Your Solar Home Inc. SolarSheat Hot Water System Installation, Operation and Maintenance Manual Rev. 8.3 1 of 44
Table of Contents Section Description Page 1.0 The System 5 1.1 What is Included 5 1.2 What you will need 7 1.3 Skills & Equipment required for Installation 7 1.4 Important Safety Considerations 8 2.0 Installation Instructions 11 2.1 Main Components 11 2.2 Operating Principles and Requirements: Hot Water Mode 12 2.3 Operating Principles and Requirements: Space Heating Mode 13 2.4 Operating requirements 14 3.0 Installation 14 3.1 Selecting the best location for the system 14 3.2 Setup of the SolarSheats 16 3.3 Addition of the SSHW system to Pre-existing SolarSheats 16 3.4 Air temperature sensor and switch location and function 18 3.5 Proper location of Storage Tank 18 3.6 Setup of the SSHW Heat Exchanger 18 3.7 110 V Wiring 21 3.8 Thermostat and Space Heating or Hot Water switch setup and location 21 3.9 Pump station connection 22 3.10 Expansion tank connection 25 3.11 Storage tank connection 24 3.12 Drain Requirements 26 3.13 Connection to existing hot water system 26 3.14 Filling the Potable loop 27 3.15 Filling and Pressure testing the Solar Loop 27 3.16 System Flush 27 3.17 Venting Air from the System 27 3.18 Low Voltage Control Wiring & Sensor connection 27 3.19 Pipe Insulation 32 Rev. 8.3 2 of 44
Table of Contents - Continued Section Description Page 4.0 Testing and Operation 33 4.1 Powering up the System the first time 33 4.2 System Controller functions 33 5.0 Routine Operation 38 5.1 Fill weights, pressure and temperature ratings 38 5.2 Expecting Operating conditions 38 5.3 Switching between Space and Hot Water heating 39 6.0 Emergency Shot-Off procedures 40 7.0 System Maintenance 40 8.0 Special Conditions 42 8.1 Freezing 42 8.2 Long term shut-down 42 9.0 Warranty 43 10.0 Contact Us 44 FIGURE #1 10 FIGURE #2 17 FIGURE #3 20 FIGURE #4(A & B) 22 FIGURE #5 23 FIGURE #6 26 FIGURE #7 28 FIGURE #8 31 Rev. 8.3 3 of 44
Congratulations on your purchase of the Your Solar Home Inc., SolarSheat Hot Water system (SSHW). This manual will guide you through the installation of the system, its setup, operation and outline the required maintenance procedures. Rev. 8.3 4 of 44
1.0 The System Parts List 1.1 What is included - Complete SSHW system including SolarSheats Box # Description Quantity Switch plate for toggle switch 1 Thermostat wire 50ft 1 Sensor 1 Thermostat 1 1 Fan center relay 1 Relay box 1 6 dedicated fan 1 Solarsheat installation manual 1 SSHW installation&maint. manual 1 2 pack manual 1 Toggle switch DPST 1 5 collars 2 Collar gaskets 2 2 5 snap duct 2 Side hole gaskets 2 6 back draft damper 1 5 to 6 reducers 2 Pipe wrap 6 pcs. 4 3 Solarsheat heat exchanger box 1 Wall mount brackets 2 4 SPS-2 pump station 1 Mounting screws 4 Set of pipe adapters 1 3 way damper 2 5 Water tank 85 or 75 US gallons 1 ½ flexible copper tube 25 coil 1 Expansion tank 1 1500 GS Collector 2 o Check that you received everything in good condition o Store system indoors and protected from weather prior to installation Rev. 8.3 5 of 44
- Adding SSHW to existing SolarSheat system Parts List Box # Description Quantity Switch plate for toggle switch 1 Thermostat wire 50ft 1 Sensor 1 Thermostat 1 1 Fan center relay 1 Relay box 1 6 dedicated fan 1 Solarsheat installation manual 1 SSHW installation&maint manual 1 2 pack manual 1 Toggle switch DPST 1 5 collars 2 Collar gaskets 2 2 5 snap duct 2 Side hole gaskets 2 6 back draft damper 1 5 to 6 reducers 2 Pipe wrap 6 pcs. 4 3 Solarsheat heat exchanger box 1 Wall mount brackets 2 4 SPS-2 pump station 1 Mounting screws 4 Set of pipe adapters 1 3 way damper 2 5 Water tank 85 or 75 US gallons 1 ½ flexible copper tube 25 coil 1 Expansion tank 1 1500 GS Collector 2 o Check that you received everything in good condition o Store system indoors and protected from weather prior to installation Rev. 8.3 6 of 44
1.2 What you will need - The system comes with the major items for a standard installation and operation the following items will be required to complete the system installation: o Ductwork (6 rigid galvanized metal duct only!) o Pipe & duct insulation o Fasteners for mounting SolarSheats, ductwork, and SSHW box and brackets o Copper piping for connections of the storage tank to the water supply and existing hot water tank along with pressure relief valve drains. o ½ or ¾ valves for the required by-pass system. o Electrical wire, 15 amp GFCI breaker (check the make of your panel), two 4 x4 utility boxes, one switch, two switch boxes, two plug outlets and cover plates 1.3 Skills & Equipment required for installation The skills required to install this system include electrical and plumbing work. The fan operates on 120 V AC power and will require a licensed electrician to run a dedicated Ground Fault Circuit Interrupter (GFCI) circuit (15 Amp) to power the fan center, main shut off switch and power plug for the pump station and air dampers. Do not attempt this work without a qualified electrician! The plumbing will also require a licensed plumber as significant re-routing of the water supply to the existing water heater tank will need to be done along with several other soldered and compression fittings. All local code and safety requirements must be met and only a licensed qualified plumber should be used for this work. Rev. 8.3 7 of 44
1.4 Important Safety Considerations - Hot Water Scalding Hazards and Hot Air Duct burns are possible with this system. The water system is under pressure and hot and the air ducts can be very hot. All piping and ducting MUST be insulated both for energy conservation and safety reasons. Be careful! - Freezing of the system is possible if there is a prolonged power outage and/or if the system is allowed to freeze in its indoor location. The system is designed to be located inside the building alongside the existing hot water heating system. If the system is installed in a seasonal use building that is subject to freezing, then it must have the power shut off and be thoroughly drained in the same manner as the existing hot water heating system. See Section 8.0 for complete winterizing instructions. - Electrical safety must always be considered. The system requires a dedicated 120VAC GFCI circuit for the fan and pump station, properly wired into the breaker panel. In addition any work done to the existing hot water heating system, will require the system to be shut off (and drained possibly), as per the tank manufacturer s instructions. Electrical shock hazard is possible if the system is not properly installed and connected! - Natural gas, propane or heating oil hot water heating systems must be shut off (and drained possibly) as per the tank manufacturers requirements. It is very important that a qualified technician ensure that these systems are properly shut off and re-started. Explosion hazards are present with all gaseous and liquid fuel heating systems! - Water is heavy! It is important the ensure that the SSHW heat exchanger box is securely mounted to a wall or ceiling and that the hot water storage tank is located on a solid footing able to support the weight of the tank and the water inside (i.e. a 65 gallon tank filled will weigh approx. 750 lbs. or 340 kgs.) Local code requirements may require that the tank also be braced to a wall to prevent tipping. A drain pan may also be required underneath the water storage tank. Verify that all local codes are satisfied. - Professional installers are required. An electrician and plumber will be required to install this system, not only to ensure the proper installation, but also for insurance protection. - Fire Rating requirements. It is critical to ensure that any roof and or wall penetrations shall not reduce the building s fire resistance required by local codes, ordinances and applicable standards. Rev. 8.3 8 of 44
- Building Penetrations must be sealed properly to prevent entrance by insects and/or vermin. All places where ducting, piping or wiring are passed cannot reduce or impair the function of the space/enclosure. - All roof mount applications of the SolarSheats must conform to local code requirements and National Roofing Contactors Association practices. Structural supports attached to the roof and the associated wind and weight loading to the roof structure cannot exceed the live or dead load ratings of the building, roof, and roof anchorage. - All building penetrations, especially those required through structural members, shall comply with local building codes. - Roof mount applications should have the galvanized ductwork grounded for lightning protection. - All necessary local permits must be obtained prior to the systems being installed, i.e. plumbing, electrical. Rev. 8.3 9 of 44
Rev. 8.3 10 of 44
2.0 Installation Instructions System Main Components, Operating Principles and Requirements 2.1 Main Components: - SolarSheat 1500GS Solar Collectors The SolarSheats provide the heated air to the SSHW heat exchanger box. - SSHW AC Fan & Heat Exchanger Box The AC fan circulates the air from the SolarSheats to the SSHW box which contains a tube-fin heat exchanger. - SSHW Automatic Electronic Dampers These dampers will automatically close when the system shuts off when in the hot water heating mode. When switched to space heating mode, these dampers will remain closed and air will circulate through home air duct system and not through the SSHW heat exchanger. - SPS-2 Pump Station contains the system controller, two circulating pumps and a flat-plate heat exchanger. The controller measures the temperature difference between the air temperature coming from the collector and the water temperature in the storage tank and controls the operation of the system. One pump circulates water through the SSHW box (Solar Loop), and the other pump circulates water to and from the hot water storage tank (Potable Loop). - Hot Water Storage tank Stores the water heated by the system and is connected in series with the existing hot water tank to pre-heat the inlet water for the water heater. - Expansion Tank Allows the Solar loop system water to expand safely, without creating too much pressure in the system. The tank supplied is sized for the SolarSheat Hot Water system, based on no more than 25ft. of the 1/2 flexible copper tubing supplied, being used. Rev. 8.3 11 of 44
2.2 Operating Principles and Requirements: Hot Water Mode The system operates by circulating air through the SolarSheats, where the air is heated and then returns to the SSHW heat exchanger box (see Figure #1 and Figure #2). There are three sensors and one thermal switch that control the operation of the system. One sensor (T1-Collector) and the thermal switch are inserted into the SolarSheat panel near the hot air supply duct and ensure that the system will only operate when the air is at least 5 C (9 F) warmer than the water in the storage tank and that the minimum air temperature is at least 20 C (68 F). When these conditions are met, the fan and the circulating pumps will activate and the automatic air dampers will open, so that hot air from the SolarSheats is blown through the air-to-water heat exchanger in the SSHW box, thereby heating the water being circulated through the Solar Loop by one of the two pumps in the SPS-2 pump station. Rev. 8.3 12 of 44
The warmed water then goes through a flat-plate heat exchanger inside the pump station. The heat from the Solar Loop water is transferred to the water in the Potable Loop being circulated by the second pump that draws water from the bottom of the storage tank and pumps it back into the top of the tank. The other two sensors measure the water temperature in the storage tank (T2-Storage) and the air temperature (T3-Aux) in the SSHW box. As mentioned above, the temperature differential between the air temperature and the storage tank water temperature is the primary trigger that controls the operation of the pump station system. The temperature measured by sensor T3-Aux in the SSHW box is used to protect against system freezing. In the event that cold air enters the box and the temperature reaches 2 C or 36 F, then the pumps will be turned on to warm the heat exchanger and prevent freezing. In addition, the automatic air dampers close when the system shuts down which also isolates the heat exchanger from cold air in the ducts. See section 8.0 for more information regarding freezing. 2.3 Operating Principles and Requirements: Space Heating Mode When the system is switched manually to the space heating mode, the automatic air dampers will be closed so that air will not circulate through the SSHW heat exchanger box. The switch is wired so that the space heating mode will close the dampers and by-pass the pump station controller. The system then operates based on the thermal switch in the collector and the wall thermostat. Rev. 8.3 13 of 44
2.4 Operating Requirements: As a solar hot water heating system, the main requirement is solar energy = SUN! The SolarSheat panels must be located facing as close to south as possible and ideally in a vertical orientation, but no more than 45 degrees from the vertical. The panels can be located on a wall or on a roof and it is important to ensure that in the winter months, when the sun is lower to the horizon (in northern latitudes), that they are not shaded by trees, chimneys, dormers etc. The next most important requirement of the system is to minimize heat loss. It is important to minimize the length of duct run from the collectors to the SSHW heat exchanger box and to ensure that these ducts are VERY well insulated. In addition, ALL of the piping must be well insulated both to minimize heat loss and to prevent condensation on the cold water supply. Finally, the SSHW system is designed to be located near to the existing hot water heater, indoors. This requirement allows for the use of water only in both circuits of the system as no part of the water system is exposed to freezing conditions, only the SolarSheats are outside. The automatic dampers close when the system is shut off and thermally isolate the SSHW box from the air ducts. In addition, the backdraft damper located inside the return duct to the SolarSheats is designed to prevent cold air from the outside from circulating via convection down to the SSHW box, so the box should not experience freezing temperatures. 3.0 Installation: 3.1 Selecting the best location for the system As mentioned above, the SolarSheats must face south and be located as close to the existing hot water heater as possible. Ideally the layout of the building allows for short ducting runs to the SSHW box, however, with 6 galvanized duct, runs as long as 30 ft. (total = supply + return) are acceptable with the supplied AC fan, provided that a minimum number of elbows are used (6-8 per side). Duct insulation is VERY important to reduce heat loss. If the SolarSheats are roof mounted, then at least 2 of foam insulation should be used such as Aerocel foam sheet for all of the exterior ducting (Ensure that all insulation exposed to sunlight is UV rated or wrapped). For interior duct, a minimum of 1 foam or 2 of fiberglass (or equivalent) mat should be wrapped around all ductwork. In the event that the SSHW system is being installed with existing SolarSheats, then the inlet and outlet ducts will need to be ducted near to the location of the existing hot water heater. Rev. 8.3 14 of 44
Possible Installation Configurations Best arrangement = Direct into basement Wall Mount one floor above = OK Rev. 8.3 15 of 44
Roof mount = longest duct run = more heat loss 3.2 Setup of the SolarSheats Install the SolarSheats as per the supplied Multi-room manual (See Appendix) mounting instructions, with the plan to minimize the duct length. Whether the SolarSheats are mounted on a south facing wall or located on the roof, the ducting will need to extend down to the water storage tank with as few bends as possible and the maximum amount of insulation as possible. Be sure to route the ductwork so that the hot air supply from the SolarSheat is routed to the Inlet side of the SSHW box, (see figure #1). Ensure that if duct chases are going to be constructed, that they are large enough to allow for at least 2 of insulation if they are in a cold area and at least 1 of insulation in an interior warm area. Please note that all penetrations of walls and ceilings must meet the requirements of the local fire codes for fire rating etc. 3.3 Addition of the SSHW system to pre-existing Solarsheats The same requirements apply as outlined above for duct routing and insulation. Rev. 8.3 16 of 44
Figure #2 Rev. 8.3 17 of 44
3.4 Air temperature sensor and switch - location and function The SolarSheats are supplied with a thermal switch that is wired into the thermostat circuit to prevent the fan from operating when the temperature in the SolarSheats is below 20 C (68 F). With either an existing or new SolarSheat installation, this is required and will be used to turn the fan on when it is warm and also to prevent the fan from running in the remote event that the SSHW box temperature sensor reaches 2 C (36 F) and turns on the circulating pumps (see electrical schematic figure #2). The other sensor that is required to be installed in the SolarSheat outlet is the long sensor with the short red leads. This sensor (T1 Collector) must be inserted into the hot air outlet of the SolarSheat (the same location as the thermal switch). The easiest method is to drill a 3/8 hole (10 mm) in the back of the SolarSheat next to the black plastic outlet flange and insert both the thermal switch (if a new SolarSheat installation) and the sensor. Make sure that the sensors are fully inserted into the SolarSheat so that they are positioned in the airflow, but that the metal tip of the sensors are not touching the back of the collector absorber. It is important to make sure that the hole is well sealed with silicone after the sensors are installed and also to ensure that the duct is well insulated (at the flange and elsewhere). 3.5 Proper location of the water storage tank The position of the water storage tank is designed to be directly below the SSHW box (see photo) and hopefully this can be located near to the existing hot water heater. Please note that if the existing hot water heater is not located in the basement, then it is CRITICAL to ensure that the floor has the structural capacity to handle the additional weight of the water storage tank. Note that a 75 US gallon tank weighs 122 lbs. empty and the water weighs (75 x 8.34) = 625.5 so the total weight is 747.5 lbs. 3.6 Setup of the SSHW heat exchanger, dampers and fan The SSHW heat exchanger box is designed to be wall mounted with the two brackets provided, or if this is not possible, it can be suspended from the floor joists above, attaching to the box as shown in figure #3. Make sure that the box is securely supported if the wall brackets are not used, as the supports must be able to handle the weight of the box when filled with water and also, the fan and ductwork (approximately 36 kg. or 80 lbs.). The two automatic air dampers can be connected to inlet and outlet of the SSHW box now, being careful to install the dampers so that they are in Rev. 8.3 18 of 44
their closed position, with the damper inside closing towards the SSHW box. The damper position can be tested by plugging them into a 110V outlet and they will be powered to their closed position, provided that the two wires of the 24V cable are not connected. When the two wires are connected, the dampers will move to their open position. As per the diagrams in Section 2.2 and 2.3, the open position allows the air to circulate through the heat exchanger which is the Hot Water Mode and the closed position is the Space Heating Mode which by-passes the heat exchanger. The hot air outlet from the first damper would therefore connect to the hot air supply for the house (or be ducted to blow the hot air into the house) and the connection for the second damper is ducted to the return air duct in the house (or to a suitable return air location, or Heat Recovery Ventilator (HRV) etc.) The fan can now be mounted to the outlet of the second damper and the duct work from the SolarSheats can be connected at this time, again, making sure that the hot air supply from the SolarSheats is connected to the inlet of the SSHW box, as per figure #1. Make sure that all of the joints are sealed with foil tape to minimize leakage and the duct must be well insulated. Rev. 8.3 19 of 44
Figure #3 Rev. 8.3 20 of 44
3.7 110V power wiring The system is designed to be setup as per the wiring diagram figure #2 provided with a dedicated Ground Fault Circuit Interrupter (GFCI) protected circuit, (ENSURE THAT THE WIRING IS DONE BY A CERTIFIED ELECTRICIAN AND THAT ALL LOCAL CODE REQUIREMENTS ARE MET). There must be a master shut off switch that controls the power to the fan and pump station as per the wiring diagram. Make sure that the receptacle for the pump station and automatic dampers is located close enough for the cord(s) to reach it (see photograph on Page 4), but DO NOT PLUG IN THE PUMP STATION AT THIS TIME. 3.8 T-Stat and Space Heating or Hot Water switch setup and location The thermostat and the Space Heating or Hot Water switch can be located and wired at this time using the wiring diagram supplied (see Figure # 2) if a new SolarSheat installation or the existing thermostat can be used. Please note that in the water heating mode, the thermostat temperature setting is not the same as with the space heating mode, because the thermostat is no longer required to control the air temperature in the house (when in the hot water mode). Therefore, the thermostat should be set at a high temperature (i.e. 30 C or 80 F), to ensure that the system operates at all times when hot water is desired. If the installation is designed for dedicated hot water heating only and no air heating is required, then a simple wall switch can be used instead of a thermostat to control the operation of the system. The system has been designed so that the Space Heating or Hot Water switch can be positioned in a convenient location for an easy change over from either mode. The requirement is to be able to run a 4-wire cable of at least 18 gauge from the Relay Box to the switch box along with the required wires from the automatic dampers, thermal switch, fan centre and the Thermostat as per Figure #2 (page 17.) Rev. 8.3 21 of 44
3.9 Pump Station connection The pump station is to be attached to the storage tank using the four white hex head screws provided and mounted as per Figure #4.0 and #4.1. The pump station can be help up to the tank and an assistant can mark the hole locations so that the station is centered and level on the tank (use a small bubble level to assist with this). Be careful when mounting the pump station DO NOT OVERTIGHTEN THE SCREWS, IT IS ONLY PLASTIC. Figure #4.0 Figure #4.1 Rev. 8.3 22 of 44
The pump station has five water connections on the right hand side that are clearly marked as to what connections are to be made. There are four adapters that will be attached to the ½ copper couplings so that the ½ flexible copper tubing can be easily connected to the pump station and the SSHW box and the storage tank as per figure #5.0. Figure 5.1 on the following page shows all of the supplied adapters required for these connections except for the Tee for the inlet to the tank and the required components for the by-pass system as the customer may be using ½, ¾ or even 1 supply piping. Figure #5.0 Rev. 8.3 23 of 44
Figure #5.1 Measure the distance between the To Collector outlet on the SPS-2 to the Inlet of the SSHW box in order to cut the flexible copper tube. Allow extra length so that the tubing can be routed nicely with as few bends as possible and ensure that the bends are very gentle with no kinks in the tubing. Use a proper tube bender, if required, to make smooth bends. Follow the same procedure for the From Collector connection. When tightening the compression fittings, make sure that you support the other side of the fitting with a wrench, so that the tightening torque is not put onto the piping. Rev. 8.3 24 of 44
3.10 Expansion Tank Connection The expansion tank should be mounted on the wall next to the storage tank as shown in Figure 5.2. Use the flexible copper line as shown to connect to the pipe adapter that is attached to the From Collector fitting of the pump station. The tank should be pressurized to about 15-20 psi before the system is filled with water 3.11 Storage tank connection Figure 5.2 Follow the same procedure as above for both the To Storage piping, which connects the SPS-2 to the top of the storage tank except that this connection must be soldered to a Tee connection where the cold water supply to the tank goes into the tank (see Figure #1 and Figure #5.2). The From Storage connection which comes from the lower tank drain fitting to the SPS-2 must also be connected by installing the provided threaded 4 NPT pipe extension and the Tee fitting with the drain valve attached as per Figure #6 and then threading the adapter into the Tee, so that the ½ flexible copper can be routed to the pump station. Rev. 8.3 25 of 44
Figure #6 3.12 Drain requirements Both the SPS-2 and the storage tank have pressure relief valves that must have rigid pipe connected to them and routed to within 6 of the floor level (OR TO LOCAL CODE REQUIREMENTS). Both of these are important safety items and local code requirements must be met. Drain Pans: Many municipalities and states require these. They are also recommended for any water appliance located above a living area. Camco Manufacturing makes a line of plastic pans and have an extensive dealer network. Go to www.camco.net to find a local supplier. 3.13 Connection to the existing hot water system As per Figure #1, the existing cold water supply to the existing hot water tank will need to be re-routed to supply the new Storage tank. The outlet from the storage tank will then be routed to the inlet of the existing tank. In addition, a by-pass connection must be plumbed to by-pass the storage tank in the event of system problems, so that the existing hot water heating system can be operated independently of the SSHW system. All of these connections should be done with Type L rigid copper pipe and soldered connections. 3.14 Filling the Potable Loop The SSHW system is designed to be filled with water only, on both the Solar Loop and the potable side. The potable side involves filling the both the storage tank and existing hot water system and make sure to vent the system properly by opening a hot water tap in the house and filling the system until the air has been eliminated. To ensure that there is Rev. 8.3 26 of 44
no air in the pump, loosen the ½ coupling fitting carefully until a small amount of water comes out to release any trapped air. Once the system is filled, check for leaks. 3.15 Filling and Pressure testing the Solar Loop Pressurize the system with a garden hose and tap water by flushing into fill valve and out drain valve to remove most air from system, then slowly shutting off the drain valve and then the fill valve to slowly pressurize the system to 35 psi. DO NOT EXCEED 40 PSI on the solar loop or the pressure relief valve will vent. Watch for any pressure drop that will indicate a leak. If the pressure drops the leak will be evident. Make sure to also vent the system at the air vent on the SSHW box on the heat exchanger outlet side. 3.16 System flush The piping should be flushed with TSP or other cleanser to remove flux residue and clean the piping. It is possible to flush through the system with a garden hose, into a bucket, to remove most particulate. 3.17 Venting air from the system and Check system pressure After the initial fill, operate the system for a few days while monitoring the solar loop pressure. Manually depress the air vent valve to release any air that may have accumulated at the top of the heat exchanger loop. The system fill pressure is 35 psi and if the pressure has dropped, check for leaks and re-pressurize the system. DO NOT EXCEED 40 PSI OR THE PRESSURE RELIEF VALVE WILL OPERATE. 3.18 Low Voltage Control Wiring & Sensor Connection (see Figure #2) T1 Collector Sensor The collector sensor is to be installed in the collector, as close to the collector outlet as possible as described in Section 3.4 Air temperature Sensor. The duct near the sensor must be well insulated and protected to obtain the most accurate reading possible. The supplied collector sensor is provided with red leads and will require extension wire to connect to the SPS-2-AC terminals. The collector sensor cable should be rated for the highest stagnation temperatures of the collector. Note that the collectors can reach temperatures above 100 C on stagnation. Extension wire should be 18 AWG, two conductor cable with a PVC jacket. Belden 8760 is recommended for indoor use or Belden 8428 for use outdoors. Solder the wire splices to ensure low resistance and durable connections. The Rev. 8.3 27 of 44
collector sensor should be connected to the terminals marked Collector Sensor. Polarity does not matter. T2 Storage Bottom Sensor The storage sensor is marked with a number 2 on the cable near the sensor. The storage sensor is to be connected to the storage tank at a point near the bottom of the tank. A typical location is connected to the lower heater element, which must NOT be connected to power on solar storage tanks. The sensor should be in very tight and secure connection to the tank and be well insulated to obtain the most accurate reading possible (see Figure #7, it is taped in place with foil tape). The storage sensor is provided with a 6 ft. cable, and can be directly connected to the SPS-2-AC. As can be seen in Figure #4.1, the cable can be routed through the hole in the plastic covers and make sure that the fiberglass insulation is replaced as it was found to ensure that the storage sensor is well insulated from the surrounding room temperature. The storage sensor should be connected to the terminals marked Storage Sensor. Polarity does not matter. Figure #7 T3 Auxiliary Sensor (Freeze detection) The Auxiliary sensor is to be connected to the inlet side of the SSHW box through the hole in the bottom with the grommet as shown in Figure #3. The auxiliary sensor is used to control the auxiliary outputs of the controller, which in this case is programmed to turn on the pumps in the event that temperatures as low as 2 C or 36 F are measured. This will circulate water through the coil to prevent freezing, without turning on the fan. The Auxiliary sensor is connected to the terminals marked Auxiliary Sensor. Polarity does not matter. Rev. 8.3 28 of 44
Control Wiring Study Figure #2 and Figure #8 before attempting any wiring. The operation of the fan in the space heating or hot water heating modes requires the most forethought in order to route the low voltage cable correctly. The long runs of the 24V circuit come from the SolarSheat collector thermal switch, and also from the Thermostat, which must be located in the building living space. If not already located, the T-stat should be placed on an interior wall, with no ducts blowing air on it. The customer has the choice to also locate the Space Heating or Hot Water switch next to the thermostat, however, this will require running more 24V wire and by placing the switch by the pump station, periodic checks of the system pressure and temperatures are more likely (and recommended). The system is supplied with a Relay Box (see photograph on following page) which connects to the three pin connector from the pump station and has four wires coming out that need to be connected to the Space Heating or Hot Water switch as per Figure #8. The relay box contains two 12V relays, one (A) that is energized when the pumps come on and causes the dampers to close, and the other (B) that is normally closed (NC), but when the wall switch is moved to Space Heating, becomes energized and disconnects the power to the pumps. The system controller remains powered. Rev. 8.3 29 of 44
Rev. 8.3 30 of 44
FIGURE #8 Rev. 8.3 31 of 44
As per Figure #8, run all of the low voltage cables to the box containing the DPST (double pole single throw) wall switch. Wire the circuit as per Figure #8 with the following functions in mind: 1. The wall switch serves the dual purpose of by-passing the pump station controller when the switch is in the Space Heating (or On ) position and also disconnecting the power for the pumps. This changes the circuit for the damper control so that the water / air temperature difference requirement is not used in the Space Heating mode. 2. When the switch is moved to Space Heating= on, the circuit for the dampers remains open and they will move to their N/C (normally closed) position and direct the air to the heating and return air ducting. At the same time, the switch completes the circuit to bypass the pump station contacts and allows the fan to run even though the pumps are switched off. 3. The thermostat should be set to the desired temperature in the space heating mode and then set to a very high temperature in the hot water mode. When in the hot water mode, the thermostat is just completing the circuit for the fan, with the control for the system being managed by the controller on the pump station. 3.19 Pipe Insulation Make sure that all piping is well insulated with thick insulation such as Aerocel or Armacell pipe insulation. All elbows should have mitered joints and all valves and fittings should also be insulated. Ensure that all piping is well insulated to also protect for burn hazards. Rev. 8.3 32 of 44
4.0 Testing and Operation 4.1 Powering up the System the First Time Now that the system has been filled and pressure tested, the pump station can be plugged into the wall and the power turned on. Verify that the fan operates by turning down the thermostat (provided that the thermal switch is closed by the temperature of the panels being at least 20 C or 68 F) or turning the fan control switch to on if no thermostat is used. 4.2 System Controller Functions Overview The SPS-2-AC controller performs several basic functions in the system. Its primary function is that of a differential temperature controller. This means that it looks at the storage bottom temperature T2 and the collector temperature T1, and if T1 is greater than T2 by the programmed differential ON temperature DT, it turns on pumps to start flowing the solar loop and transferring solar heat to the storage tank. The pump will then turn off at the lower differential OFF set point. If the temperature continues to rise above the maximum safe temperature of the tank setpoint [HT2], the system switches the pumps off and the HT2 error will be displayed. All setpoints are provided with hysteresis settings to prevent short cycling of the pumps or devices. Rev. 8.3 33 of 44
Controller Indicators and Buttons Controller Faceplate PUMP indicator Illuminates when the pump power is on. AUX1 indicator Illuminates when AUX1 is activated AUX2 indicator Illuminates when AUX2 is activated SET button Used for menu navigation UP arrow button Used for menu navigation DOWN arrow Button Used for menu navigation Rev. 8.3 34 of 44
Controller Basic Functions The controller includes two menus, basic and advanced. Access to the basic menu involves pressing buttons on the faceplate for various time periods. The advanced menu is accessible by pressing both the up and down buttons simultaneously for several seconds and then entering a pass code. For detailed instructions, see Appendix 1 The basic menu allows reading the current temperatures, min/max temperatures, and clock time. It also provides access to common setpoints SP1, SP2 and Ht2 as well as selection of pump mode and AUX1 manual mode. View Current Temperatures By pressing the DOWN button quickly (and repressing until desired sensor is reached), you can view the current temperatures for each sensor, as well as the current temperature differential. Note this is differential is NOT the differential temperature setpoint Dif it is displaying the actual current value of T1-T2. View Min/Max Temperatures By pressing the UP button quickly, you can view the maximum and minimum temperatures (since last reset) for each sensor, as well as the minimum and maximum temperature differential. The controller will scroll through T-1 T-2 t-3 Dif, showing the minimum, then maximum temperatures. If the UP key is pressed again, the values are reset and the message rst will be shown on the display. Clock Display To see the current clock time and date, press SET quickly, the current hour (24 hour clock) will be displayed, followed by the minutes, and then the day of the week. For ease of understanding the menus, Day 1 should be set to Sunday, and day 7 to Saturday. Rev. 8.3 35 of 44
Adjusting Basic Setpoints: The following settings can be adjusted at the basic menu level by pressing the SET button for 2 seconds. Each setpoint name will be displayed, followed by the current setpoint. Use the up and down buttons to adjust the setpoints as required, and press SET to store the value. Clo - Adjusting the Clock and day of the week After entering the Clo menu item, press the SET key and the settings will appear in the following order: Current Hour, Minutes, Day of the Week. Adjust as required using up and down arrows and press SET when complete. For ease of understanding the menus, Day 1 should be set to Sunday, and day 7 to Saturday. Temperature Units Sub-Menu 231 To enter the Temperature Units submenu to select Celsius or Fahrenheit units, select code 231. Select the units desired (Celsius or Fahrenheit), and press SET. Pump Operation Control Use this function to turn off the pumps when in the space heating mode and also to put the pumps back on AUN when in water heating mode. To get to this mode, push and hold the DOWN button for at least 10 seconds. Then use the SELECT button to choose the desired mode. Rev. 8.3 36 of 44
Controller troubleshooting Controller errors are displayed on the screen as error codes. The following are failure / warning codes and their causes: Function Description Er1 T1 sensor (collectors) disconnected or out of range Er2 T2 sensor (tank bottom) disconnected or out of range Er3 T3 sensor (tank top) disconnected or out of range ICE Temperature for sensor 1 is freezing HT1 Temperature for sensor 1 is overheated HT2 Temperature for sensor 2 is overheated ppp Configuration parameters not programmed or out of range ON Circulation pump in manual ON mode OfF Circulation pump in manual OFF mode Rev. 8.3 37 of 44
5.0 Routine operation 5.1 Fill weights, pressure and temperature ratings: Tank weight when filled 340 kgs. or 750 lbs. (approx.) SSHW Box when filled 36 kgs. or 80 lbs. (approx.) Maximum Pressure of Solar loop 35 psi Maximum Pressure of Potable Loop 150 psi Maximum temperature of Solar loop - Air 80C or 176F. When air stagnation occurs, the air will be cooled immediately by the water. Maximum Temperature of Solar Loop Water 60C or 140F, controlled by T2 Maximum 5.2 Expected operating conditions The system performance is obviously dependent on the solar energy available; however, the system should perform within the following parameters: T1 Collector outlet air temperature (when sunny) = 30-80C (80-176F) T2 = Tank water temperature typically 3-7C/hour for a 65 Gallon tank Flow rates are set at the factory for both pumps. Rev. 8.3 38 of 44
5.3 Switching between Space heating and Hot Water heating Modes As described in Section 2.2 and 2.3, the system has dual modes of operation. The wall switch allows the operator to switch between the modes, with one simple switch. The relay box that is supplied contains two 12V relays, one that keeps the dampers closed when on Hot Water mode, and the other that shuts off the pumps when on Space Heating mode. Typical wiring setup with Relay Box Rev. 8.3 39 of 44
6.0 Emergency shut-off procedures In the unlikely event of some kind of failure, either a leak or other malfunction, 1. System power can be shut off at the master switch. 2. Shut off the cold water supply line to the storage tank. 3. Isolate the storage tank by closing all of the ball valves. 4. Check existing water heater system to verify that it is working properly and then open the bypass valve to ensure a cold water supply to the existing system. 7.0 System Maintenance Schedule - Check the system pressure on a regular basis and ensure that it is at 35 psi. If the pressure has dropped more that 2-3 psi, check for leaks. The system should not need to be drained or flushed unless the pressure drops. If so, TURN OFF THE SYSTEM POWER and drain and refill the solar loop and check for leaks again. Make sure that the system is purged of air before turning on the pumps as per the installation instructions. No special cleaning is required for the solar loop. - Air Vent check The air vent should be tested at the beginning of each season or at least once a year to ensure that all trapped air is released from the solar loop. Be careful that the water may be hot and do not release too much, as then the system will need to be re-pressurized. - Potable loop heat exchanger fouling - Areas with high mineral content (hard) water will require a heat exchanger flush periodically depending upon the extent of the mineral concentration. If the water is known to have high mineral content, the potable loops should be flushed with vinegar or other solution for this purpose by disconnecting the unions to connect a flush source. To reduce the occurrence, a water conditioner should be installed on the potable water supply. - Expansion Tank check Expansion tanks usually have a useful lifetime of about 15 years, however, they should be checked annually for correct pressure and condition. - Clean SolarSheats Depending on local dust conditions, clean the glass of the collector every 1-2 months if necessary or at least every 6 months. - Inspection and minor repair Periodically inspect the ductwork and insulation at the collector connection through to the SSHW box, ensuring that the joints are properly sealed etc. The coil of the SSHW heat Rev. 8.3 40 of 44
exchanger can be checked and cleaned once per year, with care being taken not to damage the fine aluminum fines on the coil. - Equipment life expectancy and replacement - The system has an undefined life expectancy, with the SolarSheats expected to be 20-25 years and the fan and pumps dependent on use, but 5-10 years should be expected. As mentioned above, the hardness and possibly sediment in the potable water supply can affect the heat exchanger in the pump station, but regular annual flushing should prevent any long term effects. Rev. 8.3 41 of 44
8.0 Special Conditions - Freezing In the event of freezing conditions in the interior of the house, it is critical to drain the system as would be done normally with the domestic water supply. If the coil in the heat exchanger was to freeze, the system could leak, however, the volume of water contained in the Solar Loop is approximately 4 liters (1 US Gallon), so the potential for water damage is minimal. Ensure to check the pressure in the system in the event of freezing and if the pressure is low, do not refill until the cause has been determined. - Long term shut-down Shut of the water supply and turn off the circuit breaker. Drain the storage tank and open the fill and drain valves for the Solar Loop. If the system will freeze, either blow out the Solar loop with compressed air or fill with plumber s anti-freeze and make sure to vent and run the pump to circulate the anti-freeze. With the potable loop, it is important also to remove the water from the pump and flat-plate heat exchanger, so either compressed air must be used (do not exceed 40 PSI) or anti-freeze also. In order to get the anti-freeze into the potable loop pump, the piping would need to be disconnected at the couplings and the anti-freeze poured in. When the system is re-commissioned, be sure to flush it extensively with fresh water before use, to clear the potable loop. This is required even if the system is not exposed to freezing, as there may be stagnant water in the system that should be flushed out. The flushing can be done by isolating the storage tank from the main water supply (use the by-pass), fill the tank and run the pumps for about 10 minutes, and then drain the tank. The tank can then be refilled and re-connected to the water supply. Rev. 8.3 42 of 44
9.0 Warranty Your Solar Home stands behind the workmanship and materials in our products. The SolarSheats are warranted for five years (see full warranty description in the Appendix) from the date on which you purchase your Roof Mount or Wall Mount unit. We will replace component failures related to workmanship for 1 year from date of purchase, but maintain no liability for system problems associated with improper installation or configuration. We also maintain no liability for labor costs associated with the replacement of defective components or units. Your Solar Home will also work as an intermediary for return and replacement of defective tanks, controllers, pumps, heat exchangers and power supplies within each manufacturer s warranty period and terms to provide quick return to system operation. Any defective components must to be sent to Your Solar Home for analysis and eventual return to the original manufacturer. Your Solar Home also shall not be liable for any injury, loss or damage, direct, incidental or consequential (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or other incidental or consequential loss) resulting from the use or the inability to use the product, and the user agrees that no other remedy shall be available to it. The maximum liability under this warranty shall not exceed the Your Solar Home contract price of the product. The system components have separate warranties from the respective manufacturers of the main components, namely the SolarSheats (Your Solar Home), the pump station (Purist Energy) and the tank (Rheem/Water Heater Innovations Inc.). All component warranties are included in the Appendix. If you believe that there is a warranty issue with the system or a component, please contact Your Solar Home at the address shown on page 46. Rev. 8.3 43 of 44
10.0 Contact us We hope that the system installation went well and that you enjoy many years of solar heating! If you have any questions about the system, installation and maintenance or any other related question or comments please write, call or email us. We look forward to hearing from you and if there is anything we can do to further improve this manual or our system, we would greatly appreciate your feedback. You can contact us as follows: Your Solar Home Inc. 299 Applewood Crescent, Unit 4 Vaughan, Ontario, Canada L4K 4E7 Telephone: 905-669-2212 866-556-5504 Fax: 905-669-2204 Email: info@yoursolarhome.com Rev. 8.3 44 of 44