Direct Connect 30. SRCC OG-300 Certified Solar Water Heater System Installation, Operation and Maintenance Manual. 1 P a g e V e r s i o n 2.

Direct Connect 30 SRCC OG-300 Certified Solar Water Heater System Installation, Operation and Maintenance Manual 1 P a g e V e r s i o n 2. 0

DIRECT CONNECT 30 DOMESTIC SOLAR WATER HEATING SYSTEM INSTALLATION, OPERATION AND MAINTENANCE MANUAL The Direct Connect 30 solar water heating system has gone through an extensive technical and performance review by the Solar Rating & Certification Corporation (SRCC). The installation of Direct Connect 30 system is to be performed by properly licensed and experienced professional contractors in accordance with SRCC Standard OG-300, Operating Guidelines and Minimum Standards For Certifying Solar Water Heating, and must conform to applicable federal, state and local regulations, codes, ordinances and standards governing the installation of solar water heating systems. 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 the SRCC. OG-300 system certification for the Direct Connect 30 system is granted to Sunvelope Solar Inc. by the SRCC. It may not be used for any commercial purpose without the prior written consent of Sunvelope. Sunvelope must approve any deviation from the specified materials and methods described in this manual in writing in order not to void components manufacturer warranties. The inherent Envelope design of the patented collector used in the Direct Connect 30 solar water heating system protects system against freeze damage to temperatures as low as -40ºF (-40ºC). This system should not be installed in areas where the annual ambient temperature has ever fallen below -40 Fahrenheit (-40 Celsius). 2 P a g e V e r s i o n 2. 0

This product certified by: Solar Rating & Certification Corporation www.solar-rating.org Sunvelope Solar. 96 Glen Carran Cir. #105 Sparks, NV 89431 USA Solar Energy Factor SRCC Cert. No. Model No. (SEFD) 1.99 30004157 DIRECT CONNECT 30 The installed system is marked above 3 P a g e V e r s i o n 2. 0

TABLE OF CONTENTS Safety Information A. Introduction B. System Description and Operation C. General Installation Requirements D. System Installation Requirements E. System Start Up Procedures F. System Operation G. Shut Down Procedures H. Summer Vacation Procedures I. Maintenance and Troubleshooting J. Direct Connect 30 System Component Parts K. System Operating Parameters Appendix A. OG-300 Approved Primary Components Appendix B. Direct Connect 30 OG-300 Labels Appendix C. Sunvelope Solar Collector Product Warranty 4 P a g e V e r s i o n 2. 0

IMPORTANT SAFETY INFORMATION READ ALL INSTRUCTIONS BEFORE USING. DANGER - WATER TEMPERATURE SETTING Water temperatures above 125 F can cause severe burns or death from scalding. Maximum water temperatures occur just after the heating element(s) has shut off. To find hot water temperature being delivered, turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer. The following chart may be used as a guide in determining the proper water temperature for your home. TIME/TEMPERATURE RELATIONSHIPS IN SCALDS TEMPERATURE TIME 125 F 1/2 to 2 minutes 130 F About 30 seconds 135 F About 10 seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 1/2 seconds 155 F About 1 second The temperature of the water in the heater can be regulated by setting the temperature dial on front of the mixing valve or thermostat. There is a Hot Water SCALD Potential if the mixing vale or thermostat s temperature is set too high. WARNING 5 P a g e V e r s i o n 2. 0

For your safety, the information in this manual must be followed to minimize the risk of fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of life. Be sure to read and understand the entire Installation, Operation and Maintenance Manual before attempting to install or operate this solar water heating system. Pay particular attention to the Safety Instructions. Failure to follow these warnings could result in serious bodily injury or death. Should you have problems understanding the instructions in this manual, or have any questions, STOP, and get help from a qualified service technician. FOR INSTALLATIONS IN THE STATE OF CALIFORNIA California Law requires that residential water heaters must be braced, anchored or strapped to resist falling or horizontal displacement due to earthquake motions. For residential water heaters up to 52 gallon capacity, a brochure with generic earthquake bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater dealer. However, applicable local codes shall govern installation. For residential water heaters of a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable bracing procedures. SAFETY PRECAUTIONS Have the installer show you the location of the circuit breaker and how to shut it off if necessary. Turn off the circuit breaker if the water heater has been subjected to overheating, fire, flood, physical damage or if the ECO fails to shut off. Read this manual entirely before installing or operating the water heater. Use this appliance only for its intended purpose as described in this Installation, Operations and Maintenance Manual Be sure your appliance is properly installed in accordance with local codes and the provided installation instructions. Do not attempt to repair or replace any part of your water heater unless it is specifically recommended in this manual. All other servicing should be referred to your installing contractor or Sunvelope Solar Inc. READ AND FOLLOW THIS SAFETY INFORMATION CAREFULLY. SAVE THESE INSTRUCTIONS 6 P a g e V e r s i o n 2. 0

A. INTRODUCTION Solar water heating systems are climate and site specific appliances. Different types of solar systems are installed in accordance with regional weather and water quality conditions. System performance varies as a function of the household hot water load, including daily showers, laundry and kitchen uses, the average ground water and ambient air temperatures, the home s roof pitch and orientation, and, of course, the seasonal intensity of solar radiation. These variables, some of which change from home to home on the same neighborhood street, will determine how much energy the Sunvelope Direct Connect 30 system will generate each year of operation. The Direct Connect 30 solar water heating system is an Active Open Loop System system meaning that water flows directly through the hot water solar collector, using a DC pump powered by a solar panel to circulate water in the system. This manual provides a basic solar water heating primer. Our goal is to familiarize you with the proper installation, operation, and maintenance of your Direct Connect 30 solar water heating system. This system is required to be installed by properly licensed solar or plumbing contractors in accordance with SRCC Standard OG-300 and all applicable national, state and local codes, ordinances and regulations governing solar installations as well as good trade practices. Failure to follow the procedures and practices described in this manual may void manufacturer warranties for specific component parts. This manual covers installations utilizing one Sunvelope Solar collector with a single 50-gallon electric water heater tank. Frequent reference will be made throughout this manual to specific component parts. The placement of each component in the system is depicted in Figure 1. B. SYSTEM DESCRIPTION AND OPERATION The Sunvelope Direct Connect 30 solar hot water system is designed with many unique features, safeguards and controls. Figure (1) is a basic schematic drawing showing the general location of these features, showing an active open loop configuration. Potable water is the only approved heat transfer fluid that can be utilized in the Direct Connect 30 system. The key components in the Direct Connect 30 solar water heating system include the patented FPE-30 Sunvelope solar collector, Sunvelope Pump Station which includes a circulation pump, a 10 watt PV panel to power circulating pump and a High Temperature Limit (HTL) switch. The electric hot water tank, expansion tank and mixing valve may be supplied as part of the system or supplied separately. FIGURE 1 SYSTEM SCHEMATIC 7 P a g e Collector V e r s i o n 2. 0 PV Panel

HTL Switch Expansion Tank Mixing Valve Pump Station Return into T&P Tank Supply from Boiler Drain Figure 1 System Schematic The simple and elegant design of the patented Sunvelope FPE-30 collector makes it possible to install open loop systems in hard freeze areas. The Sunvelope FPE-30 s freeze resistance has been tested in accordance with ISO 9806:2013. The FPE-30, in conjunction with the recommended PEX tubing, corrugated stainless tubing and recommended connections, enables a system that will not be damaged by freezing or static flow conditions. The Sunvelope FPE-30 collector is 3 X 10 and features a patented envelope type absorber plate in which the water inside the envelope is in direct contact with the entire internal surface. This allows for very high flow rates while providing an optimal temperature differential across the collector. Additionally, due to the greatly increased surface contact area, when the temperature of the water inside the collector rises, the efficiency of the collector drops and self modulates the high temperature potential as long as the flow is continuous. The Sunvelope FPE-30 collector is fitted with an attached thermistor and High Temperature Limit switch (HTL) which will shut off the PV powered DC pump at the factory preset temperature of 170 F. Because the thermistor is installed on the back of the absorber plate, the high limit will not permit the pump to restart as long as the collector temperature is above 170 degrees F. Corrugated stainless tubing is used for the first 3 feet past the collector outlet on the hot side to protect the PEX from potentially high temperatures. Additionally, a Pressure Relief Valve (PRV) set at 100 PSIG is installed between the corrugated stainless tubing and PEX tubing in the return loop of the collector. This sub assembly is called the TPI (Temperature and Pressure Isolator) and can be seen in figure 2. The NP-60 and NP-70 PEX tubing, as manufactured by NIBCO or equal, is rated for temperatures of 180 degrees F at 100 psi. As an alternative to PEX, stainless steel 304 corrugated tubing manufactured by Falcon Stainless (S12C- 10012EP), can be used as suitable piping in hot climates. 8 P a g e V e r s i o n 2. 0

Figure 2 TPI (Temperature and Pressure Isolator) The standard Pump Station is compact and designed to reduce installation time and complexity. The Pump Station features a DC powered, variable speed pump that is powered by a 10-watt solar PV panel. The pump varies speed according to the available solar insolation thus providing a self-modulating continuous flow which maximizes efficiency in the desirable temperature range while minimizing over temperature potential. The Pump Station also includes a built in Joule digital monitoring system, a check valve (back flow preventer), isolation valves at one end, and isolation/purge valves at the other end. The Joule monitoring system, which includes a flow meter, two built-in temperature sensors, and the AMBR edge router for internet connection, also has the capability of adding temperature and AC current sensors to monitor the water heater tank. NOTE: For areas or customers where internet is not available, analog Pump Station is available with analog read outs. The analog Pump Station comprises a DC pump and check valve, Calleffi flow meter, two temperature wells with dial thermometers, isolation valves, isolation/purge valves and connectors. The Analog Pump Station delivers the same functionality as the standard Pump Station, but does not requiring internet connection. The electric water heater tank requires a mixing valve (tempering valve) for scald protection against high temperature water. The system is designed to be compatible with a standard and readily available 50 gallon electric water heater tanks. C. GENERAL INSTALLATION REQUIREMENTS C.1 Permits: Installing contractor shall obtain all required permits and approvals. 9 P a g e V e r s i o n 2. 0

C.2 Codes, Ordinances and Standards: The installation shall conform to all federal, state and local regulations as well as all codes, ordinances and standards governing the installation of solar water heating systems. The installing contractor shall adhere to sound building safety and trade practices. Special consideration must be given to building code requirements for roof loading and the penetration of structural members and fire rated assemblies. C.3 Shading Considerations: The collectors should be located in an area of the roof that will not be shaded for the majority of the day all year round in order to maximize hot water production. Adjacent buildings and trees should be checked for possible winter shading. In addition, the collector should not be shaded by any permanent obstacle between 9:00 a.m. and 3:00 p.m. on any day of the year in order to maximize hot water production. C.4 Roof and Site Inspection: Before the installation, the contractor shall inspect the condition of the roof and notify the homeowner of any existing roof damage or necessary repairs. C.5 Structural Considerations: The collectors must be located in a structurally sound area of the roof. Penetrations into structural members must not compromise the structural integrity of the structural member. All structural member penetrations must comply with applicable codes. The collector mounting method must be capable of maintaining the required tilt and azimuth of the collector under the expected dead loads, wind loads and snow loads for the location. C.6 Building Envelope: Penetrations through the building envelope (including roof, walls or floor penetrations) must not impair the enclosure function and must meet applicable codes and best practices. Roof penetrations whether for structural mounts or pipe penetrations must be sealed and leak proofed as per applicable codes and National Roofing Contractors Association practices. Building penetrations must not allow vermin intrusion. C.7 Fire-Rated Assemblies: Penetrations through fire-rated components must not reduce the fire resistance of the assembly below code. C.8 Building Materials: Building materials adjacent to solar components must not be exposed to elevated temperatures. C.9 Confirmation of Installation Site: The homeowner and contractor shall confirm the location of all roof and ground mounted components in advance of the installation. 10 P a g e V e r s i o n 2. 0

C.10 Fluid Identity and Toxicity: The Direct Connect 30 system uses potable water as a heat transfer fluid, which is directly heated in the collector. Use of toxic heat transfer fluids is prohibited. C.11 Maintenance and Servicing: When installing the system, make sure that all the components are accessible and easy to reach. Provide for clear access to the electric water heater tank, pump station, and mixing valve. Make connections with PEX connectors or other approved connections. D. SYSTEM INSTALLATION REQUIREMENTS D.1 Collector Orientation and tilt The performance of solar water heating systems in the Northern Hemisphere is optimized when the collector is mounted facing True South. However, performance suffers very little when the collector is oriented no more than 45 East or West of True South. The FPE-30 Collector can be mounted flush or slightly raised and parallel with the roof. It can also be mounted raised to an angle of latitude plus 15 degrees to maximize winter efficiency and minimize over heat potential in summer. If raised to an angle it should always be mounted landscape to reduce wind loads. It can be oriented perpendicular to, parallel to, or at an angle with the slope of a roof to achieve proper Southerly orientation. NOTE: The outlet of the collector must be at the high point of the collector. Collectors are manufactured in two configurations to accommodate installation. Specify which orientation is required when ordering. D.2 Mounting Procedures The collector should be mounted as close to the electric water heater tank as possible to minimize heat loss in the piping runs. Collector shall be mounted in landscape orientation. The PV panel may be mounted on either end or in the middle or even away from the collector as long as the collector and the PV panel share the same orientation and tilt angle. Differences in orientation, tilt angle or shading between the collector and the PV panel will result in sub-optimal performance of the system. NOTE: The collector has a top and bottom. Be sure to mount the side of the collector that has the High Temperature Limit switch (HTL) slot, at the top. Figure 3 Typical Installation 11 P a g e V e r s i o n 2. 0

Be sure to read the plumbing procedure in Section D.3 prior to mounting the collectors. Tilt-Up Mounting Option: For the tilt-up installation option the collector requires a minimum of three legs connected to swivel clips at the collector (as shown below) and bolted to feet connected to the roof. Figure 4 Swivel Clip and Top Bracket The legs are 1.5 square aluminum tube with holes at the bottom which are connected to the channel feet with a 2 long ¼-20 bolt. At the top of the square tube use one of the 10 long aluminum channels over the square tube to adjust the length so the collector is evenly mounted at the proper angle. Slide the channel over the 1.5 square tube, on the end of the square tube without a hole. The back feet can be moved closer or back from the bottom feet to adjust the collector to the desired angle. The square tube legs can also be shortened if necessary. Sunvelope recommends latitude plus 15 degrees from horizontal to maximize hot water production. Once the desired angle is achieved, use self-drilling screws to attach the channel to the leg. Figure 5A Swivel Clip 5B Mounting Foot Three feet connect to swivel clips at the bottom of the collector and attach to the roof. The most important structural consideration is to securely anchor the collector and the Sunvelope mounting hardware to the structural members of the roof with an approved roof attachment method. Roof connections can usually be made at the roof trusses by sliding the connector clips to align correctly. More connectors and legs may be used in high wind or snow load areas. If it is not 12 P a g e V e r s i o n 2. 0

possible to align with trusses you must attach to blocking under the roof sheet. 5/16 lag screws are recommended long enough to allow 2 ½ engagement into roof member. Engineering may be required for lag screw requirements. Consult a Structural Engineer and or building department about loading and local codes and requirements. 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. The collector should 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 ½ of clearance between the roof surface and the bottom of the solar collectors. Local codes may require greater clearance. 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 best roofing practices. Figure 6A Roof Attachment 6B Flush Mount Foot BEST PRACTICE Mounting Snap a line at the location where you want the bottom of the collectors. You must stay 3 above the edge of the roof. Using lag screws, screw 3 of the channel feet to the roof in line with each other to provide the support at the bottom of the collectors. The feet at the ends of the collector should be 6 to 12 from the end of the collector at each end. The middle leg or legs should be as evenly spaced as possible with the two ends. The PV panel may mount as shown in Figure 1 or in any alternative location as long as it shares the exact solar resource. Pre drill and use silicone seal under the feet to seal the lag screws from leaking. Once the front (bottom) feet are mounted, determine the spacing between the feet at the bottom of the collector and the feet at the bottom of the legs. The best way to determine this is to attach the bottom of the collectors to the front feet with the ¼-20 bolts provided. Note: Be sure that the bottom fitting in the back of the collector is connected with a ½ brass 90 fitting on the stub in the back of the collector before mounting the collector. Place one of the 10 channels over the square tube leg with 3 minimum overlap. Then use one of the legs with the 10 end channel at the top of the leg but not attached yet and lift the collector to the desired angle and hold the leg from the top of the collector to the roof. Mark the location of the back foot and snap a line parallel to the bottom of the collector. Screw all the back legs to the roof using silicone seal under the foot to seal the lag screws. Lag screws must penetrate a strut or a blocking. 13 P a g e V e r s i o n 2. 0

Now you can finish mounting the collector. Hold the collector at the desired angle and with the bottom of the square tube held in place with a 1/4-20 bolt, and a top clip in place on the collector frame; you can slide the channel up or down the leg to adjust the angle exactly. Then repeat with the other legs being careful to align the collector top at the same angle on both ends. Make final attachment channel to 1 1/2 inch square tube with self-drilling screws. Flat Mounting Option: Use six "Flat Mount Feet" attached to collector (see figure 5-B) where they can connect to roof trusses. Start 6" to 12" from ends and maintain maximum span of 4' between feet. Plumbing connections can be made underneath the collector but on top of the roof for appearance. D.3 Collector Loop Plumbing The collector loop must be plumbed using ¾ PEX tubing, rated for potable water, and lead free brass, bronze or stainless steel fittings. Use of galvanized steel, CPVC or PVC is prohibited. Pre-insulated ¾ PEX tubing, insulated with ¾ wall closed cell insulation tubing with a R value of 2.6 Btu/hr-ft 2 F or greater, can be supplied by Sunvelope. This optional material is cost effective and significantly reduces installation time. If using PEX, use type PEX rated for potable water. Alternatively, 1/2" corrugated stainless steel coil with 3/4" EPDM insulation and control wire (as manufactured by Falcon Stainless) can be used in lieu of PEX tubing in locations with occasional freeze exposure and minimum temperatures above 25 degrees F (- 4 degrees C). The inlet (return) and outlet (supply) fittings are on opposite corners of the collector. The collector is mounted landscape, and if the outlet is on the right at the top from the back of the collector, it is a right hand collector, and vice versa. If the collector is mounted parallel to the slope of the roof or at an angle other than horizontal, the outlet MUST be at the high point of the collector. Both the plumbing fittings are located in the back of the collectors and are male copper adapters silver brazed onto stainless steel stubs. The best practice is to use a ½ brass elbow threaded onto the male adapter at the bottom of the. Screw a male PEX adapter into the elbow. Sunvelope recommends using 5 wraps of Teflon tape on the male threads. The elbow with the PEX adapter should point toward the opposite end of the collector. Thread the elbow on the lower fitting before mounting the collector. Once the elbow is in place, attach the mounting clips into the feet and secure with the ¼ -20 bolts and nuts provided. At the top of the collector, screw the female ½ NPT fitting which is attached to the 3 corrugated stainless tubing supplied, onto the ½ male adapter on the collector outlet. This is the hot side or return side, and can be connected after the collector is fully mounted. Connect the pressure relief valve to the return side of the collector loop, between the corrugated stainless tubing and the PEX at the transfer connection. Set pressure setting at 100 PSIG. Sunvelope provides pre-assembled corrugated stainless tubing pigtails with a ½ female connector at one end and the pressure relief valve at the other end. The female end screws onto the male fitting at the outlet of the collector. Use ½ male pipe to PEX adapter to connect to the tee with the pressure relief valve and to the Pump Station. All vertical piping between the back tank and the collector shall be supported at each story or at maximum intervals of ten feet (10 ). Hangers and supports can be used to prevent sagging of the piping. Hangers must be installed in a manner that do not damage or inhibit insulation. Although the Direct Connect 30 system does not require any slope for drainage since the system is pressurized (does not rely on drainage for normal operation), the best practice is to slope for drainage to allow the system to be easily emptied for service. The system utilizes domestic water pressure to fill and purge the system Allowance should be made for expansion and contraction of piping due to changes in temperature of the water and piping. Use flexible pipe supports and avoid long straight piping runs. Include bends and elbows to allow for expansion such as swing joints at the collector inlet & outlet. The installation of all horizontal and vertical piping must not reduce the performance or rating of any structural member or fire rated assembly. Adhere to all applicable local codes and ordinances. 14 P a g e V e r s i o n 2. 0

D.4 Pipe Insulation WARNING: HOT PIPES MAY CAUSE BURNS IF TOUCHED. ENSURE THAT ALL PIPES AND FITTINGS ACCESSIBLE TO THE PUBLIC ARE WELL INSULATED. COMPONENTS ACCESSIBLE TO PUBLIC TRAFFIC MUST BE KEPT BELOW 140ºF OR CLEARLY LABELLED WITH AN APPROPRIATE WARNING. The collector loop piping, plus any interconnecting hot water piping shall be well insulated with a high quality flexible closed cell insulation to minimize heat loss. In addition, the final 5 feet of metallic cold water supply pipe leading to the system, or the length of piping which is accessible if less than 5 feet, shall also be insulated. The insulation shall have a maximum operating temperature of 220 F or higher and a minimum thermal resistance of R-2.6. The wall thickness of the pipe insulation should be ½ or thicker. A 1 wall thickness is required for exposed piping in all areas prone to annual hard freeze conditions. When it comes to pipe insulation the rule is simple: thicker is better. 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 the collector in the summer months or under static conditions can melt this type of material. Any above ground exterior pipe insulation shall be protected from UV degradation and moisture damage. Use EPDM UV resistant insulation (available from Sunvelope ) above the roof or a UV protectant wrap such as Venture Clad. D.5 PV Panel Mounting and Wiring Mount the PV panel which is supplied to the collector at either end or alternate position if desired, maintaining the same orientation and tilt angle as the collector. The side shields must be vertical as shown in Figure 2. Connect the PV panel to the High Temperature Limit switch (HTL) provided and installed at the factory on the back of the PV panel. The wires at the high limit switch are marked to Pump Station. Connect the high limit switch to the Pump Station. Always connect colors red to red and black to black wires. Install the thermistor connected to the HTL switch on the back on the collector in the slot provided. The low voltage wiring used to connect the PV panel to the Pump Station shall be a minimum18 AWG. The wiring should be two conductor, stranded, PVC insulated, with a PVC UV rated jacket suitable for exterior use. See note 3 in Figure 7. Sunvelope can supply pre-insulated and wired PEX tubing. NOTE: Do not connect the PV panel wires to the DC Pump in the Pump Station until the system is fully charged and purged of air. D.6 Pump Station Mount the Pump Station in the orientation shown in figure 6, on a wall near or in the electric water heater tank and in an accessible location. Preferably mount to a stud but if one isn t available use adequate sheet rock mounting to support the weight. Looking at the Pump Station the left hand fittings are the supply side to the collectors and the right side fittings are the return side from the collectors. See the markings on the label. All 4 ball valves and the two purge/drain valves should be in the closed position. Route the PEX tubing from the corrugated stainless tubing pig tail to the Pump Station. Connect one end to the corrugated stainless tubing and the other end to the top return outlet of the Pump Station as marked. Route the tubing from the bottom of the collector at the elbow to the pump side of the Pump Station as marked. Connect to the PEX or other approved tubing connector at the bottom of the collector and to the pump side at the top of the Pump Station as marked. Connect PEX or other tubing from the ¾ brass tee fitting at the bottom of the tank at the drain valve to the bottom pump side of the Pump Station. Then connect the return side of the Pump Station at the bottom of the Pump Station to the ¾ brass tee fitting at the T and P valve. 15 P a g e V e r s i o n 2. 0

FIGURE 6 PUMP STATION SUPPLY RETURN T Flow Purge Valve T Flow Purge Valve Thermo Well Tee Back Flow Preventer Flow Sensor Variable Speed DC Pump Thermo Well Tee Ball Valve Ball Valve ¾ PEX to Tank Bottom Figure 7 Pump Station Schematic ¾ PEX to Tank at T&P Valve 16 P a g e V e r s i o n 2. 0

D.7 Electric Water Heater Tank When installing the electric water heater tank make sure that all the components are accessible and easy to reach. Ensure that there is clear access to the tank, pump station, mixing valve and expansion tank. Use only brass nipples and unions, and copper and brass fittings, in plumbing water heater tank and expansion tank. The use of galvanized fittings or nipples, CPVC or PVC piping is prohibited. Use standard connections to the city cold water supply line and the home hot water feed lines. The 3/4 cold water supply line to the water heater tank shall be insulated with R-2.6 or greater pipe insulation to a minimum distance of 5 behind the storage tank, or to the wall if closer than 5. A boiler drain must be installed at the lowest point in the system to serve as a drain valve for manual draining, tank flushing, and maintenance. A brass shut-off isolation valve, allowing isolation from water supply to the electric water heater, must be installed in the cold water supply line, ahead of the electric water heater and expansion tank connection. A high quality thermostatic mixing valve is a required component in all OG-300 certified systems and should be plumbed in line with brass union connections for ease of future repair or replacement. The mixing valve shall be standard ASSE 1017 approved. The specified mixing valve should have an operating range between 95 F and at least 120 F. The mixing valve shall include a set point of 120 F delivered water temperature. WARNING: SCALDING CAN OCCUR WITHIN FIVE SECONDS WHEN WATER TEMPERATURES APPROACH 140 F. DESPITE THE INSTALLATION OF A MIXING VALVE, ALWAYS EXERCISE CAUTION WHEN OPENING A HOT WATER FIXTURE OR FAUCET IN YOUR HOME. To maximize solar heat capture from your Direct Connect 30 system, Sunvelope recommends disconnecting the bottom water heating element. To disconnect bottom heating element of the electric water heater tank, shut off power to the water heater. Remove the access covers over the heating elements. Fold insulation outwards, or if the insulation is plastic foam, just remove the insulating block and set it aside. Remove the plastic thermostat cover found under this insulation that protects the thermostat electrical connectors from touching the water heater thermostat cover, and then disconnect the electrical wires connected to the water heater element. Insulate the electrical wires with wire nuts. All electric water heater tanks used with this system must have a minimum of R12 external insulation. An exterior insulation blanket may be used to satisfy this requirement. D.8 Expansion Tank The expansion tank is used to accept expansion of the potable water as it heats, preventing a pressure increase and subsequent dumping from the pressure relief valve. For the Direct Connect 30 installation, a 3.2 gallon expansion tank is specified as suitable capacity. Use only high temperature expansion tanks rated up to 200 F. The expansion tank is to be pre-charged to 45 psi. Connect the expansion tank to the cold water supply line, between the water heater isolation valve and the water heater. Use only drinking water safe copper, brass, or PEX fittings and piping in plumbing the expansion tank. The use of Teflon tape on the threaded fittings is recommended. 17 P a g e V e r s i o n 2. 0

D.9 Electrical Requirements The DC pump inside the Pump Station is powered by a 10 watt PV panel, which is mounted in an unshaded area outside at the same orientation and tilt angle as the collector. No other power source is required to operate the water heating portion of the Sunvelope system. The Energy Heat Meter included in the Pump Station to capture temperature and flow data does require an electrical outlet within 6ft of the pump station. E. SYSTEM START UP PROCEDURE E.1 Charging and Purging the System Once the piping is completed, the system is ready to be charged. First connect a garden hose to the purge valve hose connection on the Pump Station on the return side. Use a good quality hose and use extreme care; the discharged water may be EXTREMELY HOT. Make sure the end of the hose is in a location where the discharge will not cause any damage. NOTE: The collector is usually super-heated and will generate steam. Be sure everyone is a safe distance from the end of the hose. The system is now ready to connect power from the PPV panel to the DC Pump in the Pump Sation. Leave the ball valve on the return side of the Pump Station closed and open the purge valve to the hose. Open the ball valve on the supply side of the top of the Pump Station and leave the purge valve closed. Then slowly open the ball valve from the tank at the bottom of the Pump Station supply side through the pump and to the collector until the flow is full. Leave the flow full until the system is purged. You can tell when the system is fully purged when the return temperature cools to around 100 degrees F and you hear no air bubbles or steam. Then open the valve from the top of the tank to the Pump Station while leaving the purge valve open for a second or more. Close the purge valve and examine the entire system for leaks. All 4 ball valves should be fully open and the purge valves should be closed and the caps screwed in place. The system is now ready to connect to the DC power from the PV panel and HTL switch. F. SYSTEM OPERATION Once the Direct Connect 30 system is properly installed and connected, the DC pump in the Pump Station will automatically modulate its speed to match the available solar irradiance, which in turn will control the flow rate thru the solar collector and the amount of heat produced by the system. The heat collected by the solar hot water system will be used to heat the water going to the electric water heater tank, reducing or eliminating the need for the electric water heater to turn on. The Pump Station s integrated monitoring incorporates four system status LEDs. The yellow LED indicates flow; this is only lit when the system detects flow though the Pump Station. The red LED indicates that the monitoring system is ON. The green LED reports that all temperature probes are reporting. Lastly, the blue LED indicates a link between the monitor and the AMBR edge router. To determine whether the solar hot water system is working, go into the Energy Dashboard of the monitoring solution; compare the Supply Temperature with the Return when the solar loop pump is running. The Return temperature from the collector on a sunny day should be at least 4 F warmer than the Supply temperature going up to the collector. In order to utilize the electric water heater as a backup to the solar hot water system, leave the circuit breaker on to the electric water heater tank and set the tank thermostat to the lowest acceptable temperature setting. The electric resistance heating element will come on only when the tank temperature falls below the thermostatic set point. If the solar heated water entering the tank is warmer than the thermostatic set point, the electric heating element will not come on. 18 P a g e V e r s i o n 2. 0

G. SHUTDOWN PROCEDURES The Direct Connect 30 solar water heating system is designed so that the key components can be isolated for emergency repairs or routine maintenance. By shutting the shut off valve installed in the incoming water line (Figure 7), the entire system can be isolated from the cold water supply line. In the case of a leak immediately shut this valve and call your installation contractor for service. The collector loop can be quickly drained if a leak is detected or for routine maintenance. First, disconnect the DC power pump in the Pump Station from its DC power source. Next, close both ball valves (supply and return) in the bottom of the Pump Station to isolate the collectors loop. Then attach a hose to the T Flow Purge Valve on the return side of the Pump Station. Use a good quality hose and use extreme care. Make sure the end of the hose is in a location where the discharge will not cause any damage. Open the valve to drain the system. NOTE: The collector is usually super-heated and will generate steam. Be sure no one is in range of the end of the hose. CAUTION: THIS WATER MAY BE EXTREMELY HOT! H. SUMMER VACATION PROCEDURES Solar water heating systems can build up very high temperatures during summer months if there is no periodic draw on the system. The Sunvelope Direct Connect 30 system has excellent over temperature protection features so it is recommended to simply close the shut-off valve in the cold water supply of the electric water heater tank and allow the system to operate normally. When user returns, just open the valve to the tank. If for any reason the user desires to drain the collector loop the pump should be disconnected. The two top ball valves with purge/drain valves should be closed. Hoses should be connected to the two purge valves, either simultaneously or one at a time, and the purge valves opened to release the water in the loop. Once the water is fully drained the purge valves may be close again. To recharge the system, follow the instructions in Section E-1, Charging and Purging the system. I. MAINTENANCE AND TROUBLESHOOTING The following simple procedures are intended to optimize the performance of the Direct Connect 30 system and also to extend the life of the primary components: I.1 Electric Water Heater Tank Flush The electric water heater tank should be flushed annually to minimize sediment buildup on the bottom of the tank. If you live in an area with high mineral content in your water, flush the tank on a semi-annual basis. Open the drain valve on the bottom of the water heater tank and flush a sufficient volume of water to eliminate the sediment. It is also possible to flush the entire system including the collector by connecting a hose to the purge valve at the return side of the Pump Station. Close the ball valve and purge there. I.2 Electric Water Heater Tank Anode Rod Replacement Typically constructed from magnesium, anode rods are installed in glass lined electric water heaters to inhibit corrosion. The anode rod is consumed so that the tank lining is not. By changing the anode rod after the fifth year of system operation, and every three to five years thereafter, it is possible to extend the life of the electric water heater tank. Periodic replacement of the anode rod in the backup water heater tank can significantly extend the tank life. System temperatures and water quality affect the rate at which the anode rod is consumed. In general: the higher the average system temperature the faster the rate of corrosion. 19 P a g e V e r s i o n 2. 0

I.3 Collector Glass Cleaning If you live in a dusty climate it is beneficial but not necessary to wash off the dirt that settles on the collector glass once every two months. Normal rain and snow is usually sufficient to maintain collector reasonably clean. Clean glass allows the collector to maintain a high level of thermal performance. I.3 Pipe Insulation Maintenance Check the exterior pipe insulation annually and patch or repair any exposed surfaces or degraded areas. Repair as necessary with manufacturer s recommended jacket or coating or a high quality exterior latex paint. I.4 System Leaks If you detect a water leak in the solar loop piping or in the water heater tank, follow the Shutdown Procedures in Section G, and contact your installation contractor for additional troubleshooting and repair support. I.5 Pump Failure Use the flow meter in your monitoring system or check the analog flow meter when the sun is shining directly on the PV panel (no shading). If you are not getting hot water and the flow reading is zero, the pump may not be operating and may need to be replaced. Contact your installation contractor for service. 20 P a g e V e r s i o n 2. 0

J. DIRECT CONNECT 30 SYSTEM COMPONENT PARTS Figure 7 below depicts the key components of the Direct Connect 30 system: Figure 8 System Schematic 21 P a g e V e r s i o n 2. 0

Table 1 System Components Number in Component Manufacturer Catalog # Quantity Figure #7 1 Solar Collector Sunvelope FPE-30 1 2 Pump Station Sunvelope SPA-15 1 3 Electric Water Heater Tank, 50 Rheem or comparable XE40M06ST45U1 1 gallons 4 Expansion Tank, 3.2 gallons Amtrol ST-8 1 5 PV 10W panel Dasol DS-A18-10 1 6 High Temperature Limit Switch Wangwanqui 261247778904 1 (HTL) and thermistor 7 Solar loop piping - PEX tubing Uponor, NIPCO, EverPEX F6040750, NP60/70, varies encased in ½" PEX-foam insulation or equal 64766 8 Pressure Relief Valve Watts 530C 1 9 Shutoff Ball Valve Webstone Ball valve 1 10 Boiler flush valve Included as part of Electric N/A 1 Water Heater 11 Mixing Valve Honeywell-Sparco AM100C-UT-1LF 1 12 Temperature and Pressure Relief Valve Included as part of Electric Water Heater N/A K. SYSTEM OPERATING PARAMETERS K.1 Collector Loop Pressure The pressure in the solar collector loop should be within 0 80 PSIG. K.2 Collector Loop Temperature The temperature in the collector loop should not exceed 170 degrees F. K.3 Circulation Flow Rate The flow rate in the collector loop should be 0.5 2 GPM while the pump is operating (clear days from 9AM to 6 PM). K.4 FPE-30 Collector s Dry and Fill Weights Dry Weight: 141 lbs. Fill Weight: 145 lbs. K.5 Tank Temperature and Pressure Refer to tank manufacturer s specification label for tank maximum working temperature and pressure. 22 P a g e V e r s i o n 2. 0

APPENDIX A DIRECT CONNECT 30 OG-300 APPROVED COMPONENTS Primary Components Manufacturer Model Number Solar Collector Sunvelope FPE-30 Collector Mounting Hardware Sunvelope LS-30 Electric Water Heater -50 gallon Rheem XE50M06ST45U1 Pump Station (including PV panel, HTL switch and DC pump) Whirlpool AO Smith E1F50RD045V ENT-50 Sunvelope SPA 15 Expansion Tank Amtrol ST-8 Other Components Thermostatic Mixing Valve Ball Valves Boiler Drains Pressure Relief Valve Description The thermostatic mixing valve shall have a bronze, brass or stainless steel body with a rated maximum working temperature no less than 200oF and a rated maximum working pressure no less than 125psi. The range of temperature set points shall be at least 18ºF (10ºC) and shall include a set point of 120ºF (50ºC). The Thermostatic Mixing valve shall be third party listed and certified to one of the following ASSE standards: ASSE 1016; ASSE 1017; ASSE 1070. Ball valves shall be of bronze, brass or stainless steel construction. Maximum working temperature shall be no less than 200oF and maximum working pressure shall be no less than 125 psi. Boiler Drains shall be of bronze, brass or stainless steel construction. Maximum working temperature shall be no less than 200oF and maximum working pressure shall be no less than 125 psi. The pressure relief valve shall be of bronze, brass or stainless steel construction with a pressure setting between 30psi and 100psi. The pressure relief valve shall be set to discharge at a pressure below the maximum design pressure of all other components in the collector loop. 23 P a g e V e r s i o n 2. 0

APPENDIX B DIRECT CONNECT 30 SYSTEM & COMPONENTS LABELS FLUID IDENTIFICATION THE HEAT TRANSFER FLUID USED IN THIS SYSTEM IS WATER. NO OTHER FLUID SHALL BE USED THAT WOULD CHANGE THE ORIGINAL CLASSIFICATION OF THIS SYSTEM. BE EXTREMELY CARFUL WHEN DRAINING THIS FLUID. IT MAY BE DISCHARGED AT A VERY HIGH TEMPERATURE AND PRESSURE. FREEZE LABEL THE DIRECT CONNECT 30 SYSTEM IS PROTECTED FROM FREEZING BY THE INHERENT DESIGN OF THE SOLAR COLLECTOR. WHEN PROPERLY INSTALLED AND OPERATED THE SYSTEM IS PROTECTED TO TEMPERATURES AS LOW AS -40 DEGREES F. BOILER FLUSH VALVE (COMPONENT #9) WATER HEATER TANK DRAIN VALVE VALVE 11 IS NORMALLY CLOSED. WHEN OPENED IT IS USED TO DRAIN THE WATER HEATER TANK. BE EXTREMELY CARFUL WHEN DRAINING THIS FLUID. IT MAY BE DISCHARGED AT A VERY HIGH TEMPERATURE AND/OR PRESSURE. PUMP STATION S T FLOW PURGE VALVE (RETURN SIDE) VALVE IS NORMALLY CLOSED. WHEN OPENED, IT IS USED TO CHARGE AND DRAIN THE SOLAR COLLECTOR LOOP PIPING. THE HEAT TRANSFER FLUID USED IN THIS SYSTEM IS WATER. NO OTHER FLUID SHALL BE USED THAT WOULD CHANGE THE ORIGINAL CLASSIFICATION OF THIS SYSTEM. UNAUTHORIZED ALTERATIONS TO THIS SYSTEM COULD RESULT IN A HAZARDOUS HEALTH CONDITION. BE EXTREMELY CAREFUL WHEN DRAINING/PURGING THIS FLUID. IT MAY BE DISCHARGED AT A VERY HIGH TEMPERATURE AND/OR PRESSURE. SHUTOFF SUPPLY ISOLATION VALVE (COMPONENT #8) THIS VALVE IS NORMALLY OPEN AND ALLOWS POTABLE WATER TO FILL THE WATER HEATER TANK. WHEN CLOSED THE SOLAR STORATANK IS ISOLATED FROM THE PRESSURIZED CITY COLD WATER SUPPLY LINE PIPING. PRESSURE RELIEF VALVE (COMPONENT #11) THE PRV WILL AUTOMATICALLY OPEN AND DISCHARGE FLUID OR AIR IN THE EVENT OF THE COLLECTOR LOOP PRESSURE EXCEEDING THE MAXIMUM WORKING PRESSURE OF THE SYSTEM. 24 P a g e V e r s i o n 2. 0

APPENDIX C FPE SERIES COLLECTOR PRODUCT WARRANTY 1. GENERAL: The patented Sunvelope Solar FPE Series Collectors are warranted to be free from defects in parts and workmanship under normal use and service including freezing. 2. THE EFFECTIVE DATE: The effective date is the completion date of original installation if properly documented; or the date on the building permit for installation of your Collector plus thirty (30) days. Installation of a collector without a building permit voids warranty. 3. APPLICABLE WARRANTY PERIOD: Subject to proof of purchase of your collector, the Applicable Warranty period is ten (10) years from the Effective date. 4. EXCLUSIONS: This Warranty will not apply: To damage from abuse, accident, fire, flood, wind or other event beyond control of the manufacturer; To defects or damage caused by the use of any component, attachment, or device not authorized in writing by Sunvelope Solar, Inc.; To a collector which has been moved from its original installation location; To a collector that has been modified in any way; To damage caused by negligence or vandalism; To Collectors with structural attachments not authorized by the manufacturer; 5. LABOR, SHIPPING AND PROCESSING COSTS: This Limited Warranty does not cover any labor expenses for service, repairs, reinstallation, permits, or removal and disposal of defective component part(s). All such expenses are the responsibility of the Customer. This limited Warranty does not extend to any shipping cost, transportation cost, or delivery expenses. 6. HOW TO MAKE A CLAIM: To obtain Warranty Service, contact Sunvelope Solar Inc. The ORIGINAL DATED RECEIPT OR OTHER PROOF OF PURCHASE AND DATE OF INSTALLATION, accompanied by the model and serial numbers are required. Please be prepared to provide proof that the Collector meets the Limited Warranty requirements. 7. EXCLUSIVE WARRANTY LIMIT OF LIABILITY: This Limited Warranty is the only Warranty for products provided by Sunvelope Solar, Inc. No outside parties are authorized to make any warranties for or on behalf of Sunvelope Solar, Inc. ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED PREVIOUSLY. THE DEALER S SOLE LIABILIY, WITH RESPECT TO ANY DEFECT, SHALL BE SET FORTH IN THIS LIMITED WARRANTY, AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGE FROM WATER LEAKAGE) ARE EXCLUDED. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESDRIPTION ON THE FACE HERE OF. Some states do not allow limitations on how long an implied warranty lasts, or for exclusion of incidental or consequential damages so the above limitations or exclusions may not apply to you. 8. This limited warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. 25 P a g e V e r s i o n 2. 0