Heat Transfer SuperStor SB SERIES Installation Manual Download

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SB SERIES

WITH BACK-UP

HEAT EXCHANGER

SE SERIES

WITH BACK-UP

ELECTRIC ELEMENT

• Installation • Operation • Maintenance

The solar energy system described in 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 SRCC.

E113265

Summary of Contents for SuperStor SB SERIES

Page 1: ...LEMENT Installation Operation Maintenance The solar energy system described in 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 SRCC E113265 ...

Page 2: ...r Solar Water Heater Potable Water Piping Solar Heat Exchanger Piping Tank Sensor Placement Solar Heat Exchanger Piping to Collector Panel Boiler Back Up Heat Exchanger Connection Boiler Tank Control Circulator Sizing Boiler Back Up Heat Exchanger SB Models only Electrical Connection Thermostat Adjustment Combination Thermostat and High Limit Control ECO Charging the System Commissioning the Syste...

Page 3: ... specified SRCC components for this design may affect your ability to certify this system WATER TEMPERATURE ADJUSTMENT If the SuperStor ContenderSolar Water Heater is going to have a set temperature above 120 F you must use a rated anti scald device to avoid severe burns or death from scalding temperature PART 1 PRODUCT AND SAFETY INFORMATION SPECIAL ATTENTION BOXES The following defined terms are...

Page 4: ...components required in the SuperStor Contender Solar Water Heating System include the solar collector The SuperStor Contender Solar Tank circulator pump differential solar control expansion tank pressure gauge mixing valve and non toxic propylene glycol heat transfer fluid The solar collector is the engine of the SuperStor Contender Solar System When the sun is shining the heat energy is absorbed ...

Page 5: ... upon an assumed set of environmental conditions Refer to the DOWFROST Specification sheet in the back of this man ual for recommended concentrations The differential controller uses 10k ohm thermistors or 1k RTDs depending on the contoller model to monitor the temperature difference between the collector and the SuperStor Contender Solar Water Heater The controller turns on when the collector is ...

Page 6: ... the integrity of the roof membrane is the most important roofing con sideration Ensure that all roof penetrations required to plumb and mount the solar collector are properly flashed and sealed in accordance with standard roofing practices Tremco POLYroof is the recommended elastomer for sealing roof penetrations Henry Co 204 208 or 209 mastic or Dow Corning Glazing Sealant are also acceptable Th...

Page 7: ... maximum intervals of ten feet 10 Copper plumbers tape or tube strap is required The pipe insu lation may not be compressed or crimped by the strapping material The installation of all horizontal and vertical pip ing may not reduce the performance or rating of any structural member or fire rated assembly Adhere to all applicable local codes and ordi nances COLLECTOR SENSOR PLACEMENT The collector ...

Page 8: ...ged of air Expansion tank and pressure temperature gauge are operating properly Solar control shows circulators operating properly on the solar panels Boiler Heat Exchanger SB Models Only Heat Exchanger is completely purged of air Expansion tank and pressure temperature gauge are operating properly Boiler control is operating circulator for the boiler back up heat exchanger Anti Freeze Fluid Make ...

Page 9: ...tors be used so heater can be easily serviced Install a shut off valve in the cold feed near the Solar Water Heater to isolated the tank for future service See Figure 3 1 Provide clear access to the storage tank pump expansion tank mixing valve time clock and other key components The components on the potable side of the system may require future service or maintenance so it is recommended that th...

Page 10: ...N TO SUITABLE OPEN DRAIN DISCHARGE LINE OUTLET HOT WATER RELIEF VALVE SOLAR SENSOR AUXILIARY CATCH PAN POTABLE WATER HEATING SYSTEM NON POTABLE HEAT TRANSFER FLLUID SHALL BE CONNECTED TO THE SOLAR HEAT EXCHANGER ONLY NEVER INTRODUCE ANTI FREEZE SOLUTION INTO ANY OTHER CONNECTION OTHER THAN THE SOLAR HEAT EXCHANGER THESE CONNECTIONS ARE FOR THE NON POTABLE HEAT TRANSFER FLUID LOOP DO NOT MAKE POTAB...

Page 11: ...ind the storage tank or to the wall if closer than 5 TANK SENSOR PLACEMENT Make sure the sensor is secured inside the well located in the lower section of the water heater Secure the sensor by packing Rubatex insulation behind the sensor This will also help the sensor react to temperature change Freeze protection fluid must be used to protect the system from freezing and must be rated as non toxic...

Page 12: ...orm the system 9 Expansion Tank Pre charged with air to allow for the expansion as the HTF fluid gets expansion and contraction with heating and cooling 10 Drain Valve Valve 10 Used to charge the collector loop with glycol purge air form loop and drain the Solar water heater heat exchanger of fluid 11 Collector Array Isolation Valve for system fill Valve 11 When closed is used to direct the flow o...

Page 13: ...e not be threaded or concealed and should be pro tected from freezing No valve of any type restriction or reducer coupling should be installed in the discharge line 20 Anti Scald Mixing Valve Automatically blends the hot water and the cold water feed line to control the discharge tempera ture to an acceptable and safe temperature This will also increase the amount of hot water that is drawn from t...

Page 14: ...Y THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING BY LOCAL CODES 2 ANTI FREEZE NON POTABLE HEAT TRANSFER FLUID SHALL BE USED FOR THE SOLAR HEAT EXCHANGER CIRCUIT ONLY NEVER NTRODUCE ANTI FREEZE SOLUTION TO ANY OTHER CONNECTION OTHER THAN THE SOLAR HEAT EXCHANGER 3 IF THERE IS A CHECK VALVE ON THE COLD WATER FEED LINE A THERMAL EXPANSION TANK SUITABLE FOR POTABLE WATER MUST BE SIZED AN...

Page 15: ...HE BACKUP HEAT SOURCE 7 CIRCULATORS SHOWN IN THE HYDRONIC BOILER PIPING ABOVE SHOULD HAVE AN INTEGRAL FLOW CHECK OR ALTERNATELY USE A STOCK PUMP WITH AN EXTERNAL SPRING TYPE CHECK VALVE CIRCULATORS WITH INTEGRAL FLOW CHECKS ARE NOT TO BE USED IN SOLAR SYSTEMS DUE TO EXTREME SOLAR COLLECTOR SENSOR ISOLATION TANK SENSOR TEMPERATURE PRESSURE GAUGE RELIEF VALVE VALVES SHOWN OPEN CONTROLLER CHECK VALVE...

Page 16: ...ont of the water heater Wire the boil er tank control to the boiler control or r e l a y c e n t e r Additional equip ment may be need ed in order to wire the control to the existing system Controls also have the ability to monitor and displaying solar collector tempera ture and also upper and lower tank tem p e r a t u r e S e e Control Installation Detail Fig 3 4 CIRCULATOR SIZING The circulator...

Page 17: ...recommend a flow rate of 1 gpm for every 10 000 BTU based on a 20 degree temperature difference between the supply and return of the Heat Exchanger Example Boiler is 100 000 BTU output 100 000 BTU 10 000 BTU 10 gpm flow rate The Heat Exchanger at 10 gpm will require a circulator that will operate at 8 feet of friction Fig 3 5 Pressure Drop Solar Heat Exchanger Boiler Back Up Contender Solar 0 2 4 ...

Page 18: ...nd the water heater The preferred way to ground is to use rigid metal conduit between the main panel and the water heater junction box with approved end fittings The separate ground wire connection provided in the water heater junction box must also be grounded Replace the junction box cover and insulation after you ve made the all wiring connections n CAUTION The manufacturer s warranty does not ...

Page 19: ...ace the insula tion and black access cover before turning on power to the heater CHARGING THE SYSTEM Solar Tank Fill the solar tank with water Do this by open ing the cold water isolation ball valve to the solar tank See Fig 3 2 Inspect all fittings for leaks The solar collector loop should be pressure tested with air 25 lbs before you pressurize the solar collector loop with glycol Mix the DowFro...

Page 20: ...must be insulated with a wall thickness of at least A 1 thickness is required in areas prone to hard freeze conditions Above ground insulation must be protected from Ultra vio let degradation All piping must be supported at a maximum interval of 10 feet and the piping sup ports must not crimp or compress the insulation COMMISSIONING THE SYSTEM After the glycol loop has been charged and pressure is...

Page 21: ...erials 8 The electric element may need cleaning A hissing sound while operating will happen when the element starts to build up deposits that will require cleaning This should be done only by a qualified individual or licensed plumber 9 Anode Rod Inspection The anode rod should be removed from the water heater tank annually for inspection If the anode core wire is exposed more than few inches it i...

Page 22: ...terways rendering it inoperative When the lever is operated hot water will discharge if the waterways are clear PRECAUTIONS MUST BE TAKEN TO AVOID PERSONAL INJURY FROM CONTACT WITH HOT WATER AND TO AVOID PROPERTY DAMAGE BEFORE operating lever check to see that a discharge line is connected to the valve directing the flow of hot water from the valve to a proper place of disposal If no water flows w...

Page 23: ...HEATER DIMENSIONS lbs SSC 50SB 50 1 NPT 3 4 NPT 187 SSC 80SB 80 1 NPT 1 1 2 NPT 286 SSC 119SB 119 1 NPT 1 1 2 NPT 367 CONTENDER SOLAR WATER HEATER SPECS 8 47 1 4 7 3 4 23 1 2 36 30 37 3 4 AMOUNT OF WATER DRAWN OUT OF STORAGE TANK WITHOUT ANY ENERGY INPUT 8 MODEL 7 3 4 33 1 2 GAL 43 55 1 2 HEAT SSC 119SB 119 10 27 CONTENDER GLASS LINED SOLAR SB SERIES MODEL HX VOLUME GALLONS HEATED WATER VOLUME OF ...

Page 24: ... 2 8 7 3 4 50 119 SSC 50SE LBS 1 WEIGHT SHIPPING 175 1 1 2 NPT SIZE 3 4 NPT OUTLET 336 1 INLET OUTLET SIZE CONTENDER SOLAR WATER HEATER DIMENSIONS EXCHANGER 23 SSC 50SE 71 1 2 60 1 4 F 8 7 3 4 E 33 1 2 SSC 119SE D 119 27 64 51 10 1 2 10 27 SSC 80SE 80 1 ALL DIMENSIONS ARE APPROXIMATE 80 SSC 80SE 23 1 2 CONTENDER SOLAR GLASS LINED SE SERIES MODEL SOLAR HX VOLUME GALLONS HEATED WATER VOLUME OF BACK ...

Page 25: ...ERMOSTAT CONTROL 1 7 6060P 633 6060P 633 THERMODISC MOUNTING CLIP 1 8 6060P 632 6060P 632 5 16 18 HEX NUT THERMODISC MOUNTING CLIP 2 9 6060P 636 6060P 636 PLASTIC PROTECTIVE COVER 1 10 6060P 635 6060P 635 MINERAL WOOL INSULATION 1 11 6060P 187 6060P 187 ELECTRICAL ENCLOSURE COVER 1 12 6075P 006 6075P 006 8 X 3 4 SELF TAPPING SCREW ELECTRICAL ENCLOSURE COVER 2 13 N A N A SOLAR PANEL SURFACE MOUNTED...

Page 26: ... THERMODISC MOUNTING CLIP 1 6 6060P 632 6060P 632 5 16 18 HEX NUT THERMODISC MOUNTING CLIP 2 7 6060P 634 6060P 634 PLASTIC PROTECTIVE COVER 1 8 6075P 053 6075P 053 FIBERGLASS INSULATION 1 9 6060P 187 6060P 187 ELECTRICAL ENCLOSURE COVER 1 10 6075P 006 6075P 006 8 X 3 4 SELF TAPPING SCREW ELECTRICAL ENCLOSURE COVER 2 11 N A N A SOLAR PANEL SURFACE MOUNTED SENSOR 1 12 TP1000 TP1000 3 4 RELIEF VALVE ...

Page 27: ... connections Replace Check Installation Replace Element Make sure all faucet s are closed and check water meter Not enough hot water 1 Heater undersized 2 Defective Element 3 Defective thermostat or wired incorrectly 4 Solar System Incorrectly Installed 5 See 6 above in No Hot Water Reduce rate of hot water use Check amperage replace element Check wiring or replace Check Installation Water too hot...

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Page 30: ...er DOWFROST nor DOWFROST HD fluids are flammable because they have no measurable flash point Pensky Martens Closed Cup in concen trations up to 80 glycol Undliluted DOWFROST and DOWFROST HD have a flash point of 214 F Pensky Martens Closed Cup It is possible to ignite solutions of propylene if enough water has been vaporized and the concentration of propylene glycol increases to greater than 80 pe...

Page 31: ...IRST AID WASH OFF IN FLOWING WATER OR SHOWER INGESTION Single dose oral toxicity is considered to be extremely low No hazards anticipated from swallowing small amounts incidental to normal handling operations FIRST AID NONE REQUIRED INHALATION At room temperature vapors are minimal due to physical properties Mists may cause irritation of upper respiratory tract nose and throat FIRST AID REMOVE TO ...

Page 32: ...9SE SB DW SUN EARTH INC EP 32 2 AET AE32E 2 HEAT TRANSFER HP 30SC 2 APRICUS AP 30 2 LIST OF SOLAR COLLECTORS WITH MATCHING SOLAR TANK MODELS LP 200 M REV 3 3 08 LP 199 M 1 REV 11 1 07 SOLAR SYSTEM REPLACEMENT PARTS CONTROLLER STECA TRO301 GOLDLINE GL 30 HELIOTROPE Thermal Delta T PUMP TACO OO7 GRUNDFOS 15 58F EXPANSION TANK AMTROL Extrol 30 CHECK VALVE WATTS SERIES 600 ALTERNATE APPROVED EQUIVALEN...

Page 33: ...SOLAR STORAGE TANK IS ISOLATED FROM THE PRESSURIZED CITY COLD WATER SUPPLY LINE PIPING VALVE 8 COLLECTOR ARRAY FILL DRAIN VALVE WARNING HOT VALVE 8 IS NORMALLY CLOSED WHEN OPEN IT IS USED TO CHARGE AND DRAIN THE SOLAR COLLECTOR LOOP PIPING THE HEAT TRANSFER FLUID USED IN THIS SYSTEM IS DOWFROST HD PROPYLENE GLYCOL IT MUST BE HANDLED AND DISPOSED OF IN ACCORDANCE WITH THE DOW CHEMICAL COMPANY MATER...

Page 34: ...33 MAINTENANCE NOTES ...

Page 35: ...fer Products 120 Braley Road East Freetown MA 02717 System Serial No ___________ SRCC Document OG 300 System Model SSC 50SE SSC 80SE SSC 119SE SSC 50SB SSC 80SB SSC 119SB SSU 60SE SSU 80SE SSU 119SE SSU 80SE DW SSU 119SE DW SSU 60SB SSU 80SB SSU 119 SB SSU 80SB DW SSU 119SB DW PH 80S PH 119S SRCC Certification Number 300 2007 011A 300 2007 011B 300 2007 011C 300 2007 012A 300 2007 012B 300 2007 01...

Page 36: ...ber _________________________________________________________________ Contractor Name____________________________________________________________________ Address____________________________________________________________________________ Phone Number _____________________________________________________________________ Emergency Number ______________________________________________________________...

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