.Thereleaseofsteamandliquidisharmless.Itspurposeistoreleasepressureina
malfunctioningsystem.Theliquidwillnot damageanyroofingmaterial.Ifyouseeorhearanyofthe
above,callyourinstallerorSageAdvanceCorporation.
Ifyouwishtotestfurtherforproperperformance,refertotheinstallationsectionofthismanual,
"6.0TestingforProperPerformance,"whichprobesmuchdeeperintotheCricket'soperation.

GENERALMAINTENANCE
DOWHAT? WHEN?
CleanGlass Spring,Fall
FlushSolarPadandStorageTank Atleastonceperyear
Cleaningtheglass
RainwaterusuallycleanstheCopperCricketDuringdryspells,rinsedustfrom theglass(inthe
lateeveningorearlymorningtoavoidstrainontheglass)bysprayingtheglasswithwater,orbywashing
withmilddetergentfollowedbya rinse.Repairdamagetopipeortankinsulationasnecessary.
SOLARPADANDTANKMAINTENANCE
TheSolarPadheatexchangerhastwoliquidpipes,thesolarlooppipeandthewaterlooppipe.
Thesolarlooppipedoesnotrequiremaintenancebecauseitcontainsonlyinertliquidsina vacuum.The
waterloop,ontheotherhand,containsdomesticwater,whichisusuallysaturatedwith
airandmaycontainfoulingminerals.Minerals whichbuilduponthewallsofthewaterloop
(calciumcarbonate,ironrust,sulfates,andsulfides)reduce theSolarPad'seffectivenessbyreducingheat
transfer from onepipetotheother.Sand,silt,rustandothersedimentsmaydepositinthepipes.These
depositssloworstopthethermosiphonflowthroughthewaterloop,causingthesolar
looptooverheat,blowthefuseplug,andshutdownthesystem.Ifthelocaldomestic
waterispronetofouling,theSolarPadmustbecleanedperiodically.Onceeveryyearis
enoughfornormalwater,butyoumayhavetoflushmoreoftenifyourwaterhasa highmineralcontent.
Yourlocalwatertreatmentspecialist (for exampleBruner,Culligan,Lindsay-Ecowater,or Watersoft) can
tellyouifyourwaterispronetofouling.
Werecommendthat6 monthsafteryourinstallationthatyouflushyourSolarPad
andTankasoutlinedinthenextsection.Asa resultofwhatyoucollectinthebucketyoucan
judgehowoftenyoushouldflushyoursystem.
Page7

SolarpadandTankflush
Sediment isflushedfrom theSolarPadandfrom thebottomofthetankwheneveryoufollowthese
instructions.RefertoFigures2 and4.
A.Removethehosecapfrom,andconnecta hosetotheYELLOW3-wayvalve#2.Directthe
hoseintoa cleanbuckettoseewhatcomesoutof the tankandSolarPad.
B.TurntheYELLOW3-wayvalve(#2)toitsFLUSHpositionandholdthehosetightlytokeepit
from whippingaboutThisforceswaterfrom thetankthroughtheSolarPadandoutthrough
thehose.ItalsoflushesthebottomofthetankAfteryouhavecollectedyourwatersamplein
thebucket flush, untilthewaterisclear.
C.ReturntheYELLOW3-wayvalve#2toitsFLOWposition,removeanddrainthehose,and
replacethehosecap.
D.Recordyourobservationsonpage14.
DE-SCALINGFLUSH.
Ifthewaterflushdoesnotremovethescale,werecommendflushingwitha commercialde-scaling
solution.Becausewateracidityandfoulingmineralsvaryfromplacetoplace,youshouldconsulta water
treatmentspecialist(forexampleBruner,Culligan,Lindsay-Ecowater,or Watersoft). Theycan
recommenda de-scalerandtellyouwhetheryourwaterneedstreatment.RefertoFigures2 and4.
A.Ifthesunisshiningstrongly,eithercoverthecollectororwaituntileveningtoavoidboiling
thede-scaler,possiblycausingsevereburns.
B.Removethehosecapfrom,andconnecta hosetotheGREEN3-wayvalve#3ontheSolar
Pad.Directthehoseintoa sewerdrain.
C.TurnboththeYELLOWandtheGREEN3-wayvalves#2and#3totheirFLUSHpositions.
D.RemovethehosecapfromtheYELLOW3-wayvalve#2onthesolarstoragetank.This
allowsairinsotheSolarPadcandrain.Waituntilwaterstopsdrainingfrom thehose.
E.LifttheopenendofthedrainhoseabovetheleveloftheYELLOW3-wayvalve#2.Usea
funneltopourde-scalerintothehose,filling theSolarPaduntilde-scalerflowsfromthehose
fittingontheYELLOW3-wayvalve#2.Keepa canorbucketundertheYELLOW3-way
valve#2toavoida mess.
F.KeeptheopenendofthedrainhoseabovetheleveloftheYELLOW3-wayvalve#2tokeep
thede-scalerinthewaterconduitforaslongasisrecommendedinthede-scalerinstructions.
Page8

G.Lowertheopenendof the drainhoseandplaceitina sewerdrainorthechemicals
recommendeddisposalmethod.PlacethehosecapontheYELLOW3-wayvalve#2.
H.TurnthehandleontheYELLOW3-wayvalve#2toitsFLOWposition.Thisforceshotwater
fromthetankthroughtheSolarPad,flushingthede-scalerout throughthehose.Hushuntil
thewaterisclear.
I.TurnthehandleontheGREEN3-wayvalve#3toitsFLOWposition,removethedrainhose,
andreplacebothhosecaps.
J.Uncoverthecollector.
Keepa record
Recordflushdates andwhatcameoutReadandrecordtemperaturesatleastoncea year.Use
theformsonpages13and14fora convenienthistoricalrecord.Havetherecordpage,aswellasthe
"SystemInformationSheet",page1,availableifyoucallyourinstallerorSageAdvanceCorporation.
RE-ROOFING
Ifyoure-roofandwanttohandletheremovalandre-installationoftheCopperCricketyourself,
see'7.0Re-Roofing"intheinstallationsection.Ifnot,callyourinstallerorSageAdvanceCorporation.
ABSENCEFROMHOME
Winter:
Ifyouareabsentforseveraldaysinthewinter,noharmwillcometoyourCopperCricket
providingyoudonot drainyourwatersystem.Ifyoumustdrainyourwatersystemtoavoidfreezingof
thewaterpipes,coverthecollectorwitha tarporcanvascover.Securethecoveragainsthighwind.The
CopperCricketsystemisfieezeproofandwillstartupwhenyouturnonthewateranduncoverthe
collector,inthatorder.
Summer:
Ifyouareabsentforthreeormoredaysinthesummerandyouliveina climatewheresummer
daytimetemperaturesexceed~90°F,thereisrisk ofoverheatingyourstoragetankandreleasinghot water
throughthetemperature-pressurereliefvalve(T-Pvalve).Werecommendthatyoucoveryourcollector
witha tarporcanvas,fastenedsecurelyincaseofhighwind.OR,installanoverheatprotection(OHP)
valvewhichreleaseshot waterfromthetankbeforeitcanoverheat.TheOHPvalveisdesignedtoopen
andclosesafelythousandsof times. ItisavailablefromSageAdvanceCorporation.
Page9

SOLARACCESS
Somecitiesandcountieshavespeciallawsprotectingyourrighttothesunlightwhichilluminates
yourhomeandsolardevices.Checkwithyourlocalbuildingorplanningdepartmenttoseeifyouhave
rightsundersuchlaws. SAFETY
EMERGENCYSHUTDOWNPROCEDURES:
A.LeakIntheSolarPadheatexchanger:
(1)IsolatetheCopperCricketsystemfrom thedomesticwatersystembymovingthe3-way
Valves#2and#3totheirflush positions.SeeFigures2 and4.
(2)Thencoverthecollectortokeepitfrom overheatingandmeltingthefuseplug.
(3)CallyourinstallerorSageAdvance'sCustomerService(503)485-1947.
B.Leakinthesolarstoragetank.Ifyourtankhasnoisolationvalves.
SeeFigures2 and5.
(1)Shutoffthewateratthecoldwaterinletvalve#1.Ifwatercontinuestorun,shutitoffatthe
watermeter.
(2)Usea wrenchtodisconnectbothflexesfrom thestoragetank.
(3)Coupletheflexesusingthebrassnippleattachedtothewaterline;use2 wrenchestotighten.
(4)Turnthewateronatvalve#1,andatthewatermeterifthatvalvewas shut.
(5)Coverthecollector.Replacethetank.
C.Leakinthesolarstoragetank.Ifyourtankhasisolationvalves.
SeeFigures3.
(1)Shutoffthevalves #7and#8.
(2)Turnonvalve#6.
(3)Coverthecollector.Replacethetank.
D.Leakintheauxiliarytankorthewaterconduitsconnectingthetanktothehouse
watersystem.
YoucanonlystoptheleakbyCLOSINGTHECOLDWATERSHUT-OFFVALVE#1(SEEFIGURE2).
Ifwatercontinuestorun,shutitoffatthewatermeter.Immediatelyturnofftheelectricityorgastothe
auxiliarytank.Coverthecollector.Repairpipesorreplacethetank.
E.Ifindoubt,calla plumberorSageAdvance'sCustomerService(503)485-1947.
Page10

FIGURE5.Isolationofthesolarstoragetankusingthebrassnipple.
SeeSAFETY,EMERGENCYSHUTDOWNPROCEDUREB.
Beforeisolation ToIsolateYour
SolarStorage
Tank:
1)Shutoffthe
wateratthecold
waterinletvalve.
2)Usetwo
wrenchesto
disconnectboth
flexesfromthe
storagetank.
3)Couplethe
flexesusingthe
brassnipple,which
iswiredtothecold
waterpipejust
abovethetank.
Usetwowrenches
totighten.
4)Turnthewater
onatthecold
waterinletvalve.
Page11

IMPORTANTNOTES
Donotopenthesealedplugsortheaccessvalveonthesolarloop.Severesteamburns
couldresult.
Thesolarloopcontainsraethanol-water solutionwhichisextremelyhotwhentheCopperCricket
isoperating.Yourinstallerhassealedthesolarloopandremovedtheair.Undernormaloperating
conditionsthesolutionwillnotrequireanymaintenance.Ifmaintenanceisneeded,callyourinstalleror
SageAdvanceCorporation(503)485-1947.
Takeprecautionsnottodrill,saw,orpuncturethecopperpipesofthesolarloop.
WhendoingrepairormaintenanceonanyothersystemnearthesolarloopoftheCopperCricket
SEVERESTEAMBURNSCOULDRESULT.
Hotwatercaninjurechildrenandpets,orkillgardenplantsandgrassifdirected
outside.
TakeprecautionsifyoumustdirecthotwateroutsidewhileflushingtheSolarPadandtank.
Page12

TEMPERATURERECORD
<TEMPERATURES> SUN
DATETIMERedBlueRed-BlueYellowTank(bright,hazy,overcast)
Page13

ANNUALHEATEXCHANGERMAINTENANCERECORD
(seepage7)
DATEOBSERVATION:(WHAT'SIN THEFLUSHWATER?!)
Page14