Complete Retrofit Kit Installation Manual
Complete Retrofit Kit Installation Manual DISCLAIMER OF LIABILITY Solaris Energy does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way connected with improper installation, operation, use, or maintenance by using this manual. No license is granted by implication or under any patent or patent rights. The information in this manual is believed to be reliable, but does not constitute an expressed and/or implied warranty. Solaris Energy reserves the right to make changes to the product, specifications, data sheets and this manual without prior notice.
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Table of Contents Introduction
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About Our Product
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Safety Instructions
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Installation
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Frequently Asked Questions
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Complete Retrofit Kit Installation Manual
INTRODUCTION Thank you for making a wise decision to switch to Solar Water Heating Thousands of homeowners who have electric water heaters installed, experience high electricity cost, and often endure service disruption. At Solaris, we want to empower homeowners with the necessary skills to convert their electrical water heaters to Solar by incorporating a solar energy collector, leading to a reduction in costs, as well as an environmentally friendly solution to your energy needs. The general installation of our retrofit kit lends itself to easy adaptation to be powered by solar energy. In essence this Solaris Retrofit Kit offers: • Savings on energy costs; • Ease of adaptation; • Hot water during an electrical outage; WHO should purchase our retrofit kit? Our kit has been designed for ANY do-it-yourselfer (DIYer). The kit takes into account your basic skill set from your experiences as a DIY person and practical do’s and don’ts.
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WHAT skills must a DIY homeowner have to believe they can do this? • Basic plumbing skills; • Basic electrical skills; • Dexterity in the use of a drilling machine; • Basic mechanical engineering skills; • Fastening equipment skills and technique; (e.g. rivets, sheet metal screws). WHEN should you consult with a professional installer? • If you have a water heater located against an internal wall; • If you recognize your installation may be basic but has extensive pipe runs; • If the building is too high; (e.g. more than two story high) • If the roof is too steep; (more than 25° gradient) • If the physical structure proves too difficult to maneuver; • If the installation required exceeds your capabilities/ knowledge/ability to understand the instructions; Throughout this document and the installation steps, various warnings and cautions will be provided. Once you see these symbols, please pay particular attention.
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Complete Retrofit Kit Installation Manual
The meaning of this symbol is Warning! Attention! Become Alert! Your SAFETY is Involved!
The meaning of this symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to draw your attention to unsafe practices that may cause damage to property
Always remember, if the structure of the building is complex, the work will be very complicated.
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ABOUT OUR PRODUCT Competent manufacturers produce all the components of the Retrofit Kit. International standards that the components of this product generally adhere to include: • ASME • CE standards The Solaris Retrofit Kit is designed mostly for residential homes. It is designed to adapt any 30 gallon, 40 gallon, 50 gallon, 50 gallon, 80 gallon and 120 gallon domestic electric water heaters. Before Installation The components in the Retrofit Kit are comprised of mostly metal fittings. However, the PV panel, which is included in the Kit, can be cracked or broken during delivery. These pieces would typically shatter in those instances as it is tempered glass. Be careful when opening the Kit if there are any external signs of damage to the packaging. The Solaris Retrofit Kit requires a Solar Energy Collector to work and this is not included in the Kit. We recommend that you contact your nearest Solaris office/distributor and have it installed or your nearest hardware store that sells Solaris energy collectors.
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Complete Retrofit Kit Installation Manual
Once you have opened your Solaris Retrofit Kit, please check to ensure the following is included in your package:
Name
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Size
Ball Valve FPT *Female Pipe Thread
½”
Ball Valve FTP
3/4”
Female Copper Adapter
¾”
Copper Cap
¾”
Image
Non-Return Valve
½”
Galv Tee With 3/4' Galv Plug
3/4”
Female Adapter
½”
Copper Tee
¾”
Galvanized Nipple 3" Long
3/4"
Galvanized Tee
¾“
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Complete Retrofit Kit Installation Manual
Long Lead Free Solder
16”
Teflon Tape
Air Vent Valve
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1/4"mpt
Copper Couplings
¾”
Sweat Ball Valve
½”
Brass Fpt X Cpvc Transition Union
1/2"
12Vdc Pv Panel
12 Vdc Circulation Pump
½”
Transition Fitting
Air Vent Brass Bushing
(sweat x 1/8" fpt)
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Complete Retrofit Kit Installation Manual
Now that you have opened your Solaris Retrofit Kit, we are sure you are even more excited with your purchase. Please check the parts listing included in your package to ensure you have all the parts you need. In addition ensure you have all the components needed for installation (not included in the Kit) • Electrical wires (for use in connecting the power supply from the PV panel to circulation pump) • Wall clamps (for fixing the electrical conduit and for fixing copper tubing to the wall) • Solder flux (for soldering the copper) • CPVC or copper pipe (1/2 “ diameter) (to link the solar hot water panel to the tank) • Pipe insulation (to place over all piping) • Duct tape (for fastening the insulation to the pipes) • Small wire connector (to connect the wires to the PV panel or to the circulation pump) • Flat bit Screwdriver (use as needed) • Philips screwdriver (use as needed) • Pliers (use as needed) • Adjustable wrench (use as needed) • Shears (for cutting or trimming any metal) • PVC pipe cutter or hacksaw blade (to cut pipes at required lengths) • Propane Torch • Solder wire - 100% lead free • Teflon tape - Roll (1) • Cordless Power drill • Copper/PVC elbows • Ladder (to access the roof for installation if needed)
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SAFETY INSTRUCTIONS SAFETY is important to us please read thoroughly before proceeding. • Be sure to turn off the electricity supply to the electric water heater before commencing work on the water heater. • If you do not know how this is done --do not start the work. • Check all ladders and other working gear and appliances before work starts. • Never climb ladders without an assistant present to stabilize the ladder. • Always use anti-fall gear or harness when working at heights. • Always wear eye protection when using drilling machines or other abrasive or cutting tools. • Wear gloves when necessary to protect against burns or abrasions.
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Complete Retrofit Kit Installation Manual
INSTALLATION NOW YOU ARE READY TO START INSTALLATION Safety Equipment needed Solaris believes that good safety practices cannot be overstated. Please ensure that you adopt and implement all necessary safety precautions during installation, including wearing: • Safety glasses; • Rubber gloves; • A harness when going on to the roof; • Anti-slip boots; THIS INSTALLATION will require you to go on the roof to make adaptation to your Solar Energy Collector and to install the PV Panel included in your kit. Therefore: • The structure, if not a roof, should be able to take up to 500lbs of weight (minimum load bearing), which would include the weight of the installer; • If the roof is made of clay/cement tiles, this may be challenging as they break easily making installation difficult. The drill bit would be critical during affixation to the roof, as such special precaution should be taken to prevent breakage or slippage; • Plastic tiles after constant exposure to sunlight for a number of years may become brittle and may break away. Therefore caution should be taken during installation if this is observed;
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Step-by-Step Instruction STAGE 1 For this part of the installation you will need to view the Figure 1-Diagram in your package showing retrofitting of water tank First Steps: Plumbing Circuit a. Turn off ALL the electrical supplies to the tank. b. Turn off the cold water supply to the tank (see valve on the water supply). c. At the bottom of your tank there should be a drain valve (see #1 on the figure 1 diagram). If it is not located there please consult the manufacturer’s manual. d. Open the drain valve and drain about 1 gallon/4 Litres of water from the tank, to relieve pressure from the tank. e. Assuming that at the top of your tank the galvanized nipples are already installed in the tank, cut the cold water line and place the first galvanized Tee between the water supply and the tank (see #2 on the figure 1 Diagram). f. Then cut the hot water line and place the other galvanized tee between the hot water supply to the house and the tank (see #3 on the Figure 1 Diagram).
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Complete Retrofit Kit Installation Manual
Second Steps: Cold Water Line g. On the cold water line, place a reducing bushing in the top of the Galvanized Tee. h. Then connect a ball valve to the top of the Galvanized Tee (see #4 on the Figure 1 Diagram). i. iThen connect the ½ inch copper union on to the ball valve (see #5 on the Figure 1 Diagram). j. j. Then insert the PV pump into the copper union (see #6 on the Figure 1 Diagram). CARE SHOULD BE TAKEN TO AVOID INSTALLATION OF THE PUMP WHERE IT IS EXPOSED TO RAIN OR WATER. CARE SHOULD BE TAKEN WHEN INSTALLING THE PUMP TO ENSURE IT DOES NOT COME INTO CONTACT WITH WATER UNTIL TESTED. IT IS RECOMMENDED TO COVER THE PUMP WITH A PLASTIC BAG k. Then connect the Brass check valve / non-return valve (with Teflon seat) to the pump and then insert a male adapter (see #7 on the Figure 1 Diagram). l. Ensure that the spring is removed from the brass check valve/non-return valve. m. Run enough pipelines to connect to the solar collector on the roof. Ensure you check the location of your solar energy panels to determine pipe length required. CPVC pipe may also be used where plumbing codes permit.
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THE PIPES RUNNING TO AND FROM THE COLLECTOR MUST BE INSULATED WITH PIPE INSULATION TO AVOID LOSS OF HEAT AND ANY PHYSICAL DAMAGE IF YOU COME INTO CONTACT WITH IT. NEVER USE PVC PIPE IN A RETROFIT SYSTEM THIRD STEPS: Hot Water Side a. On the hot water line, place a reducing bushing in the top of the Galvanized Tee. b. Then connect a ball valve to the top of the Galvanized Tee (see #9 on the Figure 1 Diagram). c. Then connect the ½ inch copper union on to the ball valve (see #10 on the Figure 1 Diagram). d. Then run your copper line to the roof for connection to the solar energy panel. IF YOU HAVE ALREADY PURCHASED A SOLARIS ENERGY COLLECTOR FROM ONE OF OUR DISTRIBUTORS (OR FROM A QUALIFIED MANUFACTURER OR DISTRIBUTOR OF SOLAR ENERGY COLLECTORS), PLEASE ENSURE IT IS INSTALLED CORRECTLY. BE AWARE OF YOUR PLUMBING CODES AND INSTALLATION CODES THAT EXIST IN YOUR AREA AND ENSURE YOU INSTALL THE COLLECTOR ACCORDING TO YOUR APPLICABLE CODES.
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Complete Retrofit Kit Installation Manual
PLEASE FOLLOW THE MANUFACTURER’S INSTRUCTIONS CAREFULLY. TAKE ALL PRECAUTIONARY MEASURES IN PLANNING YOUR INSTALLATION INCLUDING PLACEMENT, LOCATION. ROOF DESIGN AND SUN DIRECTION STAGE 2: For this part of the installation process you will need to view Figure 2 Diagram included in your package. NEXT STEPS: Solar Energy Collector Adaptation (See Figure 2 Diagram) a. On the bottom side of the collector for the cold water receiver line, place a reducing bushing onto the collector and then connect the copper pipe. b. Place a copper cap over the open end and solder it into place. c. On the opposite side at the top of the collector, connect a copper Tee. d. On the other end of the Tee, place a reducing bushing and then place the brass bushing in the reducing bushing. e. Then place a reducing bushing and an elbow and piping with enough length to connect to the Tee on the hot water side of the tank.
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f. Connect the air-vent on the upper portion of the Tee. THE COLLECTOR MAY HAVE AIR STORED IN IT. EXERCISE EXTREME CARE AS WHEN THE PIPES ARE CONNECTED AND AIR IS FORCED UP BY THE WATER PRESSURE TOWARDS THE AIR-VENT, IT WILL RELEASE HOT AIR AND HOT WATER WOULD THEN PASS BACK DOWN TO THE TANK.BE VERY CAREFUL WHEN RE-FILLING COLLECTOR AS STEAM MAY EMIT FROM THE AIRVENT g. On the bottom side of the collector, place a 3/4” female adapter. h. Place a galvanized plug in the female adapter. P/V Panel Installation a. To install your PV panel to the roof by spacing the rivet the brackets and drilling them on to the roof. b. Then attach the wires to the PV Panels terminals positive-to-positive and negative-to-negative. (Use no. 12 AWG wire red for the positive and 12 AWG wire black for the negative). c. Turn over the PV panel and then bolt to the roof. ENSURE YOU HAVE ENOUGH LENGTH FOR THE WIRES TO RUN FROM THE PV PANEL ON THE ROOF TO THE PUMP CONNECTED TO THE TANK.
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Complete Retrofit Kit Installation Manual
d. To join the wires from the PV panel to the pump, use the electrical connector and then electrical wire taping around the connector to prevent water penetration. e. Having completed installation, turn back on the cold water supply, your water tank will now be powered by the Solar Energy Connector when fully charged. CARE SHOULD BE TAKEN TO ENSURE THAT THE PV IS NOT IN A SHADED AREA BE CAREFUL, AS THE PV PANEL WITH EXPOSURE TO THE SUN WILL BE ABLE TO POWER UP THE PUMP ALMOST IMMEDIATELY. ENSURE YOU RUN THROUGH THE STEPS AGAIN TO ENSURE YOU HAVE NOT MISSED ANYTHING. THEN TURN YOUR WATER SUPPLY BACK ON. TESTS TO BE DONE AFTER INSTALLATION On completion of installation you should perform the following checks. 1. Turn the cold water supply back on and check that there are no leaks in the system. 2. Please note that leaks may appear many hours after the system has been re-pressurized.
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3. Purge air from all the plumbing lines by ensuring that the air vent valve on the roof is not tightly closed. 4. It is recommended that the valve be first tightened and then slackened about three revolutions. 5. If the sun is shining, check that the solar pump is running. 6. Hold the body of the pump with your hand and if you feel a continuous vibration, the pump is running. 7. Check that hot water is coming down from the collector to the tank. 8. Identify the hot water line -place your hand under the insulation and you should feel warmth. 9. Turn your electricity supply to the heater back on. 10. This is important if you have finished your installation late in the afternoon. 11. If all of these checks are ok, the system is ready to function on the next sunny day. 12. Be sure to repeat the leak test a few days after commissioning as weak joints may develop leaks WARRANTY AGAINST DEFECTS We will pass on manufacturer’s warranty on parts not manufactured by Solaris Energy. A one (1) Year warranty will be provided for the Circulation pump.
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Complete Retrofit Kit Installation Manual
Frequently Asked Questions (1) Question - What size tanks can function with a Solaris Retrofit Kit? Answer - A retrofit kit can be used with any electric water heater tank of capacity 20 gallon to 120 gallon. (2) Question - Can a Solaris Retrofit Kit be installed outdoors? Answer - The circulation pump on the Solaris Retrofit Kit must not be installed outdoors or in areas where water spray or sea spray is present. (3) Question - Will I have to use electricity after I install a Solaris Retrofit Kit? Answer - The Solaris Retrofit Kit will supply you with a full tank of hot water at the end of each sunny day. If the water is used conservatively, and you live in a climate with good sunshine, you may go for long periods without using your electrical heating option.
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(4) Question - Where can I purchase a Solar Collector to use with my Solaris Retrofit Kit? Answer - Solaris Energy Solar Panels/collectors are available at many reputable hardware stores or may be purchased by calling our local or regional distributors. (5) Question - Can I expect a “payback� from my Solaris Retrofit Kit installation? Answer - Depending on the electricity cost in your country the payback may vary from 18 months to 48 months.
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