Freeze tolerance limits are based upon an assumed set of environmental conditions. Extended periods of cold weather, including ambient air temperatures above the specified limit may cause freezing in exposed parts of the system. It is the owner’s responsibility to protect the system in accordance with the manufacturer’s instructions if the ambient air temperature approaches the specified freeze tolerance limit.


1) INTRODUCTION

Solar water heating systems are climate and site specific appliances. Different types of solar systems are installed around the world depending upon regional weather patterns, water quality conditions and the application. System performance varies as a function of the daily household hot water load, including all showers, laundry, and kitchen uses, the average ground water and ambient air temperatures, 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, determine how much energy and money your SunSiphon system will save on an annual basis.

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 SunSiphon system. This system is required to be installed by properly licensed solar or plumbing contractors in accordance with SRCC Standard OG-300 and all applicable national, state and local codes, ordinances and regulations governing solar water heating systems as well as good trade practices. Failure to follow the procedures and practices described in this manual may void the manufacturer’s warranty for specific component parts.


fig. 1 - SUNSIPHON SYSTEM ORIENTATION


2) SYSTEM DESCRIPTION AND OPERATIONAL PRINCIPLE

The SunSiphon system consists of four main components. These are the solar collectors, the inner 316L marine grade stainless steel storage tank, the outer stainless steel heat exchange jacket and integral expansion tank and the heat transfer fluid (HTF). The solar collectors and the heat exchange jacket are filled with Dowfrost propylene glycol heat transfer fluid (HTF). The integral expansion tank prevents pressure build up in the collector loop as the sun heats the HTF. The Dowfrost HTF has a much lower freeze point than water and protects the solar collectors from freezing. The inner stainless steel storage tank is filled with potable water under mains pressure.

Your SunSiphon system is known as a “passive” solar water heater because it does not require mechanical pumps, thermostats or any moving parts to make hot water. Thermosiphon solar systems work on the principle of natural convection, or the fact that heated liquids rise. Solar energy striking the collectors warms the propylene glycol HTF in the collector piping causing it to rise into heat exchange jacket. The heat energy in the jacket is then transferred by conduction to the inner storage tank heating the potable water contained inside. The cooler HTF then falls to the bottom of the solar collector and the process is repeated.


fig.2 - SUNSIPHON TYPICAL SYSTEM CONFIGURATONS


The SunSiphon storage tank is equipped with an electrical heating element that can provide hot water during periods of inclement weather or high use. In two tank systems the supplemental electric or gas water heater will provide backup water heating if necessary.

Depending upon the season and the hot water load, the SunSiphon is designed to (1) allow for 100% solar operation, (2) serve as a preheater, or (3) run 100% on utility power. Section 6 this manual explains the normal operation of the SunSiphon system.

The Dowfrost HTF protects the solar collectors in your SunSiphon system against freezing. Dowfrost can provide reliable freeze protection for the solar collectors at temperatures as low as -60º Fahrenheit if properly applied and maintained.

The solar storage tank itself and the piping to and from the roof are susceptible, however, to freezing temperatures much higher than -60º F. In order to protect the integrity of the solar storage tank and piping the SunSiphon should not be installed in any area where the ambient air temperature has fallen below 15º F for 18 consecutive hours.


fig.3 - SUNSIPHON SYSTEM PLACEMENT


Use of uninhibited propylene glycol, plain water or a concentration of these two fluids as the HTF in the SunSiphon system is strictly prohibited.


3) INSTALLATION REQUIREMENTS - GENERAL

3.1 The contractor shall obtain all required permits and approvals.

3.2 The installation shall conform to all federal, state and local regulations, codes, ordinances and standards governing solar water heating system installations, and the contractor shall adhere to sound building safety and trade practices. Special consideration must be given to building code requirements for the penetration of structural members and fire rated assemblies.


fig.4 - TYPICAL EAST FACING SYSTEM

3.3 The SunSiphon solar water heating system must be located in a structurally sound area of the roof that will be unshaded between 9:00 a.m. and 3:00 p.m. each day of the year. Adjacent buildings and trees should be checked for possible winter shading. An instrument such as the Solar Pathfinder can be used for solar site analysis.

3.4 Before the installation the contractor shall inspect the condition of the roof and notify the homeowner of any existing roof damage or necessary repairs.

3.5 The homeowner and contractor shall confirm the location of all roof and ground mounted components in advance of the installation.


4) INSTALLATION REQUIREMENTS – SPECIFIC

4.1 LOCATION, ORIENTATION AND TILT
Depending upon the SunSiphon model purchased, the solar storage tank weighs between 523 and 1,232 pounds when completely filled with water. The most important structural consideration is to mount the solar storage tank at a right angle to the rafters no more than 3’ from the roof peak. Span as many rafters as possible. The tank should be located over a load bearing interior wall.

Do not proceed with the installation unless the roof members can safely support the wet weight of the solar storage tank. Consult your local building code for structural requirements before beginning the installation.

The thermal performance of the SunSiphon is optimized in the Northern Hemisphere when the unit is mounted facing True South. Actual performance, however, suffers very little when the system is oriented no more than 45º east or west of True South. By adding an additional collector or using larger collectors the SunSiphon typically can be oriented up to 90º east or west of True South, i.e. due east or west, with little or no impact on annual thermal performance.


fig.5 - TYPICAL WEST FACING SYSTEM

The slope of your roof also has an impact on annual thermal performance. Optimum system performance can be achieved by tilting the unit to an angle equal to your latitude plus an additional 10º. This tilt angle favors the lower winter sun when system performance may suffer and also minimizes overheating during the long summer days when the sun is highest in the sky. For aesthetic reasons it remains a common practice to flush mount the SunSiphon if the roof is pitched from 4/12 to 7/15 (18.4º and 30.3º slope, respectively), regardless of your latitude.


fig. 6 - TILT MOUNT RACK

The appearance of the SunSiphon system on your roof is a very important installation consideration. If you do not have a good southern roof exposure, or your roof orients east and west, we recommend that you simply add an additional collector or use larger collectors rather than racking the entire system to achieve a south orientation (see figures 4 & 5).

There may be some tradeoffs in the performance vs. appearance equation, but we find that most homeowner’s are willing to give up a few BTU’s each year in order to have an attractive, low profile installation.

If you have a flat roof or wish to mount the SunSiphon on the ground, a mounting rack will be required. To ensure proper water drainage from the collector glazing the SunSiphon rack always must maintain a minimum angle from horizontal of at least 10º. Use SolarStrut tilt mount kits to rack the unit to the proper angle (see figures 6 & 7).

4.2 Water Quality
The following table defines acceptable potable water quality conditions. If the supply water exceeds any of these levels please contact the manufacturer before installing the system.


fig.7 - GROUND MOUNT RACK 

                                          TABLE 1
               Description                     Maximum Recommended Level
                      PH                                                   6.5-8.5
                     TDS                                                  600 mg/liter
                     Total Hardness                                 200 mg/l 
                     Chlorides                                          300 mg/lt
                     Magnesium                                      10 mg/l
                     Calcium                                            12 mg/l
                     Sodium                                             150 mg/l  
                     Iron                                                   1 mg/l

4.3 SUNSIPHON ROOF MOUNTING PROCEDURES, MATERIALS AND METHODS
In accordance with the preceding discussion, locate the SunSiphon on a south facing roof that lies within 135º southeast and 225º southwest of True South. If the installation lies between 90º east and 135º southeast or 225º southwest and 270º west you will need to add a collector or use larger collectors. Remember that True South varies slightly from magnetic south (180º) on the compass rose depending upon the exact location of the installation.

Your SunSiphon system must be mounted in accordance with the materials and methods detailed in the drawings and figures in this manual. Note carefully the mounting requirements for different roofing materials and surfaces. Always use integrated SolarStrut anodized aluminum mounting hardware and stainless steel fasteners when mounting the unit.


fig.8 - FOR ROOF TRUSS OR FRAMING MEMBER SPACED AT 16” O.C.

Secure the SolarStrut mounting hardware with stainless steel lag, hanger bolts or threaded rod directly to the rafters or support cross bracing. Use Table 2 to determine the minimum number of SolarStrut or standoff flange mounting supports required for each solar tank option. Attach the SunSiphon storage tank to the SolarStrut mounting hardware with stainless steel earthquake/ hurricane straps and a stainless steel sliding nut, bolt, lock washer and flat washer. Span as many rafters as possible when mounting the solar storage tank.


fig.9 - FOR ROOF TRUSS OR FRAMING MEMBER SPACED AT 24” O.C.


Please note when securing the solar collectors to the SolarStrut mounting hardware that the collectors must be installed with a very slight 1” rise to the right to allow for proper thermosiphoning of the HTF (see figure 10

                                                      TABLE 2
                              ASPHALT SHINGLE/ROLL ROFFING
                                    MINIMUM REQUIREMENTS
                    Tank Size               SolarStrut 1 5/8" Mounting Supports
                        48 Gallon                                    2
                        80 Gallon                                    3
                        116 Gallon                                  4
                                TILE OR CEDAR SHAKE ROOFING
                                    MINIMUM REQUIREMENTS
                    Tank Size               Standoff Flange Supports
                         48 Gallon                                   4
                         80 Gallon                                   6
                         116 Gallon                                 8

Follow these general principles when mounting the SunSiphon:

4.3.1 The roof must be rated to safely support the weight of the unit when filled with water. The storage tank should be mounted over an internal load bearing wall and must be located no more than 3’ from the roof peak.

4.3.2 In two tank systems the SunSiphon should be mounted as close to the backup water heater as practical in order to minimize heat loss in the piping runs.

4.3.3 The SunSiphon should be raised from the roof surface at least 11/2” to allow for rainwater and debris to pass under the unit and for proper ventilation of the roofing material.

4.3.4 When selecting mounting hardware and fasteners it is extremely important to avoid galvanic corrosion resulting from the direct contact of incompatible metals. Use of anodized aluminum SolarStrut mounting hardware and stainless steel lag or hanger bolts, lock washers and round washers is recommended. In climates subject to severe winters or high humidity use of galvanized fasteners is prohibited.


fig.10 - IMPORTANT! CORRECT INSTALLATION OF SOLAR PANELS

4.3.5 Preserving the integrity of the roof membrane is the most important roofing consideration. Ensure that all roof penetrations required to plumb and mount the solar collector are properly flashed and sealed in accordance with standard roofing practices. Tremco “POLYroof” is the recommended elastomer for sealing roof penetrations. Henry Co. 204, 208 or 209 roof mastic or Dow Corning Glazing Sealant are also approved sealants.


fig.11 TILE & CEDAR SHAKE SYSTEM MOUNTING

4.3.6 If the SunSiphon is mounted on a flat roof or on the ground, a SunSiphon mounting rack is required. See Section 11 for specific rack mount details. The minimum tilt angle from horizontal in the continental United States should not be less than 15º. A 20º - 25º angle is preferable. Mounting racks with tilt angles greater than 25º require very long support legs and are not recommended. The length of the solar collectors primarily determines the support leg length. See Table 3. 

                                                            TABLE 3
                  Collector Length            Tilt Angle and Support Leg Length in Inches
                                                                              15º            20º            25º
                     76” (EC/EP-21):                                 25"            34"            41"
                96” (EC/EP-24/32):                                 41"            41"            51"

Note: We do not recommend the use of 4’ X 10’ collectors for rack mount applications.


fig.12 TILE & CEDAR SHAKE TANK MOUNTING


fig.13 TILE & CEDAR SHAKE COLLECTOR MOUNTING



fig.14 TILE & CEDAR SHAKE COLLECTOR MOUNTING


fig.15 PLAN VIEW SYSTEM

4.4 Plumbing the Sunsiphon SunSiphon is an extremely broad product line. The stainless steel storage tank comes in three sizes and the manufacturer offers as many as five different collector options. Because of the numerous system permutations, the manufacturer does not prefabricate the manifolds that connect the storage tank and solar collectors. See Section 10 for a list of components required to plumb the collector, storage tank and heat exchange loop in a typical two collector system. Collector manifolds must be no less that 3/4” Type-M hard copper tubing. We recommend the use of Type-L hard copper tubing.


fig.16 MOUNTING HARDWARE


fig.17 ASHPHALT SHINGLE OR ROLL ROOFING MOUNTING


fig.18 SLIDING NUT DETAIL          fig.19 HANGER BOLT DETAIL


fig.20 PREHEAT SYSTEM SCHEMATIC


fig.21 PRIMARY HEATING SYSTEM SCHEMATIC

The manufacturer requires that the contractor use all copper and brass fittings in plumbing the storage tank and collector piping. Couplings rather than unions should be used to join the collectors to avoid leaks and fluid loss. Use only leadfree solder. Engelhard Silvabrite 100 or equal is required. Use of 50/50 lead solder is expressly prohibited. Use of galvanized steel, CPVC, PVC, or any other type of plastic pipe is prohibited.

All piping between the solar collectors, storage tank and the rest of the plumbing system must be a minimum 3/4” Type-M copper tubing. Type-L soft copper should be used for any attic pipe runs. Solder joint connections should be terminated outside the attic space.

The cold water feed manifold between the solar storage tank and the solar collectors should not be insulated.

All vertical piping shall be supported at each story or at maximum intervals of ten feet (10’). Copper plumbers tape or tube strap is required to secure the piping. The pipe insulation may not be compressed or crimped by the strapping material. All piping runs must be properly slanted to allow for complete drainage of the plumbing lines running to and from the SunSiphon system.


fig.22 PLUMBING COMPONENT DIAGRAM

The installation of all horizontal and vertical piping may not reduce the performance or rating of any structural member or fire rated assembly. Adhere to all applicable local codes and ordinances.

The solar storage tank and supplemental water heater must be plumbed so that they can be isolated from the pressurized cold water supply line for repair or maintenance as required. A two way isolation ball valve must be installed in an accessible ground level location and clearly labeled (see no. 18, figures 20 & 21).

Where the SunSiphon serves as the primary water heater a thermometer must be placed in a clearly visible and accessible location in the garage or laundry/service room. The thermometer must be placed before the thermostatic mixing valve (see No. 16, figures 20 & 21). If the SunSiphon preheats a gas or electric supplemental water heater a line thermometer must be installed on the hot return line from the SunSiphon before the supplemental water heater. The thermometer provides a simple means of checking system performance.

A high quality thermostatic mixing valve is a required component in all OG-300 certified systems and, like the thermometer, must be installed in a clearly visible and accessible location in the home or garage (see No. 17, figures 20 & 21). The mixing valve should be installed using union connections for ease of future repair or replacement. The specified mixing valve shall be the Heatguard model LSBASE or equal and have an operating range between 95ºF and 130ºF.

WARNING: SCALDING CAN OCCUR WITHIN FIVE SECONDS WHEN WATER TEMPERATURES APPROACH 140º F. THE MIXING VALVE SHOULD BE ADJUSTED BY YOUR CONTRACTOR TO PROVIDE WATER TO YOUR FIXTURES AT NO MORE THAN 120º F.

4.5 Fill The Storage Tank
Open the isolation ball valve (see No. 18, figures 20 & 21), and begin filling the solar storage tank. THE SOLAR STORAGE TANK MUST BE COMPLETELY FILLED WITH WATER AND UNDER CITY MAINS PRESSURE BEFORE THE HEAT EXCHANGE JACKET AND COLLECTOR LOOP ARE CHARGED WITH HTF. NEVER CHARGE THE HEAT EXCHANGE JACKET BEFORE THE SOLAR TANK IS FILLED AND PRESSURIZED. FAILURE TO FOLLOW THE PROCEDURES OUTLINED IN SECTION 4.5 IN THE PROPER SEQUENCE MAY CAUSE SEVERE DAMAGE TO THE HEAT EXCHANGE JACKET.

In new home construction do not fill the solar storage tank or charge the heat exchange jacket with HTF until the home is occupied and the system is ready for use.


fig.23 PIPING DETAIL

4.6 Clean The Collector Loop Piping and Check For Leaks
Piping in new solar installations can be covered with dirt, grease, solder flux or other impurities that over time can affect the quality of the glycol HTF. A thorough cleaning is required before charging the system with glycol. A simple solution of 1 to 2 percent trisodium phosphate in water will eliminate the solder flux from the collector piping. Introduce the proper volume of solution in accordance with Table 4 and the heat exchange jacket fill instructions found in section 4.7.3 below.

Once the solar storage tank is completely filled with water and pressurized, thoroughly flush the collector and heat exchanger piping with water.

-Remove the 3/4” brass vent plug from the solar storage tank.
-Attach a garden hose to the ball hose bibb and turn on the garden hose.
-Open the ball hose bibb handle and let water run through the collector piping and heat exchange jacket for a minute or two. The water will flow out of the vent plug socket.
-Close the ball hose bibb while the heat exchange jacket and collector loop piping are still filled with water.
-Turn off the hose and detach it from the ball hose bibb. Check the piping for any obvious leaks.
-Open the ball hose bibb and drain the water from the collectors and heat exchange jacket.

Once the solar collectors and storage tank are plumbed and the piping has been cleaned and examined for leaks, proceed to charge the collector loop with a mixture of heat transfer fluid (HTF) and distilled or deionized water. Do not use regular tap water.

Proceed as follows:

4.7.1 Cover the solar collectors with an opaque material such as cardboard until the heat exchange jacket has been completely charged. 

                                                                        TABLE 4
                                    Solar Storage Tank Heat Exchange Jacket Volumes
                          Storage Tank Volume       Heat Exchange Jacket       Volume Operating PSIG 
                                    48 Gallon                         1.9 Gallons                              7.3 
                                    80 Gallon                         2.4 Gallons                              7.3 
                                    116 Gallon                       4.2 Gallons                              7.3 
                          Collector Model                Absorber Piping Volume       Manifold Piping* 
                                    EP/IP-21                           0.7 Gallons                             .27 Gallons 
                                    EP/IP-24                           0.8                                          .33 
                                    EP/IP-32                           1.0                                          .33 
                                    EP-IP-40                           1.2                                          .38

*Manifold piping volumes are for 3/4” T-M hard copper tubing. 


                                                                         TABLE 5
                                       Concentration of Dowfrost HD in Water For Freeze 
                                                               and Burst Protection
                                 Temperature             Freeze Protection                Burst Protection 
                                         20 F                              18%                                     12% 
                                         10 F                              29%                                     20% 
                                          0 F                               36%                                     24%

4.7.2 Remove the 3/4” brass plug from the vent socket on the left side of the solar storage tank when filling the heat exchange jacket. This allows air to purge as the heat exchange jacket and collector loop piping is being filled with HTF.

4.7.3 Fill a large container with the proper mixture of Dowfrost HTF and distilled or deionized water. See Table 5 to determine the proper ratio of Dowfrost and distilled water required in your climate area. Table 4 indicates the total volume of the solar collectors, heat exchange jacket and manifold piping.

4.7.4 Fill the collectors and heat exchange jacket with Dowfrost. Pour the HTF mixture through a funnel and hose attached to the ball hose bibb (see figure 24). Continue to pour the HTF until the level of fluid reaches the bottom of the vent socket.


fig.24 CHARGING THE HEAT EXCHANGER & COLLECTORS

Screw the 3/4 brass plug into the vent socket. Completely seal using Teflon tape. Remove the opaque material from the solar collector glazing.

Remove any factory applied protective material from the solar storage tank.

The solar tank should now be fully filled and pressurized and the heat exchange jacket charged with propylene glycol HTF. To ensure that there is no trapped air in the system open at least two hot water fixtures in the home and purge any air in the lines.

the manufacturer recommends that the installation contractor check the HTF three months after first commissioning the system to ensure that there are no leaks in the glycol loop piping and that the HTF has maintained the proper level. The normal operating pressure of the collector and heat exchange jacket heat exchange jacket piping is approximately 7.3 psig.

Your SunSiphon solar water heating system must be charged and the fluid quality maintained by an experienced contractor. If the system is drained during the winter, or you notice a significant drop in collector loop pressure, contact your installation contractor immediately for service. The glycol HTF provides the freeze protection for your system and must be properly maintained. An experienced contractor should periodically check the HTF fluid quality.

4.8 Dowfrost HTF
To ensure maximum effectiveness for corrosion protection, the glycol inhibitor package is designed for a minimum 25-30 percent concentration of glycol in water. Table 5 shows the concentrations of Dowfrost required to provide freeze and burst protection at various temperatures. Use the mixture most appropriate for your climate. Do not use a higher glycol to water concentration than necessary, as this will adversely impact the relative heat transfer efficiency of the solution.

Generally, for an extended margin of protection, you should select a temperature that is at least 5 degrees F lower than the expected lowest ambient temperature. These figures are examples only and should not be regarded as specifications. As use conditions are not within our control, neither the manufacturer nor Dow Chemical guarantees that freeze damage may not occur at temperatures other than shown.

Water used to dilute the HTF must meet certain minimum standards for purity. Impurities in the dilution water can increase metal corrosion, reduce the effectiveness of corrosion inhibitors, increase inhibitor depletion rate, and cause the formation of scale and other deposits on the heat exchanger’s internal heat transfer surfaces. Distilled or deionized water is required.

Propylene glycol can degrade over time. The process of degradation is accelerated in presence of oxygen and/or heat. We strongly encourage you to establish a preventative maintenance schedule with your installation contractor. The HTF pH level must be maintained between 8 and 10 in order to prevent glycol oxidation and corrosion of the collector piping. the manufacturer’s collector warranty specifically excludes freeze damage for any reason and absorber plate damage resulting from the oxidation of the propylene glycol HTF.

4.9 Pipe Insulation Requirements
The cold water manifold running between the solar storage tank and the bottom of the collector array should not be insulated.

The hot water manifold piping between the solar collectors and the solar storage tank must be insulated with a high quality flexible closed cell insulation to minimize heat loss.

All exterior and attic piping between the SunSiphon and the rest of the home’s plumbing system also must be properly insulated. The wall thickness of all required pipe insulation should not be less than 3/4”. A 1” wall thickness is required in all areas prone to annual hard freeze conditions. When it comes to pipe insulation the rule is simple: thicker is better. The specified insulation material is Rubatex Insul-Tube 180 or equal.

To the extent possible, slide the insulation material over the pipe without cutting or taping. All butt joints must be sealed with contact adhesive. The use of rigid polyethylene pipe insulation is prohibited. The temperatures generated by your collector in the summer months or under stagnation conditions can melt this type of material.

Any above ground exterior pipe insulation is subject to UV degradation and must be wrapped with foil tape or painted with two coats of high quality waterbased acrylic resin coating as supplied by the insulation manufacturer. Rubatex UV Protective Coating or equal is the required coating material.

In two tank systems the 3/4” cold water supply line to the backup water heater must be insulated with minimum 7/8” X 1/2” pipe insulation to a minimum distance of 5’ behind the storage tank, or to the wall if closer than 5’.

4.10 Supplemental Water Heater Insulation
the manufacturer requires that the backup gas or electric water heater must have a minimum insulation value of R-20. Conventional water heaters have insulation values between R-12 and R-20. The R value expresses the thermal conductivity of the insulation material. The higher the “R”value the more effective the insulation material is at preventing heat loss.

If the backup water heater does not come with sufficient factory insulation to meet the manufacturer’s insulation specification, a supplemental insulation jacket also must be installed. We recommend an aluminum foil “bubble-pack” insulation material such as manufactured by Reflectix (or equal). When properly applied, the insulation jacket will increase the overall level of tank insulation by approximately R-5.

If your SunSiphon system is installed in a new home, the manufacturer specifies that the conventional water heater in a two tank system have an insulation value of R-20 (Rheem 82VR52-2, Ruud EVR52-2 or equal). No additional insulation jacket is required.

For best results, cut three 1” strips of material and affix these to the top, middle and bottom of your water heater or storage tank with the manufacturer’s tape. This space creates an air gap between the heater and the insulation and prevents heat conduction. Wrap the material around the water heater or storage tank and secure the seams with the manufacturer’s tape. Make sure to fully insulate the top of the heater. Cut around the nipples and relief valve to ensure a tight custom fit.

Ground mounted water heaters should not be placed directly on an uninsulated floor or concrete slab. The tank should be placed on a well insulated pad with a minimum R-value of 10. A 2” rigid polystyrene insulation pad such as manufactured by Frost King or equal, is recommended.

Electrical Requirements
If your SunSiphon system serves as a preheater to a supplemental gas or electric water heater, no additional electrical work is required. If the SunSiphon is the primary water heater a properly licensed contractor must make the 240 volt electrical connection to the SunSiphon storage tank and, if included, the electric time switch. Wire size, conduit and fittings must conform to National Electrical Code (NEC) requirements. If your solar contractor is not allowed by state law to make these connections consult a licensed electrician.

If the SunSiphon system serves as the primary water heater or preheats a supplemental electric water heater, we highly recommended that the contractor install a time switch near the main electrical panel to activate the electric resistance heating element during inclement weather or periods of high use. Install the Intermatic models WH-40, EH-40 or equal.

Never activate the circuit breaker controlling the electrical heating element until the solar storage tank is completely filled with water. This will prevent “dry firing” of the heating element. The electrical heating element will be destroyed almost instantaneously if not completely submerged in water when activated.

When the solar storage tank is completely filled and pressurized, turn on the electric power at the circuit breaker and test the electric resistance heating element and thermostat for continuity and voltage. If the SunSiphon serves as a preheater for a supplemental electric or gas water heater no electrical connection to the solar storage tank is required. 

                                                                        TABLE 6
                                                            Electrical Specifications 
                                             48 Gallon             80 Gallon             116 Gallon 
                        Watts         2,400 (2.4 kW)    4,800 (4.8 kW)       4,800 (4.8 kW) 
                        Amps                 10                         20                         20 
                        Volts                  240                       240                       240 
                        Phase                1                            1                           1 
        Minimum Breaker              20                          30                         30 
        Rating In Amps


5) SYSTEM START-UP PROCEDURES

Having successfully completed the tasks outlined in Section 4 above, the SunSiphon system has been fully commissioned and is ready for normal operation.


6) NORMAL SYSTEM OPERATION

The SunSiphon solar water heating system is most effective and will save the most money when no supplemental energy is consumed to heat water. For many months of the year the SunSiphon should produce the majority of your hot water. If the SunSiphon is your primary water heater the auxiliary heating element will provide some or all of your hot water during periods of very high demand or inclement weather.

When supplemental heating is required in single tank systems do not use the circuit breaker as an “ON/OFF” switch. Circuit breakers are not intended for that purpose. the manufacturer strongly recommends that your contractor install a time switch at a location near the circuit breaker to provide a convenient means of turning on and off the resistance heating element as necessary.

Two tank SunSiphon systems are designed to accommodate three separate modes of operation. Your solar system may be set to (1) provide 100% solar operation during good weather, or (2) serve as a preheater to your supplemental water heater adding solar energy when and as available, or (3) run 100% on utility power during inclement weather or heavy use.
Figures 25, 26 and 27 show the precise placement of the valve handles above the supplemental gas or electric water for each of the three possible operating modes. Set the valve handle for the desired operation. Check the valve handles at least once a year to ensure proper system function and performance.


fig.25 VALVE POSITION # 1 – SOLAR DIRECT


fig.26 VALVE POSITION # 2 – SOLAR PREHEAT


fig.27 VALVE POSITION # 3 – SOLAR BYPASS


7) ISOLATING THE SOLAR STORAGE TANK

The SunSiphon solar storage tank and the supplemental water heater can be isolated from the pressurized water system for repair or maintenance by closing the isolation ball valve No. 18 (see figures 20 & 21).


8) EXTENDED VACATION PROCEDURES

For short summer vacations no action is required. During extended summer vacations of four weeks or more it is advisable to either cover the solar collectors with an opaque material or to manually drain the collector loop HTF. the manufacturer recommends that you cover the collectors, if practical. If you choose to drain the HTF in the collector loop follow these steps:

Connect one end of a garden hose to the ball hose bibb (No 11) and place the other end in a five gallon bucket. Open the valve and gravity will drain the heat transfer fluid into the bucket. A licensed recycler, reclaimer or incinerator must dispose of the Dowfrost HTF. DO NOT DUMP DOW FROST INTO A STORM SEWER, ON THE GROUND OR INTO A BODY OF WATER. Follow the material safety data sheet instructions attached to this manual for the proper handling and disposal of the glycol fluid mixture.

BE CAREFUL! THE HTF MAY BE EXTREMELY HOT!

8.2 If the installation includes a time switch make sure the clock is not preset to go on during your absence. Remove the “ON” tripper from the clock face of a mechanical time switch or reprogram an electronic time switch to remain off. It is not necessary to drain the solar storage tank during extended vacations. When you return home contact your service contractor to recharge the system with HTF. Reset the time switch if necessary.


9) ROUTINE MAINTENANCE AND TROUBLESHOOTING

The following simple procedures are intended to optimize the performance of your SunSiphon solar water heating system and also to extend the life of the primary components.

9.1 It is extremely important to monitor the quality of the Dowfrost HD HTF on a periodic basis. The chemical composition of the heat transfer fluid may change over time. System pH must be maintained between 8 and 10 to avoid glycol oxidation and permanent damage to the collector loop and absorber plate piping.

The specified glycol HTF is Dow Chemical “Dowfrost”. An extremely complete manual is available from the Dow Chemical Co. by calling 1-800-447-4369. Dow Chemical’s “Engineering and Operating Guide for Dowfrost and Dowfrost HD” describes in detail the necessary procedures to maintain the integrity of the HTF. Ask your installation contractor to establish a maintenance schedule to inspect, balance or replace the glycol HTF as needed.

9.2 If you live in a dusty climate it is beneficial to wash off the dirt that settles on the collector glass once a month. Clean glass allows the collector to maintain a high level of thermal performance.

9.3 Check the exterior pipe insulation annually and patch or repair any exposed surfaces or degraded areas. Repaint as necessary.

9.4 In the unusual instance of collector glass breakage, the glass should be replaced immediately. Do not allow moisture or debris to enter the collector casing. Contact your installation contractor to change the glass.

9.5 If you detect a glycol or water leak, or the glycol loop pressure drops unexpectedly, contact your installation contractor immediately to diagnose the problem and recharge the system.

9.6 If the weather is poor and the auxiliary heating element will not fire, the reset button on the storage tank thermostat may have to be depressed to be reset. UNDER NO CIRCUMSTANCE SHOULD YOU REMOVE THE PROTECTIVE ACCESS PLATE ON THE SOLAR STORAGE TANK FOR SERVICE OR MAINTENANCE BEFORE DISCONNECTING THE 240 VOLT POWER SUPPLY AT THE CIRCUIT BREAKER.

If the red reset button on the thermostat clicks when depressed the heating element should immediately fire when you reconnect the circuit breaker. It you still do not have hot water after one hour contact your installation contractor for service. Note: In two tank systems the conventional electric water heater will be wired for electrical backup. The solar tank will serve solely as a storage tank.


fig.28 TILT MOUNT RACK DETAIL


fig.29 TILT MOUNT RACK DETAIL


10) COMPONENTS PARTS 

                                                         Parts List Typical 2 Panel System*
                          Component                      Part No.                   Quantity                     Included 
                     Solar Collectors                         1                            1-3                               Yes 
                     Storage Tank                             2                            1                                  Yes 
                     Brass Tee Adapter                     3                            1                                  Yes 
                     TPR Valve                                 4                            1                                  Yes 
                     Brass Adaptor Fitting                  5                            4                                  Yes 
                     3/4” CM Adapter                         6                            4                                   No 
                     3/4” Copper Tubing                    7                            14’ Prox.                       No 
                     3/4” 90º CC Elbow                      8                            4                                   No 
                     1” CC Couplings                         9                            2                                   No
                     1 X 3/4” CF Adapter                   10                           1                                   No 
                     3/4” Brass Ball Hose Bibb           11                           1                                   No 
                     1 X 3/4 CC Coupling                  12                           2                                   No 
                     1” CC Cap                                  13                           1                                   No 
                     Earthquake/Hurricane Straps                                     2                                   Yes

*Refer to figure 22 for the location of each plumbing component. 


                                                   ADDITIONAL COMPONENTS - TYPICAL SYSTEM
                                                                                 Part No.                      Quantity 
                                 Boiler Drain                                 14                                2 
                                 Protective Hose Cap                    15                                2 
                                 Thermometer                               16                               1 
                                 Thermostatic Mixing Valve          17                                1 
                                 Isolation Ball Valve                      18                               1 
                                 Three Way Valve                         19                                2    
                                 Isolation Ball Valve                      20                               1 
                                 Anode Rod                                   21                               1 
                                 TPR Valve                                    22                               1 
                                 Dip Tube                                      23                               1 
                                 Heater Drain Valve                       24                               1 
                                 Water Heater                                 25                              1 
                                 Optional time clock                       26                              1

Refer to figures 20, 21 and 22 for the location of each plumbing component.



fig.30 GROUND MOUNT RACK DETAIL


11) TILT MOUNT RACK DETAIL

SunSiphon Tilt Mount Racks are constructed of anodized aluminum angle and SolarStrut, and secured with stainless steel nuts, bolts, lock washers and washers. The specific length of anodized aluminum angle and strut material required for each rack is a function of the selected tilt angle from horiztontal (see Table 3), the collector length and the solar storage tank width. Exact dimensions for each rack are available upon request. 
      
                                                                        TABLE 7
Part Letter             Quantity 48 & 80 gal / 116 gal                      Material                         Length 
      A                                        2 / 3                                  2" X 2" X 1/8" Angle                Variable 
      B                                        2 / 3                                             "                                        " 
      C                                        2 / 3                                             "                                        "
      D                                        2 / 3                                             "                                        " 
      E                                        2 / 3                                             "                                        " 
      F                                        2 / 3                                             "                                        " 
      G                                       2 / 3                                              "                                        " 
      H                                       2 / 3                                   1.5" x 1.5" x 1/8" Angle                " 
      I                                         2 / 3                                   1 5/8" SolarStrut                         42" 
      J                                        2 / 3                                   2.5" SolarStrut                            19.75" 
      K                                       1 / 2                                   2" X 2" X 1/8" Angle                   Variable
 

12) Estimated Component Life
You can expect a long useful life from the primary components in your SunSiphon solar water heating system by adhering to the routine service and maintenance tips provided in Section 9 above.

The solar collectors have a design life of twenty-five to thirty years. The HTF must be maintained as specified in this manual to maximize collector life. The solar storage tank should last 12 to 20 years in most water quality areas. Like EPA mileage estimates for automobiles, these component design lives represent average figures for SunSiphon glycol heat exchange systems installed in the United States.

To obtain warranty service please contact your installation contractor or call the manufacturer Inc. for the name of an authorized service agent near you.

13) Model Numbers

                                                SUNSIPHON SRCC OG-300 MODEL NUMBRS
System Description           1-Tank, Supplemental Electric      2-Tank, Supplemental Electric      2-Tank, Supplemental Gas 
                                                            Model No.                                        Model No.                                           Model No.
48 gallon tank with an EP-21            EPGX48-21                                   EPGX48-21-2                                     EPGX48-21-2G
48 gallon tank with an EP-24            EPGX48-24                                   EPGX48-24-2                                     EPGX48-24-2G
48 gallon tank with an EP-32            EPGX48-32                                   EPGX48-32-2                                     EPGX48-32-2G
80 gallon tank with an EP-40            EPGX80-40                                   EPGX80-40-2                                     EPGX80-40-2G
80 gallon tank with 2 EP-21's            EPGX80-42                                   EPGX80-42-2                                     EPGX80-42-2G
80 gallon tank with 2 EP-24's            EPGX80-48                                   EPGX80-48-2                                     EPGX80-48-2G
80 gallon tank with 3 EP-21's            EPGX80-63                                   EPGX80-63-2                                     EPGX80-63-2G
80 gallon tank with 2 EP-32's            EPGX80-64                                   EPGX80-64-2                                     EPGX80-64-2G
116 gallon tank with 3 EP-21's          EPGX116-63                                 EPGX116-63-2                                   EPGX116-63-2G
116 gallon tank with 2 EP-32's          EPGX116-64                                 EPGX116-64-2                                   EPGX116-64-2G
116 gallon tank with 2 EP-40's          EPGX116-80                                 EPGX116-80-2                                   EPGX116-80-2G


14) SUNSIPHON PRODUCT SPECIFICATIONS
Due to the manufacturer’s policy of continuous product improvement, the specifications are subject to change without notice.

Model #	# of Collectors	Overal Width in Inches	Overal Length in Inches	Overall Height in Incehs	Total Collector Area SQ. FT	Minimum Pressure PSIG	TOTAL WIEGHT Pounds	MODEL #	Capacity Gallons	Diameter in Inches	Length in INches	Dry Weight  Pounds	Booster Element WA	Model #	Width in Inches	Length in Inches	Height in Inches	Gross Area SQ FT	Dry Weight Pounds
EPGX48-21	1	48	98	22	21.12	150	564	G48	48	22	48	99	2,400	EP21	40	76	3 1/4	21.12	70
EPGX48-24	1	48	120	22	24.61	150	572	G48	48	22	48	99	2,400	EP24	36 1/8	98 1/4	3 1/4	24.61	80
EPGX48-32	1	48	120	22	32.79	150	602	G48	48	22	48	99	2,400	EP32	48 1/8	98 1/4	3 1/4	32.79	106
EPGX80-40	1	75	144	22	40.81	150	941	G80	80	22	75	143	4,800	EP40	48 1/8	122 1/4	3 1/4	40.81	141
EPGX80-42	2	82	98	22	42.24	150	946	G80	80	22	75	143	4,800	EP21	40	76	3 1/4	21.12	70
EPGX80-48	2	75	120	22	49.22	150	963	G80	80	22	75	143	4,800	EP24	36 1/8	98 1/4	3 1/4	24.61	80
EPGX80-63	3	122	98	22	63.36	150	1,022	G80	80	22	75	143	4,800	EP21	40	76	3 1/4	21.12	70
EPGX80-64	2	98	120	22	65.58	150	1,021	G80	80	22	75	143	4,800	EP32	48 1/8	89 1/4	3 1/4	32.79	106
EPGX116-63	3	123	98	22	63.36	150	1,388	G116	116	22	108	209	4,800	EP21	40	76	3 1/4	21.12	70
EPGX116-64	2	108	120	22	65.58	150	1,389	G116	116	22	108	209	4,800	EP32	48 1/8	98 1/4	3 1/4	32.79	106
EPGX116-80	2	108	144	22	74.66	150	1,480	G116	116	22	108	209	4,800	EP40	48 1/8	122 1/4	3 1/4	40.81	141

SYSTEM OPTION * Imperial Series Collectors - substitute “I” for “E” in model number prefix.


ENGINEERING SPECIFICATIONS

The solar water heating system shall be of the integral thermosiphon type, and shall operate on the principle of natural convection requiring no pumps, controls, or parasitic energy consumption for its normal operation. The solar water heating system shall be certified by the Solar Rating and Certification Corporation (SRCC) under standard OG-300. The primary system components shall be specified as follows:

SOLAR COLLECTORS:
The solar collectors shall be of the liquid flat plate type__________square feet in gross dimension, with a dark bronze anodized aluminum framewall, lowiron tempered glass, polyisocyanurate foam insulation covered with a barrier of low-binder fiberglass insulation, all-copper roll formed absorber plate, semi-selective absorber plate coating, EPDM gaskets and silicone seals, painted aluminum back sheet, all stainless steel fasteners, tested in accordance with ASHRAE 93-1986 and certified by the Solar Rating and Certification Corporation (SRCC). Model__________. (See Imperial and Empire series collector specification sheets for rated collector performance)

STORAGE TANK
The SunSiphon storage tank shall be constructed of 0.64 inch marine grade 316L stainless steel and be fully MIG welded, acid washed and passivated. The storage tank shall be capable of withstanding temperatures up to 212° F (100° C) without degradation and shall not require conventional anodic protection. The test pressure shall be 300 PSI and the maximum operating pressure shall be 150 PSI. The storage tank shall be completely insulated with rigid polyurethane foam providing a minimum thermal resistance of R-8 at the bottom of the tank and R-20 at the top. The storage tank shall be equipped with an auxiliary electric heating element and field adjustable thermostat. The storage tank shall hold __________________U.S. gallons.

HEAT EXCHANGE JACKET:
The heat exchange jacket shall be constructed of 0.05 inch marine grade 316L stainless steel and is designed to envelope and heat the lower half of the storage tank where the cold potable water enters the storage tank and stratifies. The heat exchange jacket shall have an integral expansion chamber to allow for the thermal expansion of the heat exchange fluid.

THE CASING:
The exterior casing shall be weatherproof and corrosion resistant. The casing shall be treated with an AZ150 class Zincalume substrate applied by the continuous hotdip method, coated with a corrosion inhibitive high metal chromate primer, and a final oven-baked Colorbond XMA exterior coating. The exterior casing typically shall be dark bronze or black in color. The cylinder ends shall utilize a Pittsburg-type lock to prevent moisture from entering the casing.

THE SYSTEM:
The specified solar water heating system shall be the SunSiphon model no. _________________________


SUNSIPHON THERMOSIPHON SYSTEM WARRANTY STATEMENT

Under conditions of normal use and service the solar collector and absorber plate are warranted to the original or subsequent users for a period of ten (10) years from the date of sale. Under conditions of normal use and service the SunSiphon storage tank is warranted to the original or subsequent user for a period of (7) years and the heating element, thermostat and temperature and pressure relief valve are covered by a one (1) year warranty.

the manufacturer's liability under this warranty shall be limited to repairing or replacing at the manufacturer's option, without charge, F.O.B. the manufacturer's factory or an authorized distributor or service station, the solar collector or absorber plate, storage tank, heating element, thermostat, or temperature and pressure relief valve. the manufacturer will not be liable for any costs of transportation, inspection, removal, reinstallation, or any other labor or freight charges that may arise in connection with a warranty claim except as expressly delineated in this warranty statement.

FIELD LABOR
Field labor to repair or replace any defective solar collector or absorber plate is reimbursable up to $100 in year one, $75 in years two through five, and $50 in years six through ten. Field labor to repair or replace the storage tank, heating element, thermostat, or temperature and pressure relief valve is reimbursable up to $100 in the first year only.

FREIGHT AND SHIPPING EXPENSES
During the first year the manufacturer will pay the shipping costs for the new or repaired solar collector or absorber plate, storage tank, heating element, thermostat or temperature and pressure relief valve between the manufacturer and the nearest local distributor, dealer, or authorized service center. After the first year freight and packing costs are the responsibility of the owner and are not covered under this warranty.

THIS WARRANTY WILL NOT APPLY
This warranty does not apply to conditions resulting from a failed component or part that is not part of the solar collector or absorber plate, storage tank, heating element, thermostat or temperature and pressure relief valve; to freeze damage; to conditions resulting from misuse, abuse, neglect, accident, or alteration; to minor discoloration of the collector framewall, absorber plate or storage tank skin over time; to glass breakage; to conditions resulting from the introduction of harmful chemicals, caustic fluids, or liquids deleterious to copper tubing, including improperly applied or maintained heat transfer fluids; to propylene glycol pH levels above 10 or below 8; to periods of stagnation in excess of 60 days; to excessive pressure; to clouding or similar occurrence resulting from the normal intrusion of moisture into the collector box; to conditions resulting from floods, earthquakes, winds, fire, lightning, or circumstances beyond the manufacturer's control; to installation methods which do not conform to relevant national, state or local codes and ordinances, good industry practices or applicable manuals, diagrams, technical bulletins or written installation instructions; and, to applications other than medium temperature (110 -160F) domestic water heating. If the SunSiphon Thermosiphon System is purchased outside the continental United States certain conditions of this warranty may not apply. Please contact your local distributor.

HOW TO MAKE A CLAIM
To obtain service under this warranty, the defective product must be returned to the distributor or dealer nearest you, an authorized service center, or the manufacturer directly. Each claim must be accompanied by documentation indicating the homeowner's name, address, phone number, date of installation, date of failure, reason for failure, product model and serial numbers, and the installation contractor’s name and phone number. If you have questions regarding this warranty contact your installation contractor or the manufacturer.

LIMITED WARRANTY
EXCEPT AS EXPRESSLY PROVIDED HEREIN, THE SOLAR COLLECTOR OR ABSORBER PLATE, STORAGE TANK, HEATING ELEMENT, THERMOSTAT AND TEMPERATURE/PRESSURE RELIEF VALVE ARE PROVIDED WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTYOR NON-INFRINGEMENT. SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED WARRANTIES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE.

LIMITATIONS OF REMEDIES
IN NO EVENT WILL THE MANUFACTURER BE LIABLE TO YOU FOR ANY DAMAGES, INCLUDING ANY LOST PROFITS, LOST SAVINGS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES, ARISING OUT OF THE USE OR INABILITY TO USE THE SOLAR COLLECTOR OR ABSORBER PLATE, STORAGE TANK, HEATING ELEMENT, THERMOSTAT, AND TEMPERATURE/PRESSURE RELIEF VALVE, OR FOR ANY CLAIM BY ANY OTHER PARTY. SOME STATES DO NOT ALLOW THE LIMITATION OR EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

EXCLUSIVE AGREEMENT
THE WARRANTY CONTAINED HEREIN CONSTITUTES THE ENTIRE, COMPLETE, FINAL AND EXCLUSIVE AGREEMENT, AND SUPERSEDES ANY PROPOSAL OR AGREEMENT ORAL OR WRITTEN, AND ANY OTHER COMMUNICATIONS BETWEEN THE MANUFACTURER AND THE BUYER WITH RESPECT TO THE SUBJECT MATTER HEREOF.