Alternate Energy Technologies EAGLESUN, Installation, Operation And Maintenance Manual

Page 1: ...n Solar Water Heating Systems DXR Drainback This manual covers the installation operation and maintenance of the system models below DX 50 26 DX 50 32 Alternate Energy Technologies LLC 1345 Energy Cove Ct Green Cove Springs FL 32043 Toll free 800 874 2190 ...

Page 2: ...DXR Drainback Page 2 this page left blank intentionally ...

Page 3: ... that makes this system an asset to any home located in extreme hot o colder climates As the sun comes up in the morning and starts to shine on the solar collectors the collectors will begin to heat up A differential temperature control senses temperature differences between water leaving the solar collector and the coldest water in the water heater When the collector sensor temperature is about 1...

Page 4: ...en copper tube and copper fin to form the risers that make up the absorber plate Thermafin is designed to conduct the maximum amount of heat absorbed to the fluid that passes through the tube and returns to the water heater Unlike other methods that solder or braze the tube and fin Thermafin has only copper to conduct the heat and is therefore the most efficient and durable product available The g...

Page 5: ...ally off at a 5 F difference SYSTEM PROTECTION VALVES The EagleSun drainback system is equipped with several thermal protection valves A temperature and pressure relief valve on the water heater insures that excessive temperatures and system pressure is adequately relieved as needed A pressure relief valve on the drainback reservoir insures the tank does not exceed the design pressure of the syste...

Page 6: ...DXR Drainback Page 6 INSTALLATION INSTRUCTIONS ...

Page 7: ...tate Where possible cover the collectors with a tarpaulin or other opaque covering until you are ready to energize the system The circulating pump becomes very hot when running Do not touch before allowing sufficient time to cool down Wear gloves when handling the solar collectors They get extremely hot when left exposed to the sun The bright orange plastic caps should be removed prior to placing ...

Page 8: ...are located as to not disrupt the normal flow of water through the water heater In most instances the solar collectors can be attached to the roof using the standard mounting hardware provided with the solar system Certain types of roofing will require special attention for proper mounting For example a clay tile or cement tile roof Complete roofing attachment methods of solar collectors for these...

Page 9: ...ll in most locations compensate For best winter production proper orientation is achieved when the collectors are facing due south and tilted at an angle from horizontal to latitude 10 This favors the winter sun because ambient temperatures are lower during the winter and collector efficiency can suffer When collectors are mounted one behind the other they shall be spaced apart so the morning and ...

Page 10: ...0 233 80 233 88 233 100 233 124 233 AE FM MSC RRM 88 663 100 663 80 663 88 663 100 663 122 663 87 375 99 375 79 375 87 375 99 375 12 375 AE RM MSC RM 86 835 98 835 78 835 86 835 98 835 122 835 87 333 99 333 79 333 87 333 99 333 123 333 Dimensions shown length width and height are nominal and listed in inches area in ft and weight in lbs Use the formulas below for tilted applications To calculate t...

Page 11: ... or 2 x 2 x steel angle bracket under the roof as shown e The rear struts should be cut to length and drilled according to the formulas detailed on the previous page All bolts should be tightened securely A stainless steel washer should be placed where the threaded rod passes through the aluminum bracket It is very important that the penetrations through the roof be well sealed It should be carefu...

Page 12: ...e the all thread to the 2 x 2 angle Tighten down until the bracket is tightly secured to the roof Be careful not to over tighten and bell out the roof underneath the bracket NOTES Spacer Blocks Spacer blocks shall be installed within 1 of the thru bolt When thru bolt is within 2 of a rafter only one spacer block will be required on the opposite side of the bolt away from the rafter Two spacer bloc...

Page 13: ...hould be drilled into the centerline of the rafter and should be between 60 75 of the bolt diameter Apply a liberal amount of roof sealant or a sealant pad around the opening prior to securing the mounting bracket All connection hardware bolts washers to be stainless steel PITCH PAN The pitch pan is necessary any time standing water is encountered The purpose is to provide an adequate seal around ...

Page 14: ...point for alignment fasten the mount base plate through the decking and into the rafter members with 2 5 16 x 3 lag bolts 5 Apply a liberal amount of roofing caulk or mastic to the bottom of the roof flashing and position it over the mount base plate Secure its position with several roofing nails and screw in the double stud bolt with the silicone washer against the flashing 6 Attach the male sect...

Page 15: ...ions to the solar panels should be made with copper pipe only CVPC may not be attached to the solar collectors as very high temperatures may be reached on hot summer days Piping should be adequately supported for correct pitch and supports shall be designed to avoid compressing or damaging the insulation material Soldered connections should be made with 95 5 solder Multiple collectors must always ...

Page 16: ...lie cap is soldered to the copper tube This allows for expansion and contraction of the copper pipe while maintaining a rain snow barrier Polybutylene adhesive is then placed on the top and bottom of the flashing providing a weatherproof seal The sensor wire should also be run through the return flashing In roof piping hangers shall provide adequate support and correct pitch 1 4 per foot minimum o...

Page 17: ...nd 110V for the pump and controller System subassemblies which are exposed to public traffic and are maintained at elevated temperatures shall either be insulated sufficiently to keep exposed surface temperatures below 60 C 140 F during operation or they shall be suitably isolated Any other exposed areas that are maintained at hazardous temperatures shall be identified with appropriate warnings SE...

Page 18: ...eds the outdoor ambient air temperature Typical plumbing configurations are shown in the diagrams at the end of this manual The drainback system is filled at atmospheric pressure and should not exceed the normal operating pressure of the potable water system The drainback tank is equipped with a 30 psi pressure relief included to prevent excessive pressure build up in the system DO NOT PRESSURIZE ...

Page 19: ...tween them integral variable speed drive on the collector pump and turn on off on the storage pump read from the flow sensor and auxiliary 2 temperature sensors to calculate the BTU s transmit data to the PC via RS 232 for the purpose of data logging and long term diagnostics power and transmit data to the remote display panel See instructions provided with controller in box for proper installatio...

Page 20: ...DXR Drainback Page 20 OPERATION INSTRUCTIONS Refer to the diagrams on pages 30 32 for part identifications ...

Page 21: ...ding to the instructions above the final act required to commission the system is simply to plug the controller line cord into a standard 115 VAC wall outlet 1 With the controller in the off mode mark the water level on the sight glass with a Sharpie marker 2 Switch controller to on mode and let run for 5 minutes Mark the running water level on the sight glass 3 Check for leaks at collectors and i...

Page 22: ...DXR Drainback Page 22 SERVICE MAINTENANCE PROCEDURES ...

Page 23: ...f the system Either the pump controller or sensors may be malfunctioning The controller can be bypassed by running a power cable directly to the pump and checking its function separate from the control system Make sure that the problem is not a blown fuse or a tripped breaker or GFI outlet If the pump runs normally when powered externally the control circuit is the problem area Differential contro...

Page 24: ...ing Supply and return lines reversed Change so draining can occur Check and ensure that piping slopes ft Switch lines OTHER PROBLEMS A noisy pump is an indication of worn bearings obstruction loss of prime or cavitation As a rule of thumb an 8 20 temperature gain should be expected across a collector in bright sun at the proper flow rate Collectors should warm not hot to the touch MAINTENANCE DRAI...

Page 25: ... or Taco 009F5 w flange kit and Taco 003B varies EagleSun DTC ES 1 or Goldline GL 30 w 2 10k sensors BD 75 Watts BD Series or equivalent PR 30 Watts 3L Z9 30 psi or equivalent included with the drainback tank TPRV 8 Watts 100XL 8 or equivalent BV 75 Watts B6001 Series or equivalent 1170 M2 Watts 1170 tempering valve or equivalent CT 12M Type M copper tube CT 34M Type M copper tube for single colle...

Page 26: ...wire tie on valves and or peel and stick on pipe insulation All labeling must be in place at final inspection Label examples are as shown on the following page FLUID SAFETY LABELING Valve A this label is affixed to the system fill drain valve at the lowest point in the solar plumbing loop The heat transfer fluid is introduced here When properly charged the fluid level should be approximately from ...

Page 27: ... base of the water heater This valve is to be used only as directed in the water heater owner s manual or as directed in this manual Power should be disconnected at the circuit breaker prior to service WARNING HOT labels are affixed to the collector return line at the drainback tank the hot water supply line from the water heater and on all system components that could present a safety hazard due ...

Page 28: ... signature on the service ticket o If a part was purchased a copy of the distributor s invoice o Completed Claim Form All parts are available from your authorized agent or from AET direct RETURNS POLICY All returns are subject to return authorization No returned merchandise will be accepted without prior authorization from AET If the return is authorized the buyer will be issued a return authoriza...

Page 29: ... 20 0 0 3420 0 9397 0 3640 66 0 0 9135 0 4067 2 2460 21 0 0 3584 0 9336 0 3839 67 0 0 9205 0 3907 2 3559 22 0 0 3746 0 9272 0 4040 68 0 0 9272 0 3746 2 4751 23 0 0 3907 0 9205 0 4245 69 0 0 9336 0 3584 2 6051 24 0 0 4067 0 9135 0 4452 70 0 0 9397 0 3420 2 7475 25 0 0 4226 0 9063 0 4663 71 0 0 9455 0 3256 2 9042 26 0 0 4384 0 8988 0 4877 72 0 0 9511 0 3090 3 0777 27 0 0 4540 0 8910 0 5095 73 0 0 95...

Page 30: ...DXR Drainback Page 30 The collector and collector plumbing should be sloped back toward the drainback reservoir at 1 4 per foot minimum to allow the system to drain ...

Page 31: ...DXR Drainback Page 31 The collector and collector plumbing should be sloped back toward the drainback reservoir at 1 4 per foot minimum to allow the system to drain ...

Page 32: ...DXR Drainback Page 32 The collector and collector plumbing should be sloped back toward the drainback reservoir at 1 4 per foot minimum to allow the system to drain ...

Page 33: ...Drainback Page 33 Alternate Energy Technologies LLC 1345 Energy Cove Ct Green Cove Springs FL 32043 PH 904 297 9369 FAX 904 529 9837 www aetsolar com info aetsolar com Document Drainback_DXR_Retrofit_Manual ...