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ENERGY KINETICS Smart Solar EWRA1, Installation Manual, Page: 2 / 56

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ENERGY KINETICS Smart Solar EWRA1 Installation Manual Download Page 2

EnerWorks Solar Water Heating Appliance

 

Installation Manual / Energy Kinetics Inc.              -  Page 

2

  -

                           © 2011 EnerWorks Inc.

 

 

 

Recognize this symbol as an indication of important safety information! 

 

 

EnerWorks Residential Solar Water Heating Appliances must be installed as 
directed by this manual by an EnerWorks authorized dealer or warranty is void.   

 
 
 

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the 
State of California to cause cancer, birth defects or other reproductive harm. 

Summary of Contents for Smart Solar EWRA1

Page 1: ...lector Pre heat Appliances EWRA1 DWHX EWRA2 DWHX EWRA3 DWHX EWRA4 DWHX Energy Kinetics Inc 51 Molasses Hill Road Lebanon NJ 08833 Tel 908 735 2066 Toll free 1 800 323 2066 Fax 908 735 2068 www energyk...

Page 2: ...on of important safety information EnerWorks Residential Solar Water Heating Appliances must be installed as directed by this manual by an EnerWorks authorized dealer or warranty is void CALIFORNIA PR...

Page 3: ...ar Collector has SRCC OG 100 certification and the EnerWorks Residential Solar Water Heating Appliances are certified to OG 300 standards This certification does not imply endorsement or warranty of t...

Page 4: ...s are manufactured with tempered glass Though extremely resistant to impact tempered glass can break if an edge is subjected to stress During storage and installation protect glass edges Glass breakag...

Page 5: ...n 16 4 3 Thermosiphon loop installation 19 4 4 Water connections bypass valves 23 4 5 Water connections cold mains supply 25 4 6 Water connections solar storage hot outlet 26 4 7 Water connection to h...

Page 6: ...installation 40 7 Appliance Start Up 41 8 Final Steps 42 9 Scheduled Maintenance 42 10 Troubleshooting 43 10 1 Controller 43 10 2 Thermistor 43 10 3 Pump 44 10 4 Noisy pump 45 10 5 Heat transfer flui...

Page 7: ...ce are off during the installation Do not modify any electrical connections in the EnerWorks Energy Station Cover on Energy Station is designed to protect components from damage and to protect users f...

Page 8: ...through the heat exchanger and heat is transferred to the potable water After giving up its heat to the potable water the cool heat transfer fluid is pumped back to the solar collectors to be heated...

Page 9: ...ly blue Hot water supply to home red Thermosiphon loop solar heated water to storage tank red Thermometer Bypass valves to isolate Appliance for service Anti scald valve not included may be required b...

Page 10: ...capacity Solar storage tank size does not depend on size of existing water heater but on number of solar collectors Number of collectors depends on hot water use and on number of individuals in home S...

Page 11: ...nd of the day a solar storage tank larger than the minimum required size will provide greater storage capacity of hot water and better performance A smaller family may benefit from a larger tank With...

Page 12: ...ea that will prevent damage to floors ceilings and furniture in the event of a leak If this is not possible a drain pan must be installed under water heater Pan must have a pipe to a drain or other ou...

Page 13: ...leak tested charged with heat transfer fluid and purged of air Fittings are insulated and collector flashing is installed Controller and Monitor are programmed and Appliance is commissioned Installer...

Page 14: ...n from system to reservoir 15 Heat trap 6 120 VAC three prong to grounded surge protected outlet 16 Upper manifold with anti fouling valve 7 Heat transfer fluid pump positive displacement gear pump 17...

Page 15: ...electrician Do not attempt unless fully qualified This installation may have to be inspected Follow all codes and regulations EnerWorks assumes no liability for any damage to property or injury or dea...

Page 16: ...late to hide connections see 4 10 1 Over temperature control connection 4 TOP FEED TANK ONLY Remove plastic dip tube from cold port inlet at top of tank optional If no fitting is in cold port apply th...

Page 17: ...smooth surface of corrugated pipe close to manifold Figs 4 2 2 Do not over tighten as thermistor may dent and damage corrugated pipe 9 Using an accurate pressure gauge check expansion tank air pressu...

Page 18: ...ghten but do not over tighten as gasket may be damaged Fig 4 2 5 Direct connection for bottom feed tank 13 Lift Energy Station and walk it in to tank such that Energy Station mounting brackets are in...

Page 19: ...y be exceeded and must not be used 1 Visually inspect hot outlet nipple for heat trap valve or gasket Insert a screw driver into hot outlet to determine presence of heat trap valve or gasket If a heat...

Page 20: ...elbow x sweat fittings with an angled pipe length between them Thermosiphon loop will consist of vertical riser and horizontal section with angled 45 section in between Fig 4 3 2 Adjust orientation o...

Page 21: ...more hot water out of insulated storage tank A reverse thermosiphon effect will occur during times of low solar radiation transferring heat from hot water tank to surrounding room Benefit of solar wil...

Page 22: ...lar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 22 2011 EnerWorks Inc Remove thermometer from well before soldering Do not install thermometer until soldering is complete and...

Page 23: ...tting and line downstream of ball valve must be rigid copper as temperature of solar heated water may exceed PEX ratings 2 Tee fitting above ball valve will direct mains water supply to cold mains inl...

Page 24: ...EnerWorks Solar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 24 2011 EnerWorks Inc Fig 4 4 1 Bypass valve configuration...

Page 25: ...trap Sweat connections using lead free solder and appropriate plumbing techniques If supply is PEX use installer supplied fittings for connection 3 To maintain system certification SRCC requires 5 of...

Page 26: ...roduce very hot water that exceeds PEX temperature ratings 4 7 Water connection to hot water distribution network 1 Ensure hot water outlet of pre existing now back up water heater is connected to hom...

Page 27: ...loss and prevent condensation Fig 4 6 1 2 If anti scald valve is installed highly recommended or required check local code adjust set point if required by code or to homeowner s specifications 3 Do no...

Page 28: ...9 1 1 Line set connections to Energy Station Note For clarity line set is not insulated Proper installation must have insulated line set to prevent heat loss and to limit burn risk 4 9 2 Supplemental...

Page 29: ...ank tee flare to flared port on upper manifold of Energy Station Install a smooth and continuous line without unnecessary bends Slide on line insulation and cut insulation to appropriate length Slide...

Page 30: ...e on top of solar storage tank Fig 4 10 1 1 3 Punch out one round insert if necessary and install cable clamp Fig 4 10 1 2 4 Insert over temperature wire through connector nut Feed enough wire through...

Page 31: ...hermostat Connect black wire descending from top to vacant terminal of thermostat Fig 4 10 1 5 13 Set lower thermostat setting to 120 F 50 C Fig 4 10 1 5 Carefully stow wires Reinstall insulation and...

Page 32: ...d 6 to Common Com and to Source Src Fig 4 11 2 8 Replace connection cover Replace snap on cover and push Controller assembly down 9 Temporarily plug in Energy Station LCD screen default display is tem...

Page 33: ...urn fluid from appliance to reservoir to left pointing male quick connect when facing Energy Station on lower manifold Fig 5 1 1 Return connection assembly includes female hydraulic quick connect coup...

Page 34: ...Propylene Glycol Two jugs are included with two three and four collector appliances Pour 100 propylene glycol USP into EnerWorks Charge Pack reservoir or into a large clean bucket Add an equivalent am...

Page 35: ...with switch it is much easier to start and stop charge pump by using a switch Switch on charge pump to circulate fluid and remove air from appliance 4 With charge pump operating observe clear line ret...

Page 36: ...LCD will turn on for 3 seconds and temperature difference T is displayed see Appendix Controller Operation Energy Station circulation pump is a positive displacement gear pump When not operating gear...

Page 37: ...momentarily Switch off pump and close valve as before If pressure is above 30 psi let very small volume of fluid out of appliance outlet 9 Disconnect supply and return charging hoses from appliance O...

Page 38: ...Water Heating Appliance Installation Manual Energy Kinetics Inc Page 38 2011 EnerWorks Inc Before installing flashing and leaf guard confirm no leaks at panel s insulate line set and record collectors...

Page 39: ...nd snow shedding Secure upper side flashing to roof with included roofing screws 3 Insert rectangular caps into upper and lower holes created by side flashing and collector Fig 6 1 1 Secure to roof wi...

Page 40: ...etween collectors try loosening C channel bolts temporarily Be sure to re tighten C channel bolts after center flashing is started in side wall grooves It may also help to bow the center flashing sect...

Page 41: ...th included roofing screws Fig 6 3 1 4 Secure end caps to leaf guard sections and secure sections to each other at overlaps with self drilling screws 5 Bend center flashing down to leaf guard and secu...

Page 42: ...Serial numbers of Energy Station and collectors and thermistor sticker are necessary for timely and effective service 3 Provide homeowner with Owner Manual and a copy of Product Installation Registrat...

Page 43: ...is faulty If points to Storage storage tank thermistor circuit is shorted or open or thermistor is faulty Check and fix connections or replace thermistor if necessary see below 10 2 Thermistor 1 Chec...

Page 44: ...18 F 10 C hotter than mains ground water temperature and pump will operate Pump is not operating 1 If LCD screen on Controller is blank check power to Energy Station 2 If Err shows on Controller refer...

Page 45: ...If pressure is low check for and fix any leaks 1 Identify location of fluid leak wetness or discoloration may indicate source of leak 2 Quick connects fluid ports may be dirty or faulty copper shavin...

Page 46: ...EnerWorks Solar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 46 2011 EnerWorks Inc Exploded Views Fig A 1 Energy Station exploded view Fig 85 Energy Station exploded view...

Page 47: ...EnerWorks Solar Water Heating Appliance 2011 EnerWorks Inc Page 47 Energy Kinetics Inc Installation Manual Fig A 2 Expansion tank upper manifold exploded view Fig A 3 Lower manifold exploded view...

Page 48: ...EnerWorks Solar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 48 2011 EnerWorks Inc...

Page 49: ...be done with Energy Pack unplugged Do not connect or disconnect any wires to terminals at lower left of controller Current flows through these connections and there is a danger of shock and of damagi...

Page 50: ...oduction should in no way be used to assess energy displacement for billing purposes Program PRGM Mode To enter program PRGM mode push and hold all three buttons By pushing Item button Controller cycl...

Page 51: ...ly for Space SaverTM Appliance Default 185 F 85 C to 122 F 50 C Maximum Storage Diff l Differential for Maximum Storage setpoint temperature DO NOT MODIFY Default 9 F 5 C F or C blinking Temperature u...

Page 52: ...EnerWorks Solar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 52 2011 EnerWorks Inc Product Installation Registration Form...

Page 53: ...EnerWorks Solar Water Heating Appliance 2011 EnerWorks Inc Page 53 Energy Kinetics Inc Installation Manual Maintenance Log...

Page 54: ...EnerWorks Solar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 54 2011 EnerWorks Inc Residential Site Survey...

Page 55: ...EnerWorks Solar Water Heating Appliance 2011 EnerWorks Inc Page 55 Energy Kinetics Inc Installation Manual...

Page 56: ...EnerWorks Solar Water Heating Appliance Installation Manual Energy Kinetics Inc Page 56 2011 EnerWorks Inc Tool and Supply Checklist...

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