SRCC OG300 Workshop Part 1

Solar Rating and Certification Corporation OG-300 Installation Guidelines for Solar Hot Water Systems Part 1 www.solar-rating.org 1

OG 300 System Review • Solar water heating systems – residential • Criteria address all system types – Active, passive – Direct, indirect – Some criteria particular to only certain types of systems 2

OG 300 System Review • Criteria deal with: – Overall system design – Components – Freeze protection – Safety – Operation and Service – Durability and reliability – Installation – Manuals • Installation • Owner’s 3

OG300 Installation Criteria • Criteria that apply to the installation – What installation requirements have to be met to qualify as OG300 certified system • Certified systems meet the design criteria – SRCC staff have reviewed design, components, schematic, manuals • Follow instructions in installation manual – Basic installation instruction for particular system – Parts list • System schematic – All listed parts and in order indicated 4

Installation Criteria Manuals Schematics Collector installation Structural supports Building penetrations Pipe installation Insulation Controls - sensors and wiring UV protection System isolation Service connections Informational and safety labeling Operation indicators Freeze protection Solar and auxiliary tanks Accessibility Problems from past inspections 5

System Manuals • System description and operation • Approved manuals will detail – Installation and operation information – Schematic – Parts list – Fluid identity (type, disposal) – Freeze protection information – Filling volumes and methods – Piping and insulation – Operational checks – System startup and shutdown – Emergency valve-off – Maintenance requirements – Contacts for service 6

7 System Manuals

Installation and operation instructions 8

Installation instructions 9

Installation instructions 10

Parts list 11

Parts list 12

13 Component and materials installation

Component and materials installation 14

15 Instruction on fluids and fluid handling

Freeze protection and fluids 16

System filling and shut down procedures 17

System operational checks 18

System labels and tags 19

Maintenance instructions 20

21 Warranty and contact information

System Schematic • SRCC published specific system schematics on approval documents and web site – use symbol key in OG300 directory • Approved schematics are also include in all system manual • Install all components listed in schematic • Install as indicated on schematic – In proper order and location 22

System schematic 23

Symbols Shown in the OG300 System Schematics 24

Manufacturer schematic with legend 25

SRCC Schematic Internal Heat Exchanger, 2-Tank 2005009b 26

SWEP Stainless Steel 14 Plate Heat 3-Way Ball Valve (to periodically flush the heat A Exchanger L exchanger) B 009 Bronze Taco Pump M 2 Way Ball Valve C 006 Bronze Taco Pump N Flow Meter and Sight-glass D Steca TR 0301 U System Controller O Honeywell Anti-Scalding Valve (built in check valves) E Drainback Tank P Bronze T with Hot Out and T/P Valve F 80 Gallon Solar Storage Tank Q Heat Trap Dielectric Nipple G 55gal Electric Backup Heater R Stainless Flexible Piping (3/4" Female Connectors) H Solar Return Dip Tube with Diffuser End S 3/4" Compression Fitting with Male Threads I Cold In & Solar Out Dip Tube with Diffuser End T Sensor Wire Connected to Collector Sensor J Collector Loop Boiler Drain Valve U Sensor Wire Connected to Tank Sensor K Stainless Steel Y Strainer 27 Manufacturer schematic with legend

SRCC Schematic Internal Heat Exchanger, 1-Tank 2003016a 28

29

Drainback, Indirect, DB Reservoir, Tank HX, Gas Tank 30 2006024A

31

ICS, Gas Tank, No Mix Val in Return 1998006e 32

Thermosiphon, Direct 2001015a 33

Collector Installation 34

35

36

37

38

39

6.1.2.1 Collectors • Certified collectors listed on collector and system certification documents – Posted at SRCC web site • Collector certification label is affixed to collector • Collector options listed on OG300 system certification document 40

OG 300 DOCUMENT Manufacturer & Model System specifications with collector identification System schematic 41

OG 100 DOCUMENT Manufacturer & Model Rating Specifications Technical information 42

6.1.2.1 Collectors Sample Solar Corporation This product certified by the P.O. Box 12345 Solar Rating and Certification Anytown, CA 97402 Mildly Cloudy Day Corporation c/o FSEC, 1679 Clearlake Road Rating in Category C Cocoa, FL 32922 Model No.: Super Sample (407)638-1537 Gross Area: 31 MJ/day SRCC Document OG-100 3.72 m2 (40.00 ft2) 29 Mbtu/day Serial Number: ______________________ Certification label 43

Collector Mounting 44

6.5.13 Shading Of Collector • Natural obstructions – Trees, vegetation – and future growth – Seasonal sun locations • Avoid structural obstruction – Chimney – Roof wings • Site selector takes out guess work • Not as critical as photovoltaic 45

6.5.13 Shading Of Collector Potential time of day shading 46

6.5.13 Shading Of Collector Obstructed access 47

6.5.13 Shading Of Collector Clear access 48

6.5.13 Shading Of Collector 49

6.5.21 Rain and Snow on Collector • Do not restrict water or melting snow run off from collector • Ensure area around base of collector is unrestricted • Not usually a problem 50

6.5.21 Rain and Snow on Collector 51

6.5.21 Rain and Snow on Collector 52

6.5.12 Tilt And Azimuth • Methods and materials used to maintain tilt and azimuth of collector • Structural braces: Includes collector mounts, struts, bolts, etc. • Most manufacturers have a structural analysis conducted on their mounting design and materials by a PE • SRCC reviews the manufacturer’s structural mounting method for obvious flaws • SRCC does not conduct structural review or provide structural analysis 53

6.5.12 Tilt And Azimuth Use manufacturer’s structural mounting hardware as provided and follow manual instructions. 54

6.5.12 Tilt And Azimuth Mounting hardware can include cross channels (1), standoffs/mounting struts (2), mounting brackets (3), hinge mounts and fastening bolts and nuts (4). 1 3 2 4 55

6.5.12 Tilt And Azimuth Installation awareness! 56

6.5.12 Tilt And Azimuth How critical is it? Consider aesthetics! Tilt Angle Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Year 0 3.5 4.2 5.2 6 6 5.6 5.8 5.6 4.9 4.4 3.7 3.3 4.8 Latitude -15 4.1 4.7 5.5 6.2 5.9 5.5 5.7 5.6 5.1 4.7 4.2 3.9 5.1 Latitude 4.7 5.2 5.7 6.1 5.6 5.1 5.4 5.5 5.1 5.1 4.7 4.5 5.2 Latitude +15 5.0 5.4 5.6 5.7 5.0 4.5 4.8 5 4.9 5.1 4.9 4.9 5.1 90 4.1 3.9 3.4 2.6 1.9 1.6 1.7 2.1 2.7 3.5 3.9 4.1 3 Solar Radiation for Flat-Plate Collectors Facing South at a Fixed Tilt (kWh/m2/day - Average) in Miami, Florida (Latitude 25.80 N) 57

6.5.12 Tilt And Azimuth Consider aesthetics 58

6.5.12 Tilt And Azimuth Unseen from front of house – but needs to be well designed and structured for wind load resistance. 59

6.5.8 Structural Supports • Consider dead load and live load • Should not weaken structural strength of any part of the roof or truss assembly • Various mounting techniques are acceptable – Lag bolt mounting is most common • Does not require access to attic therefore is the most common and popular method – Spanner mount is often required by codes • Require extra carpentry and attic access – J-bolts are fine but seldom used • Also require attic access 60

6.5.8 Structural Supports • Follow local code enforcement requirements – Be aware of local conditions and resulting structural requirements • PE seal often required at local level – For collector as well as collector mounting method to roof 61

6.5.8 Structural Supports • Mounting material - compatible with collector frame – Use collector manufacturer hardware – Compatible anchoring materials (struts as well as bolts, etc.) • Corrosion resistant – for specific geographical area – Aluminum for coastal area – No wood 62

6.5.8 Structural Supports Lag bolt truss anchoring is the most common collector mounting method, but not allowed in many jurisdictions. 63

6.5.8 Structural Supports 64

6.5.8 Structural Supports Spanner mount penetration 65

6.5.8 Structural Supports J-bolt penetration 66

6.5.8 Structural Supports Follow local codes and requirements: For example, Dade County (Miami) requires spanner mount using 67 metal braces.

6.5.8 Structural Supports 68 Simple

6.5.8 Structural Supports Wind shear/uplift 69

6.5.8 Structural Supports 70 Tilt and weight

6.5.8 Structural Supports 71 Weight

6.5.8 Structural Supports Post Hurricane Andrew 72

6.5.8 Structural Supports 73

6.5.6 Water Damage This is not a collector issue, but a lesson learned as far as water run off is concerned. Note that roof drain was plugged. Also that T/P valve exhaust can damage roof structure. 74

6.5.5 Building Penetrations • Collector mounting penetration will not impair the function of the enclosure – Does not weaken or damage enclosure and it’s function – Any holes made during collector mounting must be properly sealed – Do not allow access for vermin or environmental conditions • Roofing penetration must follow local codes and national roofing practices • Also follow solar industry standards – Specific flashing developed for solar 75

6.5.5 Building Penetrations Roof penetration for collector mounts 76

6.5.5 Building Penetrations 77

6.5.10 Penetration Of Structural Members • Structural member? – “A support that is a constituent part of any structure or building.” • Modifications to structural members must be conducted in accordance with local codes! • Installers need to be familiar with local codes – Some jurisdictions allow only certain mounting methods 78

6.5.10 Penetration Of Structural Members 79

Piping Installation 80

Piping Material • SRCC approves specific type of materials – Primarily copper • Listed in manufacturer’s installation manual – Use only those materials • Pre-plan the route of the collector loop piping 81

6.5.15 Pitch Or Angle Of Piping Installation • Piping has to be sloped for drainage of collector and collector loop • Should be specified in manufacturer’s installation manual • Must have drainage – Critical in design and operation of specific systems (Drain down, Drain back, Direct) – Service and maintenance – Freeze protection 82

6.5.15 Pitch Or Angle Of Piping Installation 83

6.5.5 Building Penetrations • Building penetrations can not impact the function of the enclosure - same as collector mounting • Insects and vermin • National Roofing Contractors Association roof penetration methods 86

6.5.5 Building Penetrations 87 Common roof flashing method

6.5.5 Building Penetrations Note complete coverage of flashing 88

6.5.5 Building Penetrations Anticipate a leak! 90

6.5.5 Building Penetrations Avoid puddles. 91

Piping Insulation 94

6.1.6.3 Insulation • Insulate hot water piping with R-2.6 insulation (1/2” rubber insulation) • Exterior insulation protected from UV radiation • Common insulation is elastomeric (rubber) insulation – Do not use plastic insulation outdoors or on hot pipes 95

6.1.6.3 Insulation Rubber Plastic 96

6.1.6.3 Insulation 97

6.1.6.3 Insulation Not even 3 months old. 98

Valves 101

6.3.9 Entrapped Air • Automatic for open loop (direct) circulating systems using potable water as the heat transfer fluid • Manual or automatic for closed loop (indirect) systems • Not required for integral collector storage (ICS) and open loop thermosiphon systems • At high points of system and where air can accumulate 102

6.3.9 Entrapped Air 103

6.3.9 Entrapped Air Orient valve to true vertical. 104

6.3.9 Entrapped Air 105

6.3.9 Entrapped Air ICS and Open Loop Thermosiphon 106

6.1.1.8 Vacuum-Induced Pressure Protection Allows for proper drainage. Conventional Air vent – vacuum breaker vacuum breaker combination valve 107

6.3.1 Pressure Relief • Sections of systems that can be isolated require a pressure relief device – If section has heat producing capability • Pressure relief device protects system from exceeding design limits • Collector loop must be able to be isolated – Pressure relief device can be located at the array or close to the solar tank – Pressure relief only valve is commonly used – Rated capacity must exceed the equipment they are protecting 108

6.3.16 Pressure Relief • System design and schematic have been reviewed during the certification process. • Installers must follow installation instructions and schematic provided in the manual. 109

Control Related Components 110

6.5.5 Building Penetrations Wiring Piping Ideal flashing mechanism Sensor wire penetration points for sensor wiring. have to be properly sealed to maintain integrity of roof. 111

6.1.5.5 Control Lines and Sensors • Maintain proper wire installation and routing – Sharp edges that can cut into wire – Wires are exposed to harsh environment • Avoid sensor wiring next to 110V/220V lines and conduit 112

6.1.5.5 Control Lines and Sensors 113

6.5.18 Control Sensor Installation • Sensor must be protected from environmental factors that can alter the function of the sensor – Outdoor influences (rain, moisture, etc.) – Loose, long wire runs 114

6.5.18 Control Sensor Installation Must consider the complete sensor package – sensor and means of transmission. 115

6.5.18 Control Sensor Installation Proper mounting of the sensor and connection to transmission wiring. 116

6.5.18 Control Sensor Installation 117

6.1.2.2 Protection From Ultraviolet Radiation • Applies to all exterior components – Collector, insulation, wiring, valves • External components must be either resistant to UV rays because of their chemical properties – UV inhibitors • Or, be protected by an external method – Paint, jacket, etc. • PV and sensor wiring – Use wiring rated for outdoor use – Coat wiring if necessary 118

6.1.2.2 Protection From Ultraviolet Radiation 119

6.1.2.2 Protection From Ultraviolet Radiation External valves 120

6.4.5 Dirt Retention And Staining 121

Re-cap….so far • Installer must be familiar with the system manual – Install specified components – Follow system schematics • Proper collector mounting • Proper structural supports • Proper penetrations and sealing • Proper sensor attachment and wiring 122

End of Part 1 Note: Manual examples and photographs courtesy of Heliodyne, Inc, AET Solar, Butler Sun Solutions, SDI Solar, Solahart, Solene, SunSystems, Synergy, TCT, Bill Guiney, Henry Healey and all others in the solar community. Thanks to all . 123

SRCC OG300 Workshop Part 1

0 comments

Notes on slide 1

Favorites, Groups & Events