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

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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

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