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PREFACE 

Let  us  first  offer  two  words  of  grateful  appreciation. 
Thank  You!.  We  sincerely  appreciate  your  business. 
SunEarth  also  wishes  to  say  thank  you  for  “going  so-
lar”.  Solar  water  heating  systems  help  to  reduce  our 
nation’s dependence  on polluting fossil fuels, minimize 
the greenhouse gas emissions associated with conven-
tional  water  heating  and,  very  importantly,  lower  you 
monthly utility costs. 

Established  in  1978,  SunEarth  is  a  leading  U.S.  solar 
equipment  manufacturer.  Our  products  include  the  in-
dustry standard Empire, Imperial, ThermoRay and Sun-
belt  solar  water  heating  collectors  as  well  as  the  Cop-
perHeart  integral  collector  storage  system  and  SunSi-
phon  packaged  Thermosiphon  systems,  SunBurst  all 
copper  absorber  plates,  Solar  Strut  and  RexRack 
mounting hardware. We also fabricate specialty collec-
tors  for  unique  architectural  and  building  applications. 
SunEarth  SRCC  OG-300  certified  solar  water  heating 
systems are sold by leading solar plumbing and build-
ing contractors throughout the United States. 

Your  Cascade  2  solar  water  heating  system  has  been 
designed  to  meet  exacting  SRCC  OG-300  certification 
requirements.  The  components  found  in  your  system 
have  been  selected  by  your  installation  contractor  for 
their  proven  reliability,  longevity  and  performance  in 
your specific region of the country. 

SunEarth  Inc.  maintains  a  policy  of  continuous  review 
and  improvement  to  ensure  that  Cascade  2  systems 
incorporate any appropriate technological advances. To 
ensure that products represent the current state of the 
art in solar water heating Cascade 2 systems are sub-
ject  to  change  without  notice.  Please  consult    the 
SunEarth  website  at  www.sunearthinc.com  for  current 
information and the latest manual revisions. 

 

1)  INTRODUCTION 

Solar water heating systems are  climate and site spe-
cific  appliances.  Different  types  of  solar  systems  are 
installed  around  the  world  in  accordance  with  regional 
weather  and  water  quality  conditions.  System  perfor-
mance varies as a function of the household hot water 
load,  average  ground  water,  ambient  air  temperature, 
the home’s roof pitch and orientation and of course the 
seasonal  intensity  of  solar  radiation.  These  variables, 
some of which change from home to home on the same 
neighborhood  street  will  determine  how  much  energy 
and money your Cascade 2 system will save on an an-
nual basis. 

Your  Cascade 2 Drainback solar system is known as a 
“forced  circulation  closed  loop  drainback”  system  be-
cause it utilizes a mechanical pump to efficiently circu-
late  water  throughout  the  unpressurized  closed  loop 
solar piping. The “drainback” connotation refers to the 
freeze-protection  mechanism  used  in  the  system.    In 
drainback  systems,  the  heat  exchange  fluid  (water)  in 
the collector array and solar loop piping drains back by 

gravity  into  the  drainback  storage  reservoir  when  the 
pump  stops  circulating.    Air  replaces  water  in  the  col-
lector  array  and  solar  loop  piping  to  prevent  it  from 
freezing when the pump is off. 

This manual is intended as a basic solar water heating 
primer.  Our  goal  is  to  familiarize  you  with  the  proper 
installation,  operation  and  maintenance  of  your  Cas-
cade  2  solar  water  heating  system.  This  system  is  re-
quired  to  be  installed  by  properly  licensed  solar  or 
plumbing contractors in accordance with SRCC OG-300 
and all applicable national, state and local codes, ordi-
nances  and  regulations  governing  solar  water  heating 
installations, as well as good trade practices. Failure to 
follow  the  procedures  and  practices  described  in  this 
manual may void the manufacturer’s warranty and spe-
cific component parts. 

This  manual  covers  installations  utilizing  one  or  two 
SunEarth  solar  collectors  with  a  single  solar  storage 
tank  and  also  two  tank  systems  that  include  a  solar 
storage  tank  and  supplemental  tank  type  or  tankless 
water  heater.  Frequent  reference  is  made  throughout 
this  manual  to  specific  component  parts.  The  place-
ment  of  each  component  can  be  seen  in  the  system 
schematic Figures 3 & 4. A description of each compo-
nent and its function is found in Section 10. 

 

2) SYSTEM DESCRIPTION AND OPERATIONAL 

PRINCIPLE 

The key components in the Cascade 2 solar water heat-
ing  system  include  the  SunEarth  solar  collector,  solar 
storage tank, circulation pump and differential temper-
ature controller. 

The SunEarth solar collector is the heart of the Cascade 
2 system. Simply stated, when the sun is shining, heat 
energy  is  absorbed  by  the  solar  collector’s  absorber 
plate  and  transferred  to  the  potable  water  circulating 
between the solar collector and storage tank. This pro-
cess is continuously repeated during the average sunny 
day as the temperature in the solar storage tank rises. 

The  differential  temperature  controller  is  the  brain  of 
the system. The controller uses temperature sensors to 
consistently  monitor  the  temperatures  at  the  collector 
and at the tank. the  controller automatically turns the 
pump on when useful heat is available at the collector 
and turns the pump off when there is insufficient solar 
heat available or the tank had reached maximum tem-
perature.  Cascade  2  systems  are  designed  to  provide 
two modes of operation. The system will, (1) serve as a 
preheater to your solar storage tank, or (2) bypass the 
solar collector and run 100% on utility or conventional 
fuel.  The  installation  of  an  optional  water  heater  time 
switch  allows  you  to  control  both  the  frequency  and 
duration  of  supplemental  electric  resistance  water 
heating.  Supplemental  electric  heat  may  not  be  re-
quired for much of the year depending upon your spe-
cific  requirements,  thus  providing  an  effective  third 
mode of operation—100% solar. 

Содержание CASCADE 2

Страница 1: ...SRCC OG SRCC OG 300 Certified Solar Water Heating System 300 Certified Solar Water Heating System Installation Operation and Maintenance Manual Installation Operation and Maintenance Manual ...

Страница 2: ...stem certification is granted to SunEarth by the SRCC It may not be used for any commercial purpose without prior written consent of SunEarth SunEarth must approve any deviation from the mate rials and methods described in this manual in writing The Cascade 2 Drainback solar water heating systems can be protected against freeze damage to temperatures as low as 50ºF 46ºC This system should not be i...

Страница 3: ... Isolation Procedures 14 8 Vacation procedures 14 9 Maintenance and Troubleshooting 14 10 Cascade 2 System Component Parts 15 11 Estimated Component Life 16 12 System Operating Parameters 16 Appendix A Approved Primary Components 18 Appendix C System and Component Labels 22 Appendix F SunEarth Collector Warranty Statement 24 Appendix G SRCC OG 300 Certified System Model Numbers 26 Appendix H Suppl...

Страница 4: ...ng to prevent con tact with HOT water NOTICE Mixing valves should be installed to reduce the point of use water temperature by mixing hot and col wa ter in branch water lines Contact a licensed installer or the local plumbing authority for further information The temperature of the water in the water heater can be regulat ed by setting the temperature dial of the adjustable surface mounted thermos...

Страница 5: ...cian or the local utility SAFETY PRECAUTIONS Have the installer show you the location of the circuit breaker and how to shut it off if necessary Turn off the circuit breaker if the water heater has been subjected to over heating fire flood or physical damage or if the ECO fails to shut off Read this manual entirely before in stalling or operating the water heating system Use this appliance only fo...

Страница 6: ...e fluid water in the collector array and solar loop piping drains back by gravity into the drainback storage reservoir when the pump stops circulating Air replaces water in the col lector array and solar loop piping to prevent it from freezing when the pump is off This manual is intended as a basic solar water heating primer Our goal is to familiarize you with the proper installation operation and...

Страница 7: ...r of any existing roof damage or necessary repairs 3 5 Structural Considerations The collectors must be located in a structurally sounds area of the roof Penetrations into structural members must not compromise the structural properties of the member ENSURE THAT ALL STRUCTURAL MEMBER PENE TRATIONS COMPLY WITH APPLICABLE CODES The collector mounting method must be capable of maintaining the require...

Страница 8: ...nEarth Solar Collector s 2 3 4 Temperature Sensor 5 6 7 8 22 Ball Valve 11 24 35 36 Combination Valve 9 Pressure Relief Valve 10 Drain Back Tank 12 13 Pump 14 Heat Exchanger 17 Differential Temperature Controller 18 Heating Element Tank Thermostat 19 20 Temperature and Pressure Relief Valve 21 Mixing Valve 23 Water Heater 25 Solar Tank 22 35 ROOF JACKS 36 ...

Страница 9: ...l Valve 11 24 35 36 Combina tion Valve 9 Pressure Relief Valve 10 Drain Back Tank 12 13 Pump 14 Heat Exchanger 17 Differential Temper ature Controller 18 Heating Element Tank Thermostat 19 20 Temperature and Pressure Relief Valve 21 Mixing Valve 23 Water Heater 25 Solar Tank 20 48 min T1 21 9 17 4 3 10 11 12 13 14 T3 PIPE INSULATION T2 22 24 23 25 35 ROOF JACKS 36 ...

Страница 10: ...25 1 SunEarth Solar Col lector s 2 3 4 Temperature Sensor 5 6 7 8 22 Ball Valve 11 24 35 36 Combina tion Valve 9 Pressure Relief Valve 10 Drain Back Tank 12 13 Pump 14 Heat Exchanger 17 Differential Temper ature Controller 18 Heating Element Tank Thermostat 19 20 Temperature and Pressure Relief Valve 21 Mixing Valve 23 Water Heater 25 Solar Tank 35 ROOF JACKS 36 ...

Страница 11: ...slope is 1 4 vertical drop per foot of horizontal piping run 2 minimum slope Use the steepest slope possible 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 spinning the pump impeller in the re verse direction The collector should be mounted as close to the stor age tank as possible to mini...

Страница 12: ...tions The PEX tubing shall not be exposed to sunlight Water must be used as the heat transfer fluid The system shall be non pressurized capped at at mospheric on the day of installation or shall be vented to atmosphere A length of uninsulated copper tube no less than nominal diameter shall be used at the hot outlet and cold inlet of the solar collector s for a distance of no less than three feet 3...

Страница 13: ...e System out lined below All vertical piping between the storage tank and the collector shall be supported at each story or at maxi mum intervals of ten feet 10 Horizontal runs shall be sloped to drain minimum 2 slope and supported every five feet 5 to prevent sagging Roof runs shall be secured and supported providing at least 1 1 2 inches clearance from roof Pipe supports shall be con structed fr...

Страница 14: ...ector Sensor Placement The collector sensor shall be located on the solar loop return line as close to the collector as possible Sensors are typically accurate to 1 2 F if properly installed and weatherized The collector probe sensor shall be at tached to the SunEarth collector header pipe either with a stainless steel hose clamp or by inserting the probe sensor into a thermal well in contact with...

Страница 15: ...lumbing is required to provide for the isolation of the solar storage tank from the city cold water supply line by means of an isolating ball valve The differential temperature controller shall have a screen readout to show temperatures of the collector and storage tank Otherwise line thermometers shall be installed in the collector supply and return lines to allow for a simple diagnostic check of...

Страница 16: ... concrete slab in order to prevent moisture damage to the base of the tank and reduce the heat loss to the floor The tank should be raised off the floor on a pad 4 10 Choosing and Installing the Drainback Res ervoir SunEarth CopperStorTM copper drainback tanks are available in 2 5 5 7 5 and 10 gallon capacities Stain less steel drainback tanks are available in 10 15 and 20 gallons Small glass line...

Страница 17: ...illing the System Once the components have been plumbed it is time to fill the solar storage and collector loop with water as follows 4 14 1 STEP 1 Flush and Fill the potable loop with water Close potable flushing combination valves COMPONENTS 24 36 Fill the solar tank with wa ter and check that there are no leaks on the potable side of the system Do this by opening the cold water isolation ball v...

Страница 18: ...lso have been visual ly inspected for leaks and the solar loop piping has been cleaned and charged Having successfully com pleted these tasks it is time to set your system to run automatically Set the SunEarth control to the ON position Listen until you can hear water flowing through the solar loop return piping from the collector Place your ear next to the pump and listen for signs of cavitation ...

Страница 19: ...ons 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 monitoring the water levels with the pump on and off 9 MAINTENANCE AND TROUBLESHOOTING The following simple procedures are intended to opti mize the performance of your Torrent Drainback solar water heating system and also to extend the ...

Страница 20: ...e pump is running and the controller displays questiona ble temperatures at the collector or tank i e 180ºF tank and 45ºF collector check both sensors using a resistance meter to see if they are correctly calibrated If you find a defective sensor replace it immediately 9 10 Auxiliary Electric Element not Operating If the weather is poor and the auxiliary heating ele ment will not fire the bright r...

Страница 21: ...d by the plumbing code on water heaters Will automatically release and dump water at either 150 PSI of pressure or 210 F in temperature 21 Mixing Valve Automatically blends hot water from the solar storage tank with incoming city cold wa ter to an acceptable set point A mixing valve must be installed on every Torrent Drainback solar water heat ing system The mixing valve may include and integral c...

Страница 22: ...he system is not circulating pump stopped should such that the drainback tank not less than 75 full When the system is circulating pump running the water level in the drainback tank should be not less than 25 full The drainback tank should never be pumped dry in normal operation as this may result in damage to the circulator pump ...

Страница 23: ...pire Chrome EC 21 EC 24 EC 32 EC 40 EC 24 0 75 EC 32 0 75 EC 40 0 75 EC 24 1 5 EC 32 1 5 EC 40 1 5 SunEarth SunBelt SB 24 0 75 SB 32 0 75 SB 40 0 75 SunEarth Imperial Chrome IC 32 IC 40 SunEarth Imperial Selective IS 32 IS 40 SunEarth ThermoRay TRB 32 TRB 40 Make Series SunEarth SolarStrut RexRack Flush Mount Kit Universal Tilt Kit Landscape Rack Make Series Model Numbers SunEarth SunEarth SU80U 1...

Страница 24: ...ervoir Make Series Model Numbers AIC L Line LA14 10 Make Series Model Numbers SunEarth CopperStor DB 2 5 DB 5 DB 7 5 DB 10 SolarH2OT DBT DBT 10 SS DBT 15 SS DBT 20 SS Rheem Energy Miser 81VP6S 81VP15S 81VP10S 81VP20S A O Smith ProMax EJC 6 EJC 10 EJC 20 Or Approved Equal ...

Страница 25: ...e brass or stainless steel construction Maximum working temperature shall be no less than 200 F and maximum working pressure shall be no less than 125 psi Three Way Valves Optional Three Way valves shall be of bronze brass or stainless steel construction Maximum working tem perature shall be no less than 200 F and maximum working pressure shall be no less than 125 psi Boiler Drains A K A Charge Va...

Страница 26: ...rating tem perature of not less than 220o F and maximum working pressure of not less than 125 psi Pipe Insulation Pipe insulation shall have a maximum operating temperature of no less than 220o F All pipes shall be insulated to R2 6 or greater typically this will require a wall thickness of or greater When located in exposed areas pipe insulation shall be protected with a UV resistant coating or j...

Страница 27: ... WHENEVER THE CIRCULATION PUMP SHUTS OFF WHEN PROPERLY INSTALLED AND OPERATED THE SYSTEM IS PROTECTED TO TEMPERATURES AS LOW AS 50 F VALVE NO 8 COLD WATER SUPPLY ISOLATION VALVE THIS VALVE IS NORMALLY OPEN AND ALLOWS POTABLE WATER TO FILL THE SOLAR STORAGE TANK WHEN CLOSED THE SOLAR STORAGE TANK IS ISOLATED FROM THE PRESSURIZED CITY COLD WATER SUPPLY LINE PIPING BOILER DRAIN NO 11 SYSTEM FILL DRAI...

Страница 28: ...EED 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 WILL ISOLATE THE SOLAR STORAGE TANK FROM THE POTABLE WATER SYSTEM VALVE NO 5 SOLAR TANK BYPASS VAL...

Страница 29: ...APPENDIX F ...

Страница 30: ...APPENDIX F ...

Страница 31: ... 6 1 3 1 1 1 1 0 9 1 3 1 3 2 3 1 6 1 8 1 6 1 5 2 4 1 6 5 2 3 2 1 8 2 3 2 1 7 3 4 2 30004026 30004025 30004024 30004023 30004022 30004021 30004020 30004019 30004018 30004017 30004016 30004015 30004014 30004013 30004012 30004011 30004010 30004009 30004008 30004007 30004006 30004005 30004004 30004003 30004002 30004001 30004000 30003999 30003998 30003997 30003996 30003995 C2 80 120 TLG C2 64 120 TLG C...

Страница 32: ...________ System Information Model Number ___________________________________________ Date Purchased __________________________________________ Collector Serial Number ____________________________________ For Service and Repair Contact ______________________________ Comments ______________________________________________ ________________________________________________________ _____________________...

Страница 33: ...8425 Almeria Avenue Fontana CA 92335 Phone 909 434 3100 Fax 909 434 3101 Email info sunearthinc com www sunearthinc com Revised 3 17 2014 ...

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