This document provides instructions for installing a solar water heating system, including: - Proper planning such as load analysis and determining component locations is essential. - Mounting the collectors, heat exchanger, and storage tank according to manufacturer instructions. - Using the correct materials and fittings to plumb the solar loop and avoid galvanic corrosion. - Testing the system for leaks before filling it and commissioning.

1. Solar Water Heating
SYSTEM INSTALLATION

2. PREVIOUS PRESENTATIONS HAVE COVERED MOST OF THE RELEVANT TECHNOLOGIES
INVOLVED IN SOLAR WATER HEATING. THIS CHAPTER DETAILS INSTALLATION.
MANY SYSTEMS USE COMMON COMPONENTS AND HAVE SIMILAR INSTALLATION
REQUIREMENTS.
HOME POWER MAGAZINE HAS A GREAT ARTICLE ON SWH:
HTTP://HOMEPOWER.COM/BASICS/HOTWATER/

3. Installing Solar Water Heating Systems
PROPER AND THOROUGH PLANNING ARE IMPORTANT.
AN UNDERSTANDING OF HOW SWH SYSTEMS OPERATING
AND THE ABILITY TO VISUALIZE HOW A SYSTEM CAN BE
INCORPORATED INTO A STRUCTURE ARE NEEDED.
THERE ARE OPTIONS AVAILABLE TO MOST INSTALLATIONS
AND THEY NEED TO BE CONSIDERED.
THE LOAD ANALYSIS DETERMINES HOW MANY
COLLECTORS ARE NEEDED (USUALLY ONE IN FLORIDA) AND
IS THE FIRST TASK IN THE PROCESS.
THE SOLAR WINDOW DETERMINES THE BEST LOCATION
FOR THE COLLECTOR BUT, YOU MUST ALSO CONSIDER THE
LOCATION OF THE SOLAR WATER TANK (AND OPTIONAL HEAT
EXCHANGER).

4. BUILDING STRUCTURE AND
LAYOUT DETERMINE WHERE
THE SOLAR LOOP PIPING WILL
BE RUN.
After deciding where the components
will be located, make a list of all the parts
needed. A sketch of the system is helpful.
Decide on the type of mounting that will
be used for the collector(s). If rooftop,
how will the piping penetrate the roof?
Use proper roof flashing and/or sealant.
Measure pipe runs from collector to heat exchanger (or
tank). Determine all of the pipe fittings that will be used
(elbows. T’s, couplers, etc.). List and procure them.

5. THE SIZE OF THE COLLECTOR ARRAY DETERMINES
THE SIZE OF THE STORAGE TANK AND HEAT
EXCHANGER.
AFTER YOU HAVE FIGURED ALL OF THE PLUMBING
YOU CAN CALCULATE THE AMOUNT OF SOLAR FLUID
TO USE IN THE COLLECTOR LOOP. IF DIRECT
SYSTEM, NOT NEEDED.

6. Galvanic Corrosion
NEVER MIX PIPING OF DISSIMILAR METALS; IT WILL
CAUSE GALVANIC CORROSION.
Compatible metals are:
Copper, Stainless steel, brass,
bronze.
Non-compatible metals are:
cast iron, galvanized steel,
black iron, and aluminum.
To connect copper piping
to a steel tank use a
dielectric union.

7. This is a dielectric union. This device
electrically separates the water heater from
the household piping. It also provides a
convenient way to disconnect the piping for
removal or servicing of an appliance, such
as a water heater or water softener.
Components of a Dielectric Union:
The big nut clamps the brass part to
the steel threaded part. The black
washer and purple insulator keep the
brass and steel parts from touching.
The brass part gets soldered to a
copper pipe. The steel part is threaded
onto a piece of steel pipe.

8. Handling Solar Collectors
COLLECTORS ARE TYPICALLY SHIPPED STAKED ON A
WOODEN PALLET. INSPECT FOR DAMAGE BEFORE
UNCRATING. COLLECTORS WEIGH 85 TO 140LBS AND
ARE BIG AND BULKY. TO TRANSPORT SHORT DISTANCES
LAY FLAT WITH GLASS SIDE UP. IN SHIPPING THEY
SHOULD HAVE CAPS OVER THE PIPE ENDS TO KEEP
MOISTURE AND DIRT OUT.
Getting a collector on the roof
is not a one-man operation!
Keep safety first. Work when
there is little or no wind.
Always wear safety harness
when working on a roof.

9. Mounting Solar Collectors
INSTALL MOUNTING BRACKETS BEFORE LIFTING THE
COLLECTOR ONTO THE ROOF. THE MOUNTING BRACKETS
PROVIDE GOOD STRUCTURAL LIFT POINTS.
The mount supports must be into the
center of the trusses or into spanner or
blocking board. Consult your permitting
office. Use at least 4 attachment
points. The body of the collector should
be above the roof by about 2” to
prevent conducting heat into the roof. If
the collector will be tilted at an angle
other than the slope of the roof, prepare
the mount before lifting the collector to
the roof.

10. Mount at a tilt angle of latitude (up to 15° more if
improved winter production desired). Also camber the
collector so the inlet pipe is 2-3° lower in order to
facilitate draining. Use an angle finder (inclinometer) to
find the roof pitch.

11. Ground Rack Mounting
WHEN THERE IS NO APPROPRIATE ROOF SPACE
GROUND MOUNTING CAN BE DONE (EXCEPT FOR
THERMO-SIPHON SYSTEMS). ALL COLLECTOR TYPES
HAVE RIDGED FRAMES THAT CAN BE USED FOR
MOUNTING. WIND LOADING OF 130MPH MUST BE
DESIGNED FOR EAST CENTRAL FLORIDA!

12. Mounting the Heat Exchanger
(if used)
THE STORAGE TANK AND HEAT EXCHANGERS CAN BE
MOUNTED AT ANY TIME DURING THE INSTALL. HET
EXCHANGERS ARE ALWAYS LOCATED NEAR THE TANK.
LOCATE THE TANK FIRST. THE HEAT EXCHANGER IS
CONNECTED TO THE OUT TO SOLAR AND IN FROM
COLLECTOR PORTS. CHECK TUBE LENGTHS BEFORE
MAKING ATTACHMENTS.

13. Plumbing the System
USE ONLY LEAD FREE SOLDER! THIS IS WHERE
WORKMANSHIP CAN CAUSE PROBLEMS. LEAD FREE SOLDER
DOES NOT FLOW AS WELL AS LEADED OR UNTIL IT REACHES
HIGHER TEMPERATURES.
• PLAN THE ROUTE AND PRE-FIT ALL CONNECTIONS.
• CLEAN BOTH ENDS TO BE SOLDERED. WORK WITH CLEAN
HANDS.
• APPLY FLUX. AS THE FLUX DRIPS OUT, IT DRAWS THE SOLDER
IN.
• HEAT THE PIPE ON THE FAR SIDE FROM WHERE THE SOLDER
WILL
BE APPLIED (SOLDER FLOWS TO THE HEAT).
• IF WORKING IN A TIGHT SPACE USE A CERAMIC TILE TO
INSULATE.
• DO NOT BREATH FUMES.

14. Testing the System
ONCE THE WHOLE SYSTEM IS PLUMBED IT IS TIME TO
CHECK FOR LEAKS.
THERE ARE 2 METHODS: AIR OR WATER. USING AIR HAS
ADVANTAGES: NO MESS AND DRY JOINT. A BUSHING WITH
A SCHRADER VALVE (BICYCLE BALL VALVE) CAN BE
ATTACHED TO THE SYSTEM. PRESSURIZE TO ABOUT 50PSI
AND WATCH THE GAUGE TO SEE IF IT IS DROPPING. IT NOT
ALL IS GOOD. IF SO LISTEN AND FEEL FOR THE LEAK.
ONCE THE COLLECTOR LOOP IS HOLDING AIR, USE WATER
TO RINSE IT AND REMOVE ANY LEFT OVER FLUX. THEN FILL
WITH PROPYLENE GLYCOL AND WATER MIX.

15. Installing Solar Pool Heating Systems
FOLLOW MANUFACTURERS INSTRUCTIONS. POOL HEATING
SYSTEMS ARE COMMONPLACE AND DETAILED INSTRUCTION ARE
PROVIDED. MANUFACTURER'S ALSO OFFER TECHNICAL SUPPORT.
EVERYTHING NEEDS TO BE MOUNTED TO FACILITATE DRAINING.
BLACK SCHEDULE 40 PVC AND FITTINGS ARE OK. BLACK IS
IMPORTANT TO IMPROVE PERFORMANCE.

16. Installing Radiant Floor Tubing
MANY LAYOUT PATTERN ARE POSSIBLE. DELIVERING
THE HEATED FLUID TO WHERE IT IS NEEDED MOST
CAN MINIMIZE THE AMOUNT OF TUBING THAT NEEDS
TO BE RUN.