Installation Overview
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Transcript of Installation Overview
Sunward Installation Overview Solar hot water made simple
Introduction • How Sunward Works • Tools Required
Installing System • Installation Steps
• Solar Storage tank and Heat exchanger • Locating the Tank and Heat Exchanger • Prepping the Solar storage tank • Connecting the Heat Exchanger to the Tank • Installing the Manifold
• Guidelines for Installing Collectors • Mounting Options • Collector Types • Mounting the Collectors
• Roof Mount • Locating Rafters and Mounting Brackets
• Steel Rack • Timber Frame
• Installing the Photovoltaic Module • Burial Kit
• Working with the Line-set ducting • Guidelines for Running the Micro Tubing
• Connecting the Micro-Tube Lines to the Heat Exchanger and Collectors • Guidelines for Cutting Into the Existing System
• By-pass valve arrangement System Start-Up System Maintenance
Agenda
Please mute your phones during the presentation
Feel free to type your questions into the chat column to the right at any time.
We will answer all questions at the end of each section.
• Fast! Two man crew One Day • One Trip • Easy • Clean • Safe • Everything you need • No inventory needed • No CALL-BACKS!!
Sunward Installation
Sunward System Overview
wood Tools Required
Due to it’s simple design, a Sunward installation requires a very small amount of basic tools
Installation Steps
Mounting the Collectors
Installing the Tank and Heat Exchanger
Running the Micro-Tubing
Final Plumbing Hookup
& Commissioning
Things to keep in mind when assessing the utility room • Room to navigate the Tank (24”x 59”) • At least 3'x3'x5 1/2' of space • Proximity of water heater (Less than 20’) • Accessibility of anything to be serviced • Location of a Drain • Water in the Basement • HEX within 18 inches of the tank. • Base of HEX even with Base of tank • Micro-Tubing Run/penetrations
Locating the Storage Tank and Heat exchanger
Preparing the Solar Storage tank
• Insert the T&P valve and tighten carefully, Plumb to code
• Apply sealant tape to all threads
• Remove the Plug at the top of the Tank
• Apply sealant tape to the pressure relief valve
Install the Stainless Steel Street Elbow
Attach the Drain Assembly to the tank
Connect the Drain assembly to the Heat exchanger
Attach the 48" flex-hose to the outlet of the Heat
exchanger
Connect the Heat exchanger to the Tank
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Connecting the Storage tank and Heat exchanger
Mounting the Solar Manifold
• Attach (2) flex hoses to the hot and cold ports at the top of the tank and bend them to connect with the manifold
• Align the Manifold in the desired position and mark for proper clic clip location
• Install the two clic clips with the supplied self tapping screws
Mounting Options
Roof Mount
Steel Solar Rack
Timber Frame
Collector Types
There are two types of Solar Collectors, Primary and Secondary.
Primary Collector – IN and OUT Ports and a
Thermister Plug Port
Secondary Collector - Two sets of IN and OUT Ports
only
What's Included? • (2) 100' Pre-insulated Micro-Tubing • Lineset Ducting • Compression Fittings • 100' pre-wired PV cable • Installer friendly roof penetration flashing
boot • Pro-flex sealant for roof penetrations • (4) Versatile L - Brackets • (4) 3/8 Lag bolts • (8) 3/8 stainless steel wax coated bolts w/
washers and lock nuts
Roof Mount Kit
Installing the Roof Mount Kit
• Determine Optimal Location For Collectors
• Locate Rafters • Install (2) Lower mounting
Brackets • Set and secure the Secondary
collector in place • Attach the Primary Collector with
the Collector Gap Brackets • Install the two upper mounting
brackets • Attach the PV Panel • Install the Thermister and attach
the power cable • Penetrate the Roof, and install the
roof boot
Locating the Roof Rafters and Mounting Bracket Positions
It is crucial that the Lag Bolts are secured to the center of a rafter.
Use existing penetrations or markers to measure location of Rafters (ie. toilet unit,
chimney, dormer, satellite wire). Most rafters in American homes are spaced 16”
on center.
If you do not have access to the rafters or house plans, tapping the roof lightly with a rubber mallet or drilling a very small pilot hole underneath a shingle is a common way to locate rafters.
Properly flash over the pilot hole. Contact a roofing professional to ensure rafters are properly located.
Steel Solar Rack Option Includes:
• Durable, powder-coated 1/8" steel frame
• Universal leveling feet to account for uneven grades
• Stainless steel wax coated hardware
• 3" Ground Anchors w/ Drive Rod • 50" Burial Kit • 2-3" Couplers • Line-set Ducting • (2) 50 of interior tubing • Compression Fitting Kit
Steel Solar Rack
Assembling the Steel Solar Rack
• Determine the Optimum location • Lay cinder/patio blocks, • Orient the Universal leveling feet • Assemble the frame base • Attach ground anchors • Lay both collectors on spacers and
connect the two together • Attach the collectors to the hinges • Raise the collectors into position • Secure the collectors • Dig the trench
What's Included? • Rugged 4x4 hemlock
construction • 4x6 pressure treated sills • Pre-cut lumber for quick
assembly • Roof panels, ridge cap,
strapping, nails and roofing screws are included
• 3" Ground Anchors w/ Drive Rod
• 50" Burial Kit • 2-3" Couplers • Line-set ducting • (2) 50' of interior tubing • Compression Fitting Kit
Additional Features:
• Easy assembly • No need for excavation
Timber-Frame
Timber Frame Assembly:
• Determine Optimum Location
• Level the ground • Set cinder/patio
blocks • Assemble the
frame with the supplied nails and screws
• Attach Ground anchors
• Install the roof • Mount the brackets • Secure the panels • Dig the trench
Easy to read, step by step instruction manual is included
Mounting the PV Panel
• Attach the PV brackets to the PV panel • Slide (2) bolts into the bolt track of the collector • Attach the panel to the collectors
If the solar resource is not affected, the PV panel can be mounted over the roof penetration to for extra
UV and weather protection.
• Measure and Mark the Trench Layout • Dig a 4" wide trench Remove Sharp
objects • Lay the Burial kit in the trench • Bury the Kit • Cut off excess and install the 3x2 coupler • Insert the Tubing and cable through the
sill • Fill ends of Burial kit with a waterproof
Spray foam insulation. • Snap the line-set ducting over the
coupler and secure to the wall • Connect the Micro-Tubing to the
Collectors • Cover micro-tubing with Line-set Ducting
Burial Kit Installation guidelines
Working with the Line-set ducting
• Measure and cut the ducting to the needed length
• Start from one end and work to the other
• Install the base ⏐ to the wall using screws every 3 feet
• Run the Micro tubing within the line-set and secure
• Snap the second half onto the first.
What’s included? • (3) 8’ sections of Brown, ivory, or white • (2) 90’s • (2) 45’s • (2) wall inlets
Micro-Tubing Best Practices:
• Always use a tubing/pipe cutter • Remove burrs and copper shavings • Use a Tubing Bender when bending
a radius smaller than 1' • Cap the tubing to prevent
contamination. • Avoid compressing the Insulation • Make an effort to maintain a
downward slope. • Support the tubing every 4-6'
Micro-Tubing
Connecting the Micro-Tubing
• Tighten fitting with a 5/8 wrench, do not over tighten
• Determine which line is hot and cold
• Insert tubing into fitting
Working with the Power Cable
• Plug the the Power cable to the PV and Thermister Wires at the collectors
• Run the Power cable with the Micro-Tube Lines
• Keep a Service loop in a convenient but aesthetic location
• Plug the Power cable into Delta-T controller lead at the heat exchanger
• Shut off the cold water inlet to the existing heater
• Drain at least 2 gallons from existing heater • Cut at least 8 inches out of the cold inlet
pipe • Install a By-pass valve arrangement • Divert the cold water to the cold inlet of the
solar manifold • Connect the Solar Manifold hot Outlet Pipe
to the Cold Water Inlet of the existing Hot Water System.
• Turn on the incoming water supply to fill the Solar Tank. Check all connections for leakage.
• Install a temperature rated expansion tank on the Solar return (hot)
Guidelines for plumbing into the existing water heater
System Start Up • Remove or open the pressure relief valve at the back of the heat exchanger to allow purged air to escape
• Power up the pump by flipping the rocker switch on the side of the Delta T controller, you will begin to hear bubbling
• Remove the Brass cap on the fill tube, and slowly begin to fill the Exchanger with Glycol
• Glycol level should be 6-12 inches on the dipstick while the pump is operating and the bubbling has stopped, if glycol spits out of the PRV, the system is full • Re-install or close the PRV
System Maintenance Back-flushing the tank heat exchanger
• Return all valves to the original position
• Check the Level every year, it should be 6-12 inches on the dipstick while the pump is operating. If glycol spits out of the PRV, the system is full
• Glycol PH level should be checked every 5 years and should be between 6-8
Attach a hose
• Attach a hose to the hose bib of the corresponding unit to be flushed
• Open the drain valve and drain aprox. 5 gallons of water, or until the cloudy water clears
Checking the Glycol and PH level
• Every 6 months!
System Maintenance (cont.)
Check All Fittings and connections
• Check outgoing temperatures to ensure safe and efficient operation
• Check the integrity of sealant
• Follow the chart to the right to ensure the thermisters are functioning properly
Inspect roof brackets and penetrations • Inspect for leakage
Thermister Resistance
Inspect the Mixing valve
Check PV voltage • On a sunny day, voltage should be between 18 and 24 volts under 0 load
Inspect Burial Kit and Line-set condition • Check for weather tightness
You and Us: Next Steps
Call Now TOLL-FREE 1.877.271.5993
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