EnerWorks EWRA1 Installation Manual Download Page 4

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Contents

1 – Safety
2 – EnerWorks Solar Water Heating Appliance

3 – Site Evaluation

4 – Line-Set Installation

5 – C-Channel Installation

6 – Solar Collector Installation

7 – Collector Flashing and Leaf-Guard Installation

2.1 Description
2.2 Pre-heat Appliance Schematic
2.3 Single Tank Appliance Schematic (USA only)

3.1 Collector Location, Orientation and Shading

tanding Seam M

3.2 Available Roof Space
3.3 Collector Racks
3.4 Line-Set
3.5 Location of Energy Station and Solar Storage Tank

4.1 Line-Set Description
4.2 Line-Set Routing
4.3 Line-Set Installation

5.1 Locating Rafters and Positioning C-Channel
5.2 Securing C-channel Asphalt roof (Shingles)
5.3 Securing C-channel to S

etal Roof

5.4 Roof-Penetration Flashing Boot

6.1 Preparation of Collector(s)

6.2 Hoisting and Securing Collectors to Roof

6.3 Securing Collectors to C-Channel
6.4 Collector Configurations

6.5 Line-Set and Control-Wire Connections

6.1.1 Converting Collector(s) from Left to Right
6.1.2 Installing Temperature Sensor (Thermistor)
6.1.3 Installing Collector Mounting Brackets

6.2.1 Ladder Hoist or Shingle-Lift
6.2.2 Scissor Lift or Articulating or Forklift Boom
6.2.3 Scaffolding
6.2.4 Ladder and Lift Line

6.4.1 One-Collector Configuration
6.4.2 Two-Collector Configuration
6.4.3 Three-Collector Configuration
6.4.4 Four-Collector Configuration

7.1 Side-Flashing for 1-Collector Appliances
7.2 Center-Flashing for 2, 3 and 4-Collector Appliances
7.3 Leaf-Guard Installation

Product and Installation Registration Form
Residential Site Survey
Tool & Supply Checklist

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Module 4

Solar Collector

Installation Manual

Summary of Contents for EWRA1

Page 1: ... Pre Heat Appliances EWRA1 EWRA2 1 2 Collector Single Tank Appliances USA only EWRA1 ST EWRA2 ST Solar Water Heating Appliances EnerWorks Inc 969 Juliana Drive Woodstock ON N4V 1C1 Canada Tel 519 268 6500 Toll free 1 877 268 6502 Fax 519 268 6292 www enerworks com 2013 enerworks ...

Page 2: ... properly installed and maintained meet or exceed the standards established by the Florida Solar Energy Center FSEC in accordance with Section 377 705 Florida Statutes This certification does not imply endorsement or warranty of this product by the Florida Solar Energy Center or the State of Florida The EnerWorks Pre Heat Appliance is the first system in North America to achieve the Canadian Stand...

Page 3: ...or cardboard When hoisting collectors to roof be very careful not to bang glass edge Collectors must not be levered over ladder or eave as they may be damaged Be very careful of collector connections as they are soft copper and may be easily damaged A leak proof heat transfer fluid loop can only be achieved if collector connections are not damaged Do not store collectors outside with glass face do...

Page 4: ...6 2 Hoisting and Securing Collectors to Roof 6 3 Securing Collectors to C Channel 6 4 Collector Configurations 6 5 Line Set and Control Wire Connections 6 1 1 Converting Collector s from Left to Right 6 1 2 Installing Temperature Sensor Thermistor 6 1 3 Installing Collector Mounting Brackets 6 2 1 Ladder Hoist or Shingle Lift 6 2 2 Scissor Lift or Articulating or Forklift Boom 6 2 3 Scaffolding 6 ...

Page 5: ...t exchangers Selectionmustbeacceptable inthejurisdictions Assemblies installation and materials used during installation shall meet applicable requirements of local regional state provincial and federal regulations and fire codes national roofing contractors association practices Any penetrations made in drywall or any otherfirewallmustbefixedtomaintainintegrityoffireprotection All persons working...

Page 6: ...ectors to be heated again Hot potable water is stored in the solar storage tank In the Pre Heat Solar Water Heating Appliance Fig 2 2 the solar storage tank is a standard North American electric hot water tank No power is connected to this tank it only stores solar heated water The solar storage tank is plumbed in series with the original water heater electric fossil fuel or on demand Whenever hot...

Page 7: ...id Heat transfer fluid line from Energy Station to collectors blue carries cool fluid Cold mains water supply 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 by code 1 2 3 4 5 6 7 8 12 15 16 17 18 13 9 10 11 14 Heat trap U bend limits heat loss Solar s...

Page 8: ...om collectors to Energy Station red carries hot fluid Heat transfer fluid line from Energy Station to collectors blue carries cool fluid Hot water supply to home red Anti scald valve required Cold mains water supply blue Solar storage tank with electric back up Thermometer Thermosiphon loop solar heated water to storage tank red 1 2 3 4 5 6 7 8 12 13 9 10 11 14 Energy Station Pressure relief valve...

Page 9: ...s may be necessary to proceed with installation Followallcoderequirementsandregulations Collector s should face as close to south as possible for optimal performance Within 45 of south is acceptable as there is less than 10 loss Fig 3 1 1 The roof angle from horizontal for optimal year round performance is equivalent to latitude of location plus or minus 15 A steeper angle provides better winter p...

Page 10: ...pper tube A proper and dedicated bending tool must be used for tight bends Line should be as smooth as possible with no unnecessary fittings or bends Site evaluation should include examining location and difficulty of roof and wall penetrations Appropriate techniques and materials for sealing penetrations are necessary Energy Station and solar storage tank will be located in mechanical or utility ...

Page 11: ...se transferred through lines Exterior line set and insulation must be protected by molding electrical conduit or false downspout that matches existing siding or eavestrough Fig 4 2 3 Exterior line set may be best for two or three storey applications Line set may run around eave and down exterior wall if access to attic is limited Fig 4 2 1 option 3 All exterior insulation shall be protected from u...

Page 12: ... impairing enclosure functions Roof penetration between collectors is recommended as collector flashing hides line set penetration and eliminates need to protect insulation from damaging UV When working in attics or confined spaces determine type and quality of insulation material Use appropriate respirators or masks as necessary to prevent inhalation of insulation material A dedicated tube bendin...

Page 13: ...after positions need to be transferred to exterior roof This may be done in a number of ways and will depend on access Measure from side edge of roof or carefully remove soffits to determine spacing Temporary metal clips strips or pipe may be fixed to the rafters inside the attic and a metal detector eg Zircon MT6 Bosch D Tect 100 used to determine rafter location from outside Using roof penetrati...

Page 14: ...305 mm is needed above collector for installations without leaf guards unless otherwise stated by local regulations Fig 5 1 2 5 With this information and referring to Fig 5 1 2 mark position of collector s and of C channel Note that when collectors are secured the distance between them will be approximately 5 75 146 mm 6 Collector mounting points are 48 1220 mm apart C channels must be mounted hor...

Page 15: ...tate installation as distance between peak and blocks may be measured and transferred to exterior Metal or wood 2 x 4 min spanners may be fixed horizontally across rafters C channel can then be secured with bolts or threaded rods Ø3 8 and lock nuts instead of lag bolts Fig 5 2 1 Spacers should be used between roof board and spanner to limit bowing and flexing of roof sheathing and spanner Holes ca...

Page 16: ...led hole with nylon spacer hole and stick spacer to roof Fig 5 2 4 3 Place C channel over spacer Insert lag bolt through washer Place lag bolt with washer in place through C channel slot and nylon spacer into pre drilled sealant filled rafter hole Fig 5 2 5 Tighten lag bolt with ratchet and extension or drill driver with extension Do not tighten completely until all necessary C channel lag bolts a...

Page 17: ...of raised seams Longer 6 lag bolts are also included to ensure a solid anchor Metalroofscanbeextremelyslippery especiallyif wet Donotgetonmetalroofsiftheyarecoveredin deworifitisraining Useextracautionwhenworkingonmetalroofs Before solar collectors can be installed line set with control wire must be pushed pulled through roof penetration Flashing boot must be installed to seal penetration Note in ...

Page 18: ... left to right conversion if necessary installation of temperature sensor and installation of mounting brackets Plastic foil sheet must remain on collectors until pressurization of heat transfer fluid is complete If collectors are exposed to sun during appliance charging and before pressurization flash boiling and damage of heat transferfluid will occur and there is a danger of scalding Do not rem...

Page 19: ...atand s m o o t h It m ay a l s o b e accomplishedwithcollectorstandingonlongsidewithconnectionsup Itshouldnotbeattemptedin rain 1 Remove and set aside five screws that hold grill in place at bottom of collector Fig 6 1 2 Center screw is self drilling and different from others see insert in Fig 6 1 2 Carefully remove grill by first lifting perforated section and then by gently pulling grill away f...

Page 20: ...ontrol device in grill s former location and vice versa It must be at top and grill must be at bottom of collector for stagnation control to function Be sure to firmly seat grill channel and stagnation control device assembly channel over aluminum covered back insulation Fig 6 1 4 Fig 6 1 3 Swapping stagnation control device and grill Fig 6 1 4 Removing and inserting stagnation control device Sola...

Page 21: ...blocks Fig 6 1 6 Secure damper channel with long self drilling screws Fig 61 6 Note these screws pass through outer and inner walls of damper channel sandwiching collector backing 7 Secure intake grill with removed screws Left to right conversion is now complete Fig 6 1 5 Inserting stagnation control device into hinge blocks Fig 6 1 6 Securing stagnation control hinge blocks and damper channel Sol...

Page 22: ...between fingers or you will be measuring resistance through your body and not through thermistor alligator clips work best Check associated temperature from table of resistance vs temperature Table 6 1 8 If resistance is not as expected check meter and connections and test again 2 Locate thermistor hole approximately 12 305 mm from top of one collector stagnation control device is at top on connec...

Page 23: ...fic Lower brackets are not side specific Fig 6 1 11 Upper brackets feature a unique tab that fits into C channel to support collector weight before securing Tab also allows collector to slide side to side in C channel Upper brackets also feature loops for attaching carabiners and or line to assist with hoisting With collector lying flat or on long edge but not on glass edge and resting on soft smo...

Page 24: ...h the Owner Manual and in the Appendices Serial numbers are required for warranty service and are difficult to access once collectorsareinstalled Lifting of collectors requires planning for safety Collectors are heavy 110 lb 50 kg and awkward to maneuver Different methods are available depending on budget roof access and number of collectors A lifting loop is incorporated into upper collector hook...

Page 25: ...ng on steeply pitched roofs Figs 6 2 2 6 2 3 Scaffolding is inexpensive and very effective for hoisting collectors and for providing a stable work platform Fig 6 2 4 Fig 6 2 2 Articulating s boom and scissor lift are all effective tools for hoisting collectors to roof hingle lift Fig 6 2 3 Lifting and securing collectors using forklift boom Solar Collector Installation Manual Fig 6 2 1 Upper brack...

Page 26: ...g brokenglass duetoimproperhandlingisnotcoveredbywarranty It is recommended to have two ladders in place side by side to prevent collector from sliding sideways or pivoting around ladder if it is off center Strapping or securing collector to plywood or boards may facilitate lift and prevent damage All individuals working on roofs should have completed a fall safety course and use appropriate safet...

Page 27: ... 6 3 1 Maximum torqueof9ft lbor12 2N m 3 Lift second collector if applicable into position placing upper bracket hook tabs into C channel Slide second collector far enough away from first collector to install upper custom flare fitting union 4 Connect custom flare fitting union to upper copper tube emerging from side of second unsecured collector Connect flare fitting 90 to lower copper tubes from...

Page 28: ...nions are not present EnerWorks Solar Water Heating Appliances are sized with one two three or four solar collectors See EnerWorks Site Evaluation Appliance Selection and Sizing manual to determine correct size Connection procedure 1 Install collector immediately next to roof penetration such that line set can be covered by side flashing Fig 6 4 1 2 Carefully bend line set to collector connections...

Page 29: ...nter flashing to achieve correct spacing of panels and secure it to the c channel 2 Line set connection from roof penetration to header will require 9 to 11 ft 2743 to 3353 mm depending on location of roof penetration 6 4 2Two CollectorConfiguration 6 4 3Three CollectorConfiguration Solar Collector Installation Manual Custom flare fitting union Roof penetration Flare fitting 90 elbows Fig 6 4 2 Tw...

Page 30: ...der ends and collector tube ends Do not tighten them 7 Insulate header tube with supplied 3 8 9 5 mm closed cell insulation 8 With header tube underneath panel connect and tighten flare fitting 90 elbows onto line set and collector tube ends 9 Repeat steps 5 to 8 for opposite header tube 6 4 4Four CollectorConfiguration Solar Collector Installation Manual Custom flare fitting unions Roof penetrati...

Page 31: ...nto each side of the flare fitting tees Connect f to additional tube ends Finally connect f to collector tubes 1 Cut excess length of control wire and or of thermistor wire as needed Strip about 1 3 4 cm of control wire sheathing Do not strip insulation from individual conductor wires Thermistor has very large resistance and thus negligible current flow Only voltage drop across thermistor is monit...

Page 32: ...d pressurized with heat transfer fluid Leave plastic foil cover in place until appliance is charged and pressurizedwithfluid 7 CollectorFlashingandLeaf GuardInstallation CollectorsmustremaincoveredwhilechargingAppliancewithfluid Uncoveredcollectorswill get very hot Fluid pumped through uncovered collectors will flash boil placing installer at risk of scalding Boilingwillalsodamageheat transferflui...

Page 33: ...crews 2 Insert edge of upper side flashing into side wall groove such that it overlaps lower section for shedding rain and snow 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 7 1 1 Secure to roof with included roofing screws Secure to upper and lower side flashing with included self dri...

Page 34: ...n place Fig 7 2 2 3 Secure upper center flashing section to lower section with a self drilling screw Fig 7 2 1 TIP If it is difficult to slide center flashing between 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 sections slightly upwards to get them starte...

Page 35: ...leaf guard section into side wall groove at top of collector Align side edge of leaf guard section with outer side of collector or with side flashing Leaf guard sections are overlapped to ensure edges are flush with outer collector side walls 2 Secure leaf guard to roof with included roofing screws 3 Insert triangular caps into left and right leaf guard ends Secure end caps to roof with included r...

Page 36: ...EnerWorks Inc 969 Juliana Drive Woodstock ON N4V 1C1 Canada Tel 519 268 6500 Toll free 1 877 268 6502 Fax 519 268 6292 www enerworks com ...

Page 37: ......

Page 38: ...or temp vs resistance table insulation tape for taping insulation seams pipe cutter de burr ream tool to de burr copper tupe 3 8 tube bender for tight bends necessary for 3 4 collector Appliances copper clips pipe straps for securing line set UV protection w rap for exposed insulation to protect line set false dow nspout electrical conduit pvc abs exterior conduit for line set extra spacers lag bo...

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