TYCHON ER3 User manual

TYCHON LLC.
1511 Ave. Ponce de León Bldg.
1300Apt ,1341 Ciudadela, San Juan,
00909,Puerto Rico
Phone:[phone]
[email protected]
Installation Manual
ER3 Solar Water Heater System
Document: ER3-HP300-210708

ENERGY STAR CERTIFIED
Water Heaters
ER3 - ER3 : FPS/HP 300
Specifications
ENERGY STAR Partner: Tychon LLC
Brand Name: ER3
Model Name: ER3
Model Number: FPS/HP 300
Type: Solar with Electric Backup
Solar System Type: Direct Thermosyphon
Solar Collector Type: Flat Plate
Solar Collector Panel Area (sq feet): 43
Solar Uniform Energy Factor (SUEF): 5.4
Freeze Tolerance Limit (F): 39
Solar Tank Volume (gallons): 80
Solar Auxiliary Tank Volume (gallons): 0
Solar Type of Backup: Tank
Date Certified: 2021-08-13
Markets: United States, Canada
ENERGY STAR Certified: Yes
Additional Model Information
Captured On:
08/23/2021
1

Contents:
OWNERS INFORMATION 3
What is an Open Loop System? 3
What is a Close Coupled System? 3
What is a Thermosiphon System? 3
How does my system work? 3
Auxiliary Electric Support System 3
INSTALLATION INSTRUCTIONS 4
Mounting and Connection Kits 4
Mounting Location 4
System Capacities 5
System Shape Parameters 5
Collector Technical Parameters 5
System Parts Numbers 5
The ways of pipeline to install through the roof 6
Mounting Methods 6
Building Penetrations 7
Mounting Notes 7
Mounting the Collector 8
Mounting the Thermosiphon Tank 8
Plumbing Connections 9
ELECTRIC (ER3) INSTALLATION INSTRUCTIONS 9
COMMISSIONING 9
Customer Hand Over 9
OPERATING INSTRUCTIONS 10
How do I operate the system? 10
Words of Caution 10
What should I do during holidays? 10
Why is there water discharge for the pressure valve? 10
What should I check before making a service call? 10
Solar collector shading 10
Electric (ER3) System not operating 10
Is there excessive water discharge for the Valves? 10
Are you using more hot water than you think? 10
Common Troubleshooting 11
MAINTENANCE 12
System Maintenance 12
Fluid Quality 12
System Check List 12
Estimated Component Life 12
Hazards 13
Fluid Safety Labeling 13
Warranties and Disclaimers 14
Returns Policy 15
System Schematic Drawings 16
Installation Record 17
2

Owners Information
As the owner of an ER3 solar water heater there are some questions you may have about the system and how it
operates. The solar collector(s) provided with our ER3 system has been certified for performance by the SRCC.
Our solar water heater model is commonly referred to as a roof mounted, open loop, close coupled, Thermosiphon
system and is one of the most efficient solar water heater types available worldwide.
“The solar energy system described by this manual, when properly installed and maintained, meets the
minimum standards established by the SRCC. This certification does not imply endorsement or warranty of
this product by SRCC."
What is an Open Loop System?
An Open Loop System is a system where the water used in the household (hot water) circulates through the solar
collector panels transferring solar energy into the storage tank. This system type is used in locations where the
ambient temperature never falls below freezing point (32°F) and where the water quality is good – less than 600 ppm
Total Dissolved Solids (TDS).
“Freeze tolerance limits are based upon an assumed set of environmental conditions.”
What is a Close Coupled System?
A close coupled system is one where the household hot water storage tank and solar collectors are both mounted on
the roof. Typically the tank is above but in close proximity to the collectors. The tank and collectors are connected
together with ¾” copper tube, which is used to transfer heated water from the collectors to the storage tank.
What is a Thermosiphon System?
A Thermosiphon system is a system where the heated water in the solar collectors rises up into the storage tank by
natural Thermosiphon action. Thermosiphon action occurs when water which is heated in the collectors expands
becoming lighter allowing colder heavier water to fall by gravitational force to the bottom of the collector. The cold
water falling to the bottom of the collector pushes the hotter lighter water back up into the storage tank. This natural
action commonly known as Thermosiphon action occurs without any moving parts or auxiliary electrical energy input
to the system.
How does my system work?
ER3 Thermosiphon Systems are pre-engineered systems. Proper system selection should be performed by an
experienced solar professional. A properly sized system will operate free of user intervention and minimize action of
the safety valves.
Under normal operating conditions, water in the thermosiphon tank is heated by the thermosiphon process as
described above. In the residence, water is supplied to the fixtures directly from the thermosiphon tank.
Plumbing materials in this system are to be constructed of copper, brass, bronze or stainless steel and designed to
meet or exceed the expected design temperature and pressure ratings of the system. The thermosiphon tank is used
to store the heated water ready for household use. It is constructed using high quality stainless steel to provide long
life and is insulated with a high density polyurethane material to ensure minimal heat losses and maximized structural
strength. The solar collectors contain a multi-tube copper water way system welded to a solar absorber plate, the
combination of which collects solar energy and transfers it to the fluid within the collector loop. The absorber plate
system is enclosed in an insulated metal casing covered with a high strength tempered glass sheet that protects the
absorber system from physical damage.
Auxiliary Electric Support System
In the places where needed, an Auxiliary Electric Support system will be provided. An electric heating element is
automatically controlled by an internal thermostat and only allowed to operate if the storage tank water temperature
falls below 120°F and will even then, only consume electricity until the water temperature is increased to 165°F then
turns off again.
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INSTALLATION INSTRUCTIONS
Important Note:
Do not commence an installation until all Occupational Health and Safety issues associated with working on
and lifting components onto a roof have been addressed. All work associated with the installation must
comply with local authority regulations. Where these installation instructions and local regulations are in
conflict, local regulations must prevail.
Mounting and Connection Kits
The mounting procedures to follow will provide a secure method for maintaining proper tilt and collector orientation.
There are two parts kits supplied with your Thermosiphon system; a mounting kit containing four flush-mount
mounting clips with stainless steel locking bolts and a connection kit containing the parts required to plumb the
system. The mounting kit does not include the fasteners required to secure the system to the roof structure. With the
exception of the copper tube the connection kit contains all of the plumbing components required to connect the solar
collector to the roof-mounted thermosiphon tank.
Mounting Location
There are five major factors to consider when selecting the solar water heater installation location;
1. For optimum performance the solar collectors need to face the equator (in Southern hemisphere this is north
and in the Northern hemisphere this is South). Installation on angles of up to 45° away from the equator do
not have a major effect on the annual solar output, consequently roof locations which face less than 45°
away from the equator are acceptable. If the collectors are installed with an east facing bias the best solar
input is achieved in the morning and if there is a west facing bias the best solar input is in the afternoon.
2. Careful site inspection is required to ensure the selected location is not subjected to shading from adjacent
trees or buildings throughout the day but particularly between 9am and 3pm the highest solar input times.
Shadows are longer in winter than in summer so a site that is free of shadows from adjacent objects in
summer may have some shadows in winter.
3. The solar water heater is to be located a minimum of 3 foot up from the roofs lower edge, 3 foot in from
either side of the roof, and 3 foot down from the roofs ridge line and should be located as close as possible
to the location which uses the most hot water e.g. bathroom or kitchen. This is to reduce energy losses
which may occur if the pipe work between the solar water heater and the point of usage is too long.
4. To achieve optimum performance the solar water heater should be installed on a roof pitch of greater than
8° and less than 30°. Installations on a roof where the roof pitch is greater than 30° will require additional
support at the storage tank to prevent it moving downward after installation. If the roof pitch is less than 8°
the system will require a mounting frame to increase the pitch above 8°. Installations below 8° do not
thermosiphon effectively and the collector glass will not self clean during rainy periods.
5. Careful inspection of the roof truss system is essential to ensure it can support the systems weight once
filled with water. Particular care must be taken where the front foot of the storage tank is located. Typically
the tank front foot should be located over a tile batten, purlin or similar for maximum strength. If the roof can
not support the load additional bracing must be installed before the solar water heater is installed.
4

System Capacities
Model No.
Collector(s)
Collector Dry
Weight (lbs)
Tank
Tank Dry
Weight (lbs)
Total Dry
Weight (lbs)
Approx Wet
Weight (lbs)
FPS/HP 300
PG/2.0-80
60
HP300
62
134
795
System Shape Parameters
Model
L（mm）
D1(mm)
D2(mm)
A(mm)
B(mm)
H(mm)
Installation
Angle
FPS/H P300
1775
480
570
1600
1750
1700
20º
Collector Technical Parameters
Model
Absorber
Area (m²)
Tank
Capacity(L)
Rated
Pressure(Mpa)
Collector Size
(mm)
Collector
QTY(pcs)
Total net weight
(lbs)
PG/2.0-80
4
300
0.6
2000*1000*80
2
320
System Parts Numbers
ER3 P/N
Description
T300-C
ER3 Solar collector(s) two pieces ,PG/2.0-80
T300-T
ER3 Solar storage tank: HP300
T300-D
Tank drain, drain valve, DR-3/4”
T300-TP
Temperature and Pressure Relief Value, Way-20
T300-B
Magnesium bar, 3/4”, length:18cm
T300-M
Thermostatic Mixing Valve DN20M (optional)
T300-TH
Thermostat, TP2-07505 (optional )
T300-H
Electric Heating Element (optional) 220V/1500W
5

The ways of pipeline to install through the roof
Flat roof Sloping roof
Piping shaft
Safety and relief valve discharge pipes shall be of rigid pipe that is approved for the temperature of the system. The discharge
pipe shall be the same diameter as the safety or relief valve outlet. Safety and relief valves shall not discharge so as to be a hazard,
a potential cause of damage or otherwise a nuisance. Where a solar thermal system component requiring a relief valve is located
outside the structure, the termination shall be not more than 6 inches (152 mm) above a splash block, a secured surface material
or catchment method to prevent damage.
Mounting Methods
There are 3 methods of attaching the system to the roof structure; lag-bolts, J-bolts or spanner mounting.
NOTE: All mounting bolts, washers, split-lock washers & nuts are to be stainless steel.
Lag-Bolts – Lag-bolt mounting is the preferred method
of install. The mounting clips are secured directly intothe
upper chord of the roof truss (the detail below shows an
install using a triangular mount bracket). The lag-bolt
must penetrate 3” into the structural member. A 2” deep
pilot hole must be drilled into the truss with a 1/8”
diameter bit before inserting the lag bolt.
Lag-bolt Mounting Detail
6

J-Bolts – J-bolt mounting is preferred in
installations where the roof truss members are not
easily identified from the outside of the roof.
Clearance holes for the J-bolts are typically drilled
from inside the attic space. Two install service
personnel are typically required, one in the attic
space and one on the roof, when installing J-bolts to
insure the J-bolt is secured properly.
J-bolt Mounting Detail
Spanner mounting – Spanner mounting is by far
the most common method of installation. Steel
angle or wood 2” x 4”’s are used to span between
the truss members. Two spacer blocks are required
when the threaded rod is 2” or more from the truss
member. Only one spacer block is required when
the threaded rod is within 1” of the truss. Spacer
blocks are to be no greater than 1” from the
threaded rod.
Spanner Mounting Detail
Building Penetrations
Building penetrations must be made in accordance with the National Roofing Contractors Association or the local
Authority Having Jurisdiction. Penetrations shall be sealed properly and designed to prevent the intrusion of vermin.
Penetrations shall not compromise the structural design of the building enclosure or framework. Penetrations through
fire-rated assemblies shall not reduce the fire resistance below code. Solar components placed near or adjacent to
building materials shall be isolated to prevent elevated temperatures which could result in a fire hazard.
Mounting Notes
Installation must comply with the building code, plumbing code, mechanical code, and fire code adopted by the authority
having jurisdiction or, in the absence of such codes, with the International Building Code, International Plumbing Code, International
Mechanical Code, and International Fire Code.
7

Mounting the Collector
The collector installation procedure is as follows:
1. From the inside of the roof, in the attic crawl space, measure the center-to-center distance between the
roof trusses. This distance is required to secure the mount clips to the collector prior to attaching the
collector to the roof structure.
2. Position two (2) mount clips along each end of the collector a distance apart equal to the center-to-
center roof truss spacing. Insure the mounts are centered across the collector ends and secure them
with the locking bolts (multiple collector installations will require the mount clips to be slightly off center,
this allows for the spacing between collectors).
3. Place the collector on the roof in the area selected for install.
4. Starting in the upper left-hand quadrant of the selected install area, locate the position of the nearest
roof truss. Measure down from the peak of the roof, a distance of 60” and make a mark on the roof tile.
This will be the position of the top left mounting hole of the collector mount clip.
5. Use roofing mastic or roof flashing caulk to coat the underside of a roof mount flashing. Place the
flashing into position centered over the proposed mounting hole, insuring that the top of the flashing is
under the upper roof tiles and the bottom of the flashing laps over the lower roof tiles. Secure the
flashing using a couple of roofing nails under the upper roof tiles.
6. Drill an appropriately sized hole into the roofing structure.
7. Place the collector into position with the upper-left mounting foot centered over the newly drilled hole
and align the collector to be square with the roof.
8. Using the installed mount clips as a template, mark the position of the remaining mount holes on the
roof tiles then set the collector aside.
9. Secure flashings and drill holes for the remaining mount clips.
10. Using the roof flashing caulk or roofing mastic, apply a liberal amount of sealant around the openings to
all of the newly drilled holes then place the collector into position and secure using the stainless steel
hardware selected for the install method.
11. Check to insure that all mount connections are tight and prepare to mount the tank.
Mounting the Thermosiphon Tank
The procedure for mounting the Thermosiphon tank is asfollows:
1. Position the Thermosiphon tank into place above and centered to the collector. Line up the mounting holes
(on the tank mount rail closest to the collector) centered on the marked chalk line. Mark the position of the
mount holes and set the tank aside.
2. As with the collectors, secure flashings and drill holes for each of the mount locations. Apply a liberal
amount of sealant around the newly drilled holes.
3. Position the tank into place over the mount holes and secure using the appropriate stainless steelhardware.
4. Check to insure that all mount connections are tight. Apply a liberal amount of sealant over all of the mount
hardware heads/threads (tank and collectors).
The storage tank is equipped with a temperature and pressure relief valve to handle over-temperature and/or over-
pressure conditions. By default, temperature relief occurs at 210°F and pressure relief at 150 psi. .
8

Plumbing Connections
Assemble the hot/cold interface plumbing to the collector as shown in the detail on page 5. Various lengths of ¾”
copper tubing is required and should be soldered together using lead-free solder. Service connections to the
Thermosiphon system should include isolation, mixing and drain valves (provided by installer) internal to the
residence. All hot water pipe and cold water pipe should be insulated and coated or covered to protect from UV
radiation and moisture where exposed to sunlight. Refer to the insulation manufacturer’s installation instructions for
approved methods.
“All components shall be accessible for maintenance and servicing. Components exposed to public traffic
are to be maintained below 140°F or insulated / isolated. The location of components should not impair
accessibility needed to maintain the building or site.”
Drain Valves shall be installed at readily accessible locations as to allow for filling, draining and flushing the solar
system. Ensure that the drain line from the Temperature and Pressure relief is plumbed to a safe location.
Remember this pipe can discharge very hot water carefully consider its location. In-roof piping hangers shall provide
adequate support and correct pitch of pipes. All pipe work connecting the Thermosiphon system to the ER3 system
should be sloped toward drain ports with a drainage slope of no less than 2cm vertical drop for each meter of
horizontal length (1/4” per ft) to allow for gravity draining of the Thermosiphon system. Supports for insulated pipes
should avoid compressing or damaging the insulation material.
For ER3 tanks requiring electricity, an electrician is required to install a domestic electrical outlet socket adjacent the
auxiliary water heater location. The auxiliary electric heating element typically requires a 220-240 volt 60 Hz 1500w
power supply. Be sure to check the electric heating element specification prior to the installation of the electrical
circuit.
NOTE: Use only lead-free solder. Use of 50/50 lead solder is expressly prohibited. Use of galvanized steel, CPVC,
PVC, PEX or any other type of plastic pipe is prohibited. Service connections to the Thermosiphon tank are to be
made using dielectric nipples. WARNING: Dielectric unions are expressly prohibited in these system installations.
ELECTRIC (ER3) INSTALLATION INSTRUCTIONS
Note:
1. All electrical work must comply with local regulations
2. All electrical work must be conducted by a suitability licensed electrician.
3. Installation of the Electric Heating Element must be installed in accordance with the Installation
supplied with the Electric Heating Element.
4. Overload or over-current protection of electrically operated components shall be consistent with
the maximum current rating of the device and with the provisions of article 240, Chapter 2 of the
National Electrical Code
Important
Do not turn on the power supply until the water heater has been filled with water and pressurized.
Commissioning
When all connections have been completed the solar water heater can be filled with water. Before turning on the cold
water supply open one hot tap within the household to release air from the system during the filling process. Do not
leave the open tap unattended during the filling process.
Turn on the cold water supply and wait for the system to fill. When water flows without air bursts from the open hot
tap it can be closed which will pressurize the solar water heater system. Once the system is pressurized all
connections on the water heater must be checked for leaks and repaired if necessary.
When the system is proven water tight, power can be applied to the ER3 system. To test that the element is
operational turn the circuit breaker in the switch board on and off, you should see the power meters speed change
during this action. The solar water heater is now fully operational.
Customer Hand Over
Once the solar water heater is commissioned and you are confident it is operating correctly, complete the installation
details in the Owners Instructions section of this manual .
Before leaving the installation, insure that the customer is fully aware of the systems operation and whom to contact
should there be any questions in the future.
9