SunEarth CASCADE DRAINBACK Installation, Operation & Maintenance Manual Download | Manualshive

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Summary of Contents for CASCADE DRAINBACK

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Page 3: ...CC OG 300 system certification is granted to SunEarth by the SRCC It may not be used for any commercial pur pose without the prior written consent of SunEarth SunEarth must approve any deviation from the specified materials and methods described in this manual in writing The Cascade Drainback solar water heating systems can be protected against freeze damage to temperatures as low as 50ºF 46ºC Thi...

Page 4: ...olating the Major Components and Shut Down Procedures 20 8 Summer Vacation Procedures 20 9 Maintenance and Troubleshooting 20 10 Cascade Drainback System Component Parts 22 11 Estimated Component Life Expectancy 23 12 System Operating Parameters 23 Appendix A OG 300 Approved Primary Components 24 Appendix B Pump Sizing Tables 27 Appendix C SRCC OG 300 Certified System Model Numbers 29 Appendix D C...

Page 5: ...e water heater s heating ele ment only A separate ther mostat should be utilized in monitoring the temperature from the collector To comply with safety reg ulations the thermostat is factory set at 120 F or less where local codes require DANGER Hotter water increases the potential for Hot Water SCALDS DANGER WATER TEMPERATURE SETTING Safety and energy conservation are factors to be considered when...

Page 6: ...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 Be sure your appliance is properly installed in accordance with local codes and the provided installation instructions SAFETY PRECAUTIONS Use this appliance only for its intended purpose as described in this Installation Operations and Maintenance Manu...

Page 7: ...ch and orientation and of course the seasonal intensi ty of solar radiation These variables some of which change from home to home on the same neighbor hood street will determine how much energy and money your Cascade Drainback system will save on an annual basis Your Cascade Drainback solar system is known as a forced circulation closed loop drainback system because it utilizes a mechanical pump ...

Page 8: ...t the day or constantly for hours at a time Both single and double tank Cascade Drainback systems are designed to accommodate two separate modes of system operation Your system can either 1 serve as a preheater to your conventional electric or gas water heater or 2 be bypassed entirely and run 100 on utility power during inclement weather or when maintenance is required The installation of an opti...

Page 9: ...k proofed as per applicable codes and National Roofing Contractors Association practices Building penetrations must allow vermin intrusion 3 7 Fire Rated Assemblies Penetrations through fire rated components must not reduce the fire resistance of the assembly below code 3 8 Building Materials Building materials adjacent to solar components must not be exposed to elevated temperatures 3 9 Confirmat...

Page 10: ...ssible on the return line piping to the drainback reservoir Water will drain down both the return tubes directly to the drainback reservoir and the supply tubes by spin ning the pump impeller in the reverse direction The collector should be mounted as close to the stor age tank as possible to minimize heat loss in the pip ing runs The solar collector should be mounted on the roof in accordance wit...

Page 11: ...P 7 P 7 COLLECTOR C SSN STAND OFF FLASHING STAINLESS LAG BOLT fig 3 STAND OFF ON FLAT TILE ROOF COLLECTOR C SSN FOOT MOUNT FLASHING STAINLESS LAG BOL fig 4 STRUT ON FOOT MOUNT FOR COMPOSITION ROOF ...

Page 12: ...is subject to hurricane condi tions additional steps may be required to secure the collector and mounting hardware to the struc tural 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 4 4 Collector Loop Plumbing The collector loop must be plumbed using copper or stain...

Page 13: ...pe runs or reduce the pipe size for shorter runs or higher efficiency pumps The pipe must be large enough that the velocity of the water in the pipe does not exceed 4 ft s Hot water flowing at over 4 ft s in a pipe will erode the pipe and reduce system life When more than one collector is used in the system the collectors should be plumbed in a reverse return piping arrangement in order to maintai...

Page 14: ...ing 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 or thicker A 1 wall thickness is required for exposed piping in all areas prone to annual hard freeze conditions When it co...

Page 15: ...rical connection Thoroughly wrap and weatherize the insulation with electrician s tape or insulation tape as provided by the manufacturer See Figure 8 for collector sensor installation detail If an electrical potential exists between the roof and ground this may induce current to flow down the sensor wire to the controller This current will result in a false signal being received by the control le...

Page 16: ... draining of the collectors and may result in freeze damage If the pump used has an integral check valve the check valve must be removed before installing the pump in the system Hard copper connections to the city cold water supply line and the home hot water feed lines are recommended The gaskets in standard water heater flex hose connectors can become brittle and com pressed over time and begin ...

Page 17: ... condition This is usually achieved using a pump with a steep pump curve For multistory buildings this can be especially challenging unless the drainback tank is located on the upper floor When there is a risk of pipe errosion due to high flow rates a pump throttling valve COMPONENT 22 may be located on the discharge or upstream side of the pump to adjust the solar loop flow rate and to prevent er...

Page 18: ...ctric water heaters have insulation values between R 12 and R 20 The R value expresses the thermal resistance of the tank insulation The higher the R value value the more effective the insulation material is at preventing heat loss The use of any solar storage tank with and R value below R12 is prohibited The storage tank should not be placed directly on an uninsulated floor or concrete slab In or...

Page 19: ...the control into the outlet The circulation pump line cord is plugged into the receptacle on the side of the controller A 230 VAC control and circulation pump may be substituted but troubleshooting the components in the future becomes more difficult 4 13 Heat Transfer Fluid HTF The HTF must be a non toxic fluid that meets FDA Generally Recognized as safe GRAS Classification The Cascade Drainback S...

Page 20: ... loop for leaks and ensure that there is adequate flow 4 14 4 STEP 4 Check that Collectors are Draining Back Turn the controller back to the OFF position Allow time for the collectors and piping to drain into the drainback reservoir Observe the water level in the drainback reservoir by means of the site glass visual flow meter or by checking with a dowel rod The water level in the drainback reserv...

Page 21: ...rain Back Tank 11 Boiler Drain 12 Pump 17 Differential Temperature Controller 18 Heating Element Tank Thermostat 19 20 Temperature and Pressure Relief Valve 21 Mixing Valve 48 min T1 9 17 3 10 11 ROOF JACKS PIPE INSULATION 8 20 HOT SUPPLY LINE TO FIXTURES COLD SUPPLY LINE T3 4 12 T2 22 fig 10 SINGLE TANK SCHEMATIC ...

Page 22: ...or 5 6 7 8 22 Ball Valve 9 Pressure Relief Valve 10 Drain Back Tank 11 Boiler Drain 12 Pump 17 Differential Temperature Controller 18 Heating Element Tank Thermostat 19 20 Temperature and Pressure Relief Valve 21 Mixing Valve 20 48 min T1 21 9 17 4 3 10 11 12 ROOF JACKS T3 PIPE INSULATION T2 22 TWO TANK SCHEMATIC fig 11 ...

Page 23: ...e 10 Drain Back Tank 11 Boiler Drain 12 Pump 17 Differential Temperature Controller 18 Heating Element Tank Thermostat 19 20 Temperature and Pressure Relief Valve 21 Mixing Valve 22 Tankless Water Heater 20 48 min T1 21 9 17 4 3 10 11 12 ROOF JACKS T3 PIPE INSULATION T2 22 19 HOT SUPPLY LINE TO FIXTURES TANKLESS BACKUP SCHEMATIC fig 12 ...

Page 24: ... serve as a preheater to your conventional electric or gas water heater or 2 be bypassed entirely and run 100 on utility power during inclement weather or when maintenance is required SINGLE TANK OPERATING INSTRUCTIONS 6 1 Solar Preheat Leave the circuit breaker on to your solar storage tank and set the tank thermostat to the lowest accept able temperature setting The electric resistance heating e...

Page 25: ...effect on the internal collector piping if the panel is left unprotected SunEarth s collector warranty specifically excludes stagnation conditions in excess of sixty days Remember to reset the SunEarth control to the AUTO position upon your return and check the system for proper operation and draining by moni toring the water levels with the pump on and off 9 MAINTENANCE AND TROUBLESHOOTING The fo...

Page 26: ...r as necessary with manufacturer s recommended jacket or coating or a high quality exterior latex paint 9 6 Glass Replacement In the unusual instance of collector glass breakage the glass should be replaced immediately This will reduce the likelihood of water accumulating inside the collector and deteriorating the insulation Contact your installation contractor to change the glass 9 7 Leaks If you...

Page 27: ...l the solar storage tank or back up water heater When closed isolates the solar storage tank and back up water heater from the pres surized city cold water supply line 9 Pressure Relief Valve PRV Will discharge heat transfer fluid water from the collector closed loop at the PRV pressure setting typically 30 150 PSI Under normal operating conditions the pressure relief valve will not discharge flui...

Page 28: ... To obtain warranty service please see the com pleted Appendix on the back of this manual with your installation contractor contact information or contact SunEarth Inc for the name of an authorized service agent near you 12 SYSTEM OPERATING PARAMETERS 12 1 Collector Loop Pressure The pressure in the solar collector loop should be within 0 20 PSIG 12 2 Circulation Flow Rate The flow rate in the col...

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Page 31: ...IS 40 SunEarth ThermoRay TRB 32 TRB 40 Collector Mounting Hardware Make Series SunEarth SolarStrut RexRack Flush Mount Kit Universal Tilt Kit Landscape Rack Install mounting hardware per SunEarth manuals standard residential drawings and or plan sets Storage Tank with Integral Double Wall Heat Exchanger Make Series Model Numbers SunEarth SunEarth SU80HE 1 SU65HE 1 SU120HE 1 Rheem Solaraide 81V80HE...

Page 32: ...ody and a metal or polymer impeller The pump motor shall be induction or permanent magnet ECM driven The pump shall be rated for maximum fluid temperatures of no less than 180o F and pressures of no less than 125 PSI The maximum rated amperage shall be no more than 1 5 Amps and the maximum rated power draw shall be no more than 135 Watts Thermostatic Mixing Valve The thermostatic mixing valve shal...

Page 33: ...gn pressure of all other components in the collector loop Thermometers Optional Thermometers shall be dial or scale type and shall have a metallic body and casing and a glass lens The range of measurement shall be not less than 30o F to 200o F with an accuracy of 2 An electronic temperature sensing system may be used in place of dial or scale thermometers see below Temperature Sensors Electronic A...

Page 34: ... corrosion A flow rate of more than the listed maximum through any collector should be avoided The system s static head is the most significant parameter when selecting the pump The pump selected must have a shut off head of at least the system static head plus four feet safety factor The larger the static head the bigger the pump required and the greater the risk of excessive flow once the system...

Page 35: ...inless Steel UP 15 100 SU7 Heat Exchange Tank 80 or 120 gal 1 2 Type L Supply Pipe up to 100 ft Bronze UP 26 96 BF 009 BF5 Star 32 BF 3 4 Type L Return Pipe up to 100 ft High Lift Systems Over 30ft Static Head For systems with static head in excess of 30ft no single small circulator pump will be able to fill the system In these cases it may be necessary to stack two pumps in series A combination o...

Page 36: ...ECRD 64 80 2G EPRD 64 80 TLG EPRD 64 80 75G ECRD 32 120 TLG EPRD 64 80 100G ECRD 40 120 TLG ECRD 32 80 2G ECRD 48 120 TLG EPRD 32 80 2G ECRD 64 120 TLG ECRD 32 120 2G EPRD 32 120 TLG ECRD 40 120 2G EPRD 40 120 TLG ECRD 64 120 2G EPRD 48 120 TLG EPRD 32 120 2G EPRD 64 120 TLG EPRD 40 120 2G EPRD 80 120 TLG EPRD 48 120 2G ECRD 80 120 TLG EPRD 64 120 2G EPRD 80 120 2G EXAMPLE EPRD48 80 2G Empire Seri...

Page 37: ...RS AND EXPOSED PIPING WHENEVER THE CIRCULATION PUMP SHUTS OFF WHEN PROPERLY INSTALLED AND OPERATED THE SYSTEM IS PROTECTED TO TEMPERATURES AS LOW AS 50 F BOILER DRAIN NO 11 SYSTEM FILL DRAIN VALVE VALVE 11 IS NORMALLY CLOSED WHEN OPENED IN CONJUNTION WITH PRV COMPONENT 9 IT IS USED TO CHARGE AND DRAIN THE SOLAR COLLECTOR LOOP PIPING THE HEAT TRANSFER FLUID USED IN THIS SYSTEM IS WATER NO OTHER FLU...

Page 38: ...W AIR TO FLOW IN OR OUT OF THE COLLECTOR LOOP ADDITIONAL TWO TANK SYSTEM VALVES VALVE NO 7 COLD FEED TO SOLAR TANK ISOLATION VALVE THIS VALVE IS NORMALLY OPEN WHEN CLOSED IN CONJUNCTION WITH VALVE NO 6 IT WILL ISOLATE THE SOLAR STORAGE TANK FROM THE POTABLE WATER SYSTEM VALVE NO 6 HOT OUTLET FROM SOLAR TANK ISOLATION VALVE THIS VALVE IS NORMALLY OPEN WHEN CLOSED IN CONJUNCTION WITH VALVE NO 7 IT W...

Page 39: ... the pool or spa water is isolated from the above SunEarth Products through the use of a heat exchanger FIELD LABOR Field labor to repair or replace any defective SunEarth Product is reimbursable as follows Year 1 100 collector Year 2 5 75 collector Year 6 10 50 collector FREIGHT AND SHIPPING EXPENSES In the event of a valid warranty claim approved by SunEarth SunEarth will pay for freight and shi...

Page 40: ... OR ANY WARRANTY OR NON INFRINGEMENT SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED WARRANTIES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU LIMITATIONS OF REMEDIES IN NO EVENT SHALL SUNEARTH BE LIABLE FOR ANY DAMAGES FOR LOST PROFITS LOST SAVINGS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE ABOVE SUNEARTH PRODUCTS OR FOR ANY CLAIM BY A THIRD PARTY S...

Page 41: ...ntractor Installer Information Service Warranty Information Name Address Phone Email System Info Model NO Date Puchased Date Installed Product Serial Company Comments For Service and Repair Contact APPENDIX H ...

Page 42: ...A email info sunearthinc com www sunearthinc com 8425 Almeria Avenue Fontana CA 92335 Phone 909 434 3100 Fax 909 434 3101 Revised 9 6 13 ...

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