SOLAR WATER HEATER WITH
ELECTRIC BACKUP
A Spanish language version of these instructions is available by contacting the manufacturer listed on the rating plate.
La version espanola de estas instruccions se puede obtener al escribirle a la fábrica cuyo nombre aparece in la placa de
especificaciones.
INSTALLATION/OPERATING MANUAL
WITH PARTS LISTING AND TROUBLESHOOTING GUIDE
WARNING
To avoid damage or injury, there
must be no materials stored against
the solar water heater and proper
care shall be taken to avoid
unnecessary contact (especially by
children) with the solar water heater.
ꢀ
Do not store or use gasoline
or other flammable liquids
in the vicinity of this water
heater or any other
appliance.
For your family’s comfort, safety, and convenience, we recommend this water
heater/storage unit be installed and serviced by a plumbing professional.
238-47073-00B REV 2/08
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SECTION I
IMPORTANT INFORMATION
-READ CAREFULLY-
The equipment must be installed in accordance with those installation regulations required in the
area where the installation is to be made. These regulations must be carefully followed in all cases.
Authorities having jurisdiction shall be consulted before installations are made.
All wiring on water heaters installed in the USA must be in accordance with the National Electrical Code,
ANSI/NFPA 70, latest edition, and/or local regulations; or in Canada, installed in accordance with the
Canadian Electrical Code, CSA C22.1, latest edition and/or local regulations.
The following terms are used throughout this manual to bring attention to the presence of hazards of
various risk levels, or to important information concerning product life.
CAUTION
DANGER
Indicates a potentially hazardous
situation, which, if not avoided,
may result in moderate, or minor
injury or property damage.
Indicates an imminently hazardous
situation, which, if not avoided, will
result in death, serious injury, or
substantial property damage.
NOTICE
WARNING
Indicates a potentially hazardous
situation, which, if not avoided, could
result in death, serious injury, or
substantial property damage.
Indicates special instructions on
installation, operation or
maintenance, which are important
but not related to personal injury
hazards.
TABLE OF CONTENTS
I- IMPORTANT INFORMATION…………….…..
3
6
8
II- SPECIFICATIONS……………………………….
III- GENERAL INFORMATION…………………….
IV- PRE-INSTALLATION…………………………… 10
V- WATER CONNECTIONS……………………….. 12
ONE-TANK SYSTEM INSTALLATION………………...
TWO-TANK SYSTEM INSTALLATION……...………...
13
15
VI- ELECTRICAL CONNECTIONS………………..
VII- OPERATING INSTRUCTIONS…………………
VIII- MAINTENANCE………………………………….
IX- TROUBLESHOOTING GUIDE…………………
X- PARTS LIST………………………………………
XI- NOTES …………………………………………….
18
20
22
24
25
27
3
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Important Information continued-
DANGER
DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the
vicinity of this or any other appliance.
IF YOU SMELL GAS:
ꢀ
ꢀ
ꢀ
DO NOT try to light any appliance.
DO NOT touch any electric switch; do not use any telephone in your building.
Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s
instructions.
ꢀ
If you cannot reach your gas supplier, call the fire department
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!
Liquefied petroleum gas/propane gas is heavier than air and will remain at floor level if there is a leak.
Basements, crawl spaces, closets, and areas below ground level will serve as pockets for accumulation of
leaking gas.
This water heater is supplied with adjustable thermostats to control water temperature. Hot water
temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious
personal injury and/or death. The temperature at which injury occurs varies with the person’s age and the
time of exposure. The slower response time of disabled persons increases the hazards to them. NEVER allow
small children to use a hot water tap or to draw their own bath water. NEVER leave a child or disabled
person unattended in a bathtub or shower.
WARNING
Installation is not complete unless a properly sized/capacity pressure and temperature relief valve is installed
into the side of the water heater. See the General Information section of this manual for details.
This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings or attempt
to disconnect any components of this water heater without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up, or servicing this water
heater to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the water heater. This water heater contains components that become very hot.
Do not touch any components unless they are cool.
Improper installation, adjustments, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
Read and understand all instructions, including all those contained in component manufacturer’s manuals,
which are provided with the appliance before installing, starting-up, operating, maintaining, or servicing this
appliance. Keep this manual and literature in legible condition and posted near the appliance for reference
by owner and service technician.
This water heater requires regular maintenance and service to operate safely. Follow the instructions
contained in this manual.
Installation, maintenance, and service must be performed only by an experienced, skilled, and knowledgeable
installer or service agency.
4
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Important Information continued-
WARNING
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is complete.
DO NOT operate the water heater with jumpered or absent controls or safety devices.
DO NOT tamper with or alter the water heater and/or controls.
DO NOT operate the water heater if any external part or control has been submerged in water. Immediately
call a qualified service technician to inspect the appliance and to replace any part of the control system that
was under water.
This water heater is suitable for installation on combustible flooring. DO NOT install this water heater on
carpeting.
DO NOT operate this water heater without first being certain it is filled with water.
Flammable items, pressurized containers, or any other potential fire hazardous articles must never be placed
on or adjacent to the heater. Containers of flammable gases should not be stored or used in the same room
with this water heater.
Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for
a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the
possibility of injury under these conditions, it is recommended that a water faucet be opened for several
minutes at the kitchen sink before you use any electrical appliance that is connected to the hot water system.
If hydrogen is present, there will be unusual sounds such as air escaping through the pipes as hot water
begins to flow. Do not smoke or have open flame near the faucet at the time it is open.
CAUTION
The maximum supply temperature from the solar collector must not exceed 250°F (121°C).
5
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SECTION II
SPECIFICATIONS
HOT WATER OUTLET-3/4" NPT
ANODES
COLD WATER INLET-3/4" NPT
SOLAR SENSOR WIRING
JUNCTION BOX
OPTIONAL OUTLET
FOR RECIRCULATION
( 60 & 75 GAL. MODELS)
ELECTRIC HIGH VOLTAGE
WIRING JUNCTION BOX
TEMPERATURE AND
PRESSURE RELIEF VALVE
UPPER COVER:
SOLAR THERMISTOR WIRES,
THERMOSTAT, UPPER HEATING
ELEMENT UNDER COVER
FROM SOLAR COLLECTOR-1" NPT
MIDDLE COVER:
THERMOSTAT
UNDER COVER
TO SOLAR COLLECTOR-1" NPT
DRAIN COUPLING-3/4" NPT
DRAIN VALVE- 5/8" NH
LOWER COVER:
SOLAR THERMISTOR WIRES,
LOWER HEATING ELEMENT
UNDER COVER
Figure 1 – Tank Layout
Table 1: Water Heater Dimension (Inches)
MODE
L
60-Gal.
A
B
C
D
E
F
22
24
60-1/4 59-1/4 29-1/2 7-3/8
60-1/4 59-1/4 29-1/2 7-3/8
53
53
75-Gal.
115-Gal. 28 1/4 63-1/4 62-1/2 29-1/2 7-3/8 55-3/4
6
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Specifications continued-
Table 2: Water Heater Capacities
Tank
Capacity
(Gal)
Coil
Volume
(Gal)
Coil Heat
Transfer Area
(Sq Ft)
Approximat Approximate
e
Dry Weight
(Lbs)
210
Wet Weight
(Lbs)
MODEL
60-Gal.
75-Gal.
115-Gal.
60
75
115
2.5
2.5
2.5
14.2
14.2
14.2
695
832
236
340
1248
Table 3: Electric Backup Water Heater Ratings
First Hour
Standby Heat
MODEL
Supply
(Gallons)
84
Loss Rating
(°F/Hr)
1.1
60-Gal
75-Gal
115-Gal
97
124
0.9
0.7
Solar Single-wall Heat Exchanger Flow Specifications
Heat Exchanger Pressure Drop Curve
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
0
1
2
3
4
5
6
7
8
9
10
Flowrate (GPM)
Figure 2 – Solar Heat Exchanger Pressure Drop Chart
7
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SECTION III
GENERAL INFORMATION
FEATURES
This water heater contains the following features:
HEAT EXCHANGER – The heat exchanger (coil) is made of porcelain coated single-wall carbon steel tubing and
has 1” NPT female fittings. If a confirmed leak occurs, contact the plumbing professional who installed the water
heater or the manufacturer, listed on the rating plate, for additional guidance.
SINGLE-WALL HEAT EXCHANGER MODELS – Water heaters with single-wall heat exchangers meets the
Uniform Plumbing Code for installation in all potable water systems provided that:
• The heat transfer medium (including additives) is practically non-toxic, having toxicity rating of class of 1 as listed in
Clinical Toxicology of Commercial Products.
• The heat transfer medium pressure is limited to maximum 30 psig by approved relief valve.
• The heat transfer medium is potable water or contains only substances that are recognized as safe by the U.S. Food
and Drug Administration (FDA).
• The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the
potable water system.
• The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used
in the heat transfer medium.
BACKUP HEATING ELEMENTS WITH ADJUSTABLE THERMOSTATS – The temperatures may be
adjusted from approximately 100°F to approximately 180°F. The thermostats are factory set at 120°F. It is
recommended that lower temperatures be used to avoid the risk of scalding. Refer to the “Warnings” in the section
on SCALDING in “Section VII – Operating Instructions.” It is further recommended, in all cases, that the water
temperature be set for the lowest temperature that satisfies your hot water needs. This will also provide the most
energy efficient operation of the water heater and minimizes scale formation. The thermostat located under the
middle cover controls the lower heating element. This ensures that only when the solar heating system cannot satisfy
user demand that the lower heating element is energized.
Setting the water heater temperature at 120°F will reduce the risk of scalds. Some states require settings to specific
lower temperatures.
SENSOR WIRES FOR SOLAR THERMISTOR CONNECTIONS – Twisted wires are provided under the lower
and upper covers. These wires have been provided as a means for connecting thermistors to a solar controller.
NOTICE: Neither the solar controller nor the thermistors are provided with the solar water heater and must
be purchased separately. The lower thermistor wires connect a thermistor for use in comparison to the solar
collector temperature to determine if an appropriate temperature difference for heat transfer is available. The upper
thermistor wires are an optional second thermistor connection to monitor the upper tank temperature. Some solar
controllers provide this option.
INTEGRATED MIXING DEVICE – An ASSE approved temperature mixing device is supplied with the water
heater. The solar heating system may transfer heat into the water heater above the temperature limits set by the
thermostats. This may create the potential for scald injury. To protect against injury, you must install the supplied
ASSE approved mixing valve (a device to limit the temperature of water to protect against scald injury via mixing
hot and cold water supply) in the water system. This valve will reduce point of discharge temperature in branch
supply lines. Refer to the instructions supplied in the Integrated Mixing Device box for installation procedures and
device specifications.
CAUTION
This water heater must NOT be operated without the Integrated Mixing Device included in the
box with the heater.
8
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General Information continued-
SACRIFICIAL ANODES — Two sacrificial anode rods have been installed in the tank head to extend tank life.
The anode rods should be inspected annually to determine the amount of sacrificial decay and replaced when
necessary to prolong tank life. The permanent removal of these anodes, for any reason, will nullify the warranty.
Water conditions in your area will influence the time interval for inspection and replacement of the anode rod. The
use of a water softener may increase the speed of anode consumption. More frequent inspection of the anode is
needed when using softened (or phosphate treated) water. Contact the plumbing professional who installed the water
heater or the manufacturer, listed on the rating plate, for anode replacement information.
TEMPERATURE AND PRESSURE RELIEF VALVE
WARNING
Keep clear of the combination temperature and pressure relief valve discharge line outlet. The discharge may
be hot enough to cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install temperature and pressure protective equipment
required by local codes, but not less than a combination temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or
materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot
Water Supply Systems, ANSI Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and Pressure
Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve must be marked
with a maximum set pressure not to exceed the maximum working pressure of the water heater. The combination
temperature and pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not
less than the hourly rating of the water heater/storage unit. The supplied combination temperature and pressure
relief valve, when properly installed and unrestricted, will discharge the maximum input produced by a 240°F
(115°C) collector supply temperature. A lower collector supply temperature will reduce the input required to be
discharged in the event of excessive potable water temperatures.
Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose
on the water heater/storage unit.
Some models may already be equipped or supplied with a combination temperature and pressure relief valve.
Verify that the combination temperature and pressure relief valve complies with local codes. If the combination
temperature and pressure relief valve does not comply with local codes, replace it with one that does.
Install a discharge line so that water discharged from the combination temperature and pressure relief valve will
exit within six (6) inches above, or any distance below the structural floor and cannot contact any live electrical
part. The discharge line is to be installed to allow for complete drainage of both the temperature and pressure relief
valve and the discharge line. The discharge opening must not be subjected to blockage or freezing. DO NOT
thread, plug, or cap the discharge line. It is recommended that a minimum clearance of four (4) inches be provided
on the side of the water heater/storage unit for servicing and maintenance of the combination temperature and
pressure relief valve
Do not place a valve between the combination temperature and pressure relief valve and the tank!
9
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SECTION IV
PRE-INSTALLATION
UNPACKING
INSPECT SHIPMENT carefully for any signs of damage. If damage is noted, do not install the product. Contact
the shipper or manufacturer listed on the rating plate. All equipment is carefully manufactured, inspected, and
packed. Our responsibility ceases upon delivery of the packaged water heater to the carrier in good condition.
NOTE: Any claims for damage or shortage in shipment must be filed immediately against the carrier by the
consignee.
This water heater MUST be installed indoors out of the wind and weather.
CAUTION
This water heater must be located in an area where leakage of the tank, water line connections, or the temperature
and pressure relief valve will not result in damage to the area adjacent to the water heater/storage unit or to lower
floors of the structure. When such locations cannot be avoided, a suitable drain pan must be installed under the
water heater/storage unit. The drain pan depth must be suitable for draining and collecting water. The drain pan
can be purchased from your plumbing professional. The drain pan must be piped to an adequate drain. The piping
must be at least ¾ inch in diameter and pitched for proper drainage.
Component Location
Clearance from Combustible Materials
Top
0”
Sides
0”
Front
0”
Rear
0”
Table 5 – Combustible Material Clearances
Recommended Service Clearances
Non-Piping
Side
Front
(Heat Exchanger)
16”
T & P Relief
Valve Side
6”
Rear
0”
4”
Table 6 – Service Clearances
1. Heater
CAUTION
Do not drop water heater. Do not bump water heater jacket against floor.
Location – For fastest delivery of hot water, place the solar water heater closest to the points of use.
Additional Recommended Components
1. Shut-off Valves – Allows isolation of water heater from domestic water system and/or solar system
during service.
2. Unions – Allows water heater movement during service if adequate clearance cannot be provided.
3. Thermal Expansion Tank – If the water heater is installed in a closed water supply system, such as
one having a back-flow preventer in the cold water line, provide thermal expansion control. Contact
the water supplier or local plumbing inspector for additional information.
MOVE THE WATER HEATER TO A PERMANENT POSITION BY SLIDING OR WALKING.
10
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Pre-installation continued-
NOTICE
For California installation this water heater must be braced, anchored, or strapped to
avoid falling or moving during an earthquake. See instructions for correct installation
procedures. Instructions may be obtained from California Office of the State Architect,
400 P Street, Sacramento, CA 95814.
SOLAR WATER HEATING WITH ELECTRIC BACKUP FUNDAMENTALS
The solar heating system puts the most amount of heat into the storage tank when the bottom of the tank is
cool. That is where the internal heat exchanger is located. This allows the collector temperature to be
lower and still transfer heat into the storage tank.
When hot water is taken from the top of the tank, cool water is delivered to the tank bottom by means of a
diptube. The thermostat to turn on the lower heating element is located above the internal heat exchanger’s
level to ensure that the heat exchanger stays in a cool zone unless backup heat is needed. If the lower
heating element thermostat is activated, this is an indication that there is not enough solar heating available
to meet the immediate need. Approximately 1/3 of the storage tank volume needs to be removed without
sufficient solar heating for the lower element to energize.
The typical solar water heater with electric backup has only one element. In periods were solar heating is
not available the amount of stored hot water is about ¼ of the tank volume. The dual electric element
backup will allow the entire storage tank to hold hot water during these periods. The unique design
promotes solar heating yet does not compromise heater performance when it is not available.
The amount of heat transferred into the tank due to solar heating is inconsistent. The more heat stored in
the tank through solar heating, the lower the operating costs. The integrated mixing device must be
installed to ensure that if higher temperatures are achieved, safe water temperature delivery occurs. It is
recommended that storage tank temperatures are not allowed above 185°F. Temperature levels above that
point may activate the electric backup emergency cutoff device, disconnecting the electric backup system.
11
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SECTION V
WATER CONNECTIONS
INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not factory installed)
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED TEMPERATURE AND PRESSURE
RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT
RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES.
Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank
for a long period of time. HYDROGEN GAS IS EXTREMELY FLAMMABLE. To prevent the possibility
of injury under these conditions, we recommend the hot water faucet be opened for several minutes at the
kitchen sink before you use any electrical appliance that is connected to the hot water system. If hydrogen
is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow.
Do not smoke or have open flame near the faucet at the time it is open.
Keep clear of the temperature and pressure relief valve discharge line outlet. The discharge may be hot
enough to cause scald injury. The water is under pressure and may splash.
Keep clear of the temperature and pressure relief valve discharge line outlet. The discharge may be hot
enough to cause scald injury. The water is under pressure and may splash.
Temperature and pressure relief valve discharge piping must be piped near the floor to eliminate potential of
severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or
caps to the temperature and pressure relief valve or piping.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the nipples on top of the water heater. Sweat the
tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not
applied to the nipples containing a plastic liner.
INSTRUCTIONS FOR POTABLE CONNECTIONS
1. BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.
After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water
from leaking out of the pipes while making the water connections to the water heater. After the pressure has
been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top of the
water heater. Install the mixing device supplied with the solar water heater, following the installation
instructions included with the mixing device. Make the proper plumbing connections between the mixing device
on the water heater and the plumbing system to the house. Install a shut-off valve in the cold water supply line.
2. If this water heater is installed in a closed water supply system, such as one having a back-flow preventer in the
cold water supply, provisions must be made to control thermal expansion. DO NOT operate this water heater in
a closed system without provisions for controlling thermal expansion. Warranties do not cover damages from
thermal expansions such as pressure bulges and/or deformities. A properly sized expansion tank will alleviate
most problems. Your water supplier or local plumbing inspector should be contacted on how to control this
situation.
3. After installation of the water lines, open the main water supply valve and fill the water heater. While the water
heater is filling, open several hot water faucets to allow air to escape from the water system. When steady
streams of water flow through the faucets, close them and check all water connections for possible leaks.
4. NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN THAT IT IS
FILLED WITH WATER.
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Water Connections continued-
INSTRUCTIONS FOR SOLAR CONNECTIONS
The solar water heater connection labeled “TO SOLAR COLLECTOR” should be piped to the solar return piping.
The use of a union and a shut-off valve is recommended. Pipe and fittings between the solar system and the water
heater should be ¾” diameter or larger.
CAUTION
Maximum solar collector water supply temperature to the solar heat exchanger
must not exceed 250°F (121°C).
ONE-TANK SYSTEM INSTALLATION
CONNECT SOLAR PIPING TO WATER HEATER
1. For a closed loop solar heating system, refer to Figure 3. The solar water heater connection labeled “FROM
SOLAR COLLECTOR” should be piped to the solar collector supply piping. Mount the circulator making sure
the flow arrow points toward the water heater. The use of shut-off valves and unions are recommended for
future service convenience. The use of an air separator and vent is recommended to eliminate air in the system.
Pipe and fittings between the solar collector and solar water heater must be ¾” diameter or larger.
Figure 3 – Solar Collector Piping in Closed-loop Installation
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Water Connections continued-
2. For a drainback solar heating system, refer to Figure 4. The solar water heater connection labeled “FROM
SOLAR COLLECTOR” should be piped to the solar collector supply piping. Mount the circulator making sure
the flow arrow points toward the water heater. The use of shut-off valves and unions are recommended for
future service convenience. Pipe and fittings between the solar collector and solar water heater must be ¾”
diameter or larger. The piping or drainback tank must have a site glass located at a level above the circulator and
water heater.
Figure 4 - Solar Collector Piping in Drainback Installation
FILL SOLAR COLLECTOR SYSTEM
1. Fill solar heating system appropriately with water or a propylene glycol/water mix.
2. Verify pump flow and direction. In a closed loop system, purge all air from the collector/water heater piping.
3. Check system for leaks. Repair as necessary.
a. In a closed loop system, check for leaks when flow is stopped and the operating pressure is maintained.
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Water Connections continued-
TWO-TANK SYSTEM INSTALLATION
THE TYPICAL TWO-TANK SYSTEM
A typical two-tank system is provided in Figure 5. This system holds two separate volumes of water. The cold
water supply is delivered to the solar water heater. If solar energy is available, the water in the solar heater is heated.
This heated water is delivered into the backup water heater. If no solar energy were available, the backup water
heater would heat the water through electric elements or gas combustion, depending on the backup water heater.
Figure 5 – Water Heater Piping in a Two-tank Installation
The solar with electric element backup can be used to replace either the solar or backup water heater in the two- tank
installation. Replacement installation configurations are provided in Figures 6 and 7. By replacing either tank with
the new solar with backup heater, replacing the remaining tank when it eventually fails may be unnecessary. This is
due to the solar heater’s capability to satisfy the requirements of a two-tank system.
15
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Water Connections continued-
Figure 6 – Replacing the Solar Water Heater in a Two-tank Installation
To replace the previous solar water heater with the new solar water heater with electric backup, remove the previous
solar water heater. The external heat exchanger and pump can also be removed. The new solar water heater with
electric backup has an internal heat exchanger allowing direct heat transfer to the water. For installation of the new
solar water heater with electric backup, refer to “INSTRUCTIONS FOR POTABLE CONNECTIONS” earlier in this
section and Figure 6. The potential for not transferring the solar heat into the solar water heater due to a pump
malfunction is reduced when the second pump is removed from the system.
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Water Connections continued-
Figure 7 – Replacing the Backup Water Heater in a Two-tank Installation
To replace the previous backup water heater with the new solar water heater with electric backup, remove the backup
water heater. The new solar water heater with electric backup has an internal heat exchanger allowing direct heat
transfer to the water. For installation of the new solar water heater with electric backup, refer to “INSTRUCTIONS
FOR POTABLE CONNECTIONS” earlier in this section and Figure 7. Connect the solar piping in series from the
new solar water heater to the previous solar water heater as shown in Figure 7. This allows the solar heat to transfer
directly into the backup tank. The remaining heat that was not transferred into the backup tank is then made
available to the previous solar water heater before going back to the solar collector. One installation advantage is
that the solar heat makes up for heat losses that occur when water is not flowing. Another is that more heat is
absorbed into the potable water system from the solar water heating system.
17
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SECTION VI
ELECTRICAL CONNECTIONS
Install electric wiring in accordance with the National Electric, ANSI/NFPA 70, and /or the CSA C22.1 Electric
Code, latest editions.
DANGER
Positively assure all electrical connections are unpowered before attempting installation or service of electrical
components or connections of the water heater or building. Lock out all electrical boxes with padlock once power
is turned off.
WARNING
When installed, the water heater must be electrically grounded in accordance with local codes or, in the absence of
local codes, with the National Electrical Code, ANSI/NFPA 70, and /or the CSA C22.1 Electric Code, latest
editions.
Failure to properly wire electrical connections to the water heater may result in serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempting any electrical
work.
CONNECT ELECTRIC HEATING ELEMENT BACKUP
Before any electrical connections are made, be sure that the water heater is full of water and that the valve in the cold
water supply line is open. The solar water heater is supplied with a dual electric heating element backup system. The
upper thermostat incorporates a manual reset temperature-limiting device. Please refer to the TROUBLESHOOTING
GUIDE section for manual reset operation. Both upper and lower thermostats incorporate a manual adjustable
temperature indicator to change the potable water temperature. The thermostat that controls the lower heating
element is located next to the “FROM SOLAR COLLECTOR” connection. Refer to WATER TEMPERATURE
ADJUSTMENT in the OPERATING INSTRUCTIONS section for proper instruction in adjusting water temperature.
Turn off all power related to the heating system before proceeding with the electrical connections. Any and all wiring
shall be sized and installed to satisfy the voltage and amperage used. The water heater must be well grounded. A
green ground screw is provided at the electrical connection point for connecting a ground wire. All wiring shall be
done in accordance with all applicable local and state codes.
WARNING
Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against
the water heater, and proper care must be taken to avoid unnecessary contact (especially by children) with the water
heater.
UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT
THINNER BE USED OR STORED IN THE VICINITY OF THE WATER HEATER OR IN ANY LOCATION
FROM WHICH FUMES COULD REACH THE WATER HEATER.
Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the
field involved. Plumbing and electrical work are required.
CONNECT SOLAR CONTROLLER AND THERMISTORS
Sensor wires are provided for connection to the controller in a separate junction box located on top of the water
heater. The brown twisted wires provide thermistor wiring from the controller to the lower control cover located
next to the “TO SOLAR COLLECTOR” connection. The orange twisted wires provide thermistor wiring from the
controller to the upper control cover. The orange wiring would be used for controllers that have connections for a
second tank location.
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Electrical Connections continued-
NOTICE
A solar control and thermistors are not supplied with this water heater. The Tekmar 156, when installed according
to manufacturer’s instructions, is an acceptable controller. Other solar controller manufacturers such as Steca and
Resol provide controllers appropriate for use with this water heater.
Thermistors are not included with the water heater. Thermistors must be purchased with the solar controller to
ensure capability with the selected control. Contact the solar controller manufacturer for details.
Refer to Figure 8 for connecting the thermistor and pressing it against the tank. This figure illustrates the opening
under the upper control cover. While the lower control location does not hold a thermostat, the process is the same.
1. Positively assure all electrical connections are unpowered whenever removing the control covers.
2. Strip the twisted wire ends and use wire nuts to securely connect the thermistor wires.
3. Pull the insulation material away slightly from the water heater tank.
4. Slide the thermistor between the insulation and the water heater tank.
a. The upper tank thermistor should be inserted as shown in the lower right hand corner.
b. The lower tank thermistor should be inserted half way up on the right hand side.
5. Verify that the insulation provides enough pressure to hold the thermistor in place.
6. To assure that the thermistor does not move, apply a small amount of high temperature silicon sealant in the
insulation gap produced where the thermistor has been inserted.
7. Return power to the water heater once the covers are in place.
Figure 8 – Wiring and Placement for the Solar Control Thermistor
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SECTION VII
OPERATING INSTRUCTIONS
SYSTEM START-UP
Follow solar collector installation instructions to place collector in operation. Ensure that solar fluid flow operation
is established for the installed system.
SEQUENCE OF HEATING OPERATIONS -SOLAR AND ELECTRIC BACKUP
1. The solar controller senses a large enough temperature difference between the lower tank and the solar collector
to transfer heat into the tank.
a. The solar controller activates a circulator/pump to flow fluid through the heat exchanger and solar collector,
transferring heat into the storage tank until the temperature difference is significantly reduced.
2. The upper element thermostat senses that the water temperature stored in the upper portion of the tank drops
below the desired setting.
a. The upper element is energized to heat stored water to the desired temperature. Once the water in the upper
tank is heated to the desired temperature, the element is de-energized.
3. The lower element thermostat senses that the water temperature stored above the solar heat exchanger drops
below the desired setting.
a. The lower element is energized to heat stored water to the desired temperature. Once the water in the lower
tank is heated to the desired temperature, the element is de-energized.
WATER TEMPERATURE ADJUSTMENT
Table 7 details the approximate relationship of water temperature and time with regard to scald injury and may be
used as a guide in determining the safest water temperature for your applications.
WARNING
SCALDING
This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever
using hot water to avoid scalding injury. By setting the thermostat on this water heater to obtain an
increased water temperature, you may create the potential for scald injury. To protect against injury, you
should install an ASSE approved mixing valve (a device to limit the temperature of water to protect against
scald injury via mixing hot and cold water supply) in the water system. This valve will reduce point of
discharge temperature in branch supply lines. This water heater was shipped with an ASSE approved
mixing valve. Install this valve according to the directions in the mixing device container. DO NOT
OPERATE THIS WATER HEATER A MIXING DEVICE. If this water heater was shipped without a
mixing device, contact the manufacturer.
APPROXIMATE
TIME/TEMPERATURE
RELATIONSHIPS IN SCALDS
Water temperature over 125°F
can cause severe burns
instantly or death from scalds.
Children, disabled and elderly
are at highest risk of being
scalded.
120°F
125°F
130°F
135°F
140°F
145°F
150°F
155°F
More than 5 minutes
1 ½ to 2 minutes
Review this instruction manual
before setting temperature
at water heater.
About 30 seconds
About 10 seconds
Less than 5 seconds
Less than 3 seconds
About 1 ½ seconds
About 1 second
Feel water before bathing or
showering.
Temperature limiting valves are
available.
Figure 9 – Scald Warning
Table 7 – Scald Relationships
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Operating Instructions continued-
CAUTION
Before adjusting the thermostat, turn off all power supplied to the solar water heater.
The minimum potable water temperature can be changed by adjusting the thermostat. Before any work is done on
the water heater, disconnect all power to the water heater and heat source (solar collector) by opening the switch(s) at
the main electrical circuit breaker or fuse box. Remove the cover and fold the insulation outward away from the
control. Adjust the thermostat dial using a screwdriver until the minimum acceptable temperature is achieved. The
thermostat has been factory preset to 120°F (49°C). Remember that lower temperature settings are more energy
efficient. Rotate the temperature dial clockwise
to increase water temperature. Rotate the thermostat dial
counter-clockwise to decrease the temperature setting. Replace the insulation making sure that the control is
well covered and that the plastic terminal shield has not been displaced. Replace the access panel. The water heater
is now ready for operation and the main switch can be closed.
Figure 10 – Thermostat
After the solar water heater completes a heat-up cycle, check the water temperature at a faucet. Allow enough water
to flow to ensure that the faucet water temperature reflects the tank temperature. Adjust the water heater’s
temperature setting as necessary.
Adjusting to a lower temperature setting will not immediately affect water temperature. Draw sufficient water or
allow the water heater to remain idle until a heat-up cycle is initiated. After the heater’s heat-up cycle is complete,
check the water temperature at a faucet to determine if further adjustment is necessary.
Adjusting to a higher temperature may not immediately affect water temperature. If a heat-up cycle begins, allow the
heat-up cycle to complete before checking the water temperature. If a heat-up cycle does not begin, draw sufficient
water or allow the water heater to remain idle until a heat-up cycle is initiated. After the heater’s heat-up cycle is
complete, check the water temperature at a faucet to determine if further adjustment is necessary.
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SECTION VIII
MAINTENANCE
This solar water heater is intended to provide a service life of many years. Components that require service,
however, may be subject to failure. Failure to use the correct procedures or parts in these circumstances may make
the water heater unsafe.
The owner should arrange to have the following inspections and simple maintenance procedure performed by
qualified service personnel at the frequencies suggested.
1. Solar and Domestic Water Piping (Annual) - Check all piping for signs of leakage at joints, unions, and shut-
off valves. Repair as needed.
2. Temperature-Pressure Relief Valve (Annual) - The temperature-pressure relief valve should be checked to
ensure that it is in operating condition. To check the relief valve, lift the lever at the end of the valve several
times. The valve should seat properly and operate freely. If water does not flow, remove and inspect for
obstructions or corrosion. Replace with a new valve of the recommended capacity as necessary. Do not attempt
to repair the valve, as this could result in improper operation and a tank explosion. In areas with poor water
conditions, it may be necessary to inspect the temperature-pressure relief valve more often than once a year.
CAUTION
Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the
discharge to an open drain. Failure to take this precaution could mean contact with extremely hot water
discharging from the valve during this checking operation.
If the temperature–pressure relief valve on the heater discharges periodically or continuously, it may be due to
thermal expansion of water in a closed water supply system, or it may be due to a faulty relief valve.
Thermal expansion is the normal response of water when it is heated. In a closed system, thermal expansion will
cause the system pressure to build until the relief valve actuation pressure is equaled. Then the relief
valve will open, allowing some water to escape, slightly lowering the pressure. Contact your water supplier or local
plumbing inspector on how to control this situation.
ABOVE ALL, DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE. THIS IS NOT A
SOLUTION AND CAN CREATE A HAZARDOUS SITUATION.
3. Anode Inspection and Replacement - This water heater is equipped with multiple sacrificial anodes. Anodes
protect the glass-lined tank from corrosion by sacrificing themselves through electrolysis. When the anode
material is consumed, there is no more protection and corrosion of the tank accelerates.
Inspection of the anodes every year allows you to identify spent anodes and replace. Replace the anodes when
its diameter is 3/8 of an inch, or every other year, which ever is first. Aggressive, very hot and softened water
causes rapid consumption of the anode, requiring frequent inspections. Anodes are available from your
distributor or from the manufacturer.
To inspect or replace an anode:
The anodes on this water heater are easily accessible from the top of the heater making replacement simple and
quick.
a. Turn the water heater and, if applicable, solar controller electricity off. Flow water until the discharge is cool
or allow enough time for the potable water to cool naturally. Connect a hose to the drain valve. Locate the
hose’s discharge in an area where any remaining hot water will not cause any damage or injury.
b. Open the drain valve to flush any sediment out of the bottom to the heater.
c. Shut off the cold water supply. Make sure all hot water fixtures and circulating pumps are turned off.
d. Wait for water flow from the hose to stop. Remove the anode using a socket of the appropriate size. Do not
use an impact wrench.
e. Inspect and replace the anode as required. Use pipe tape or sealant when reinstalling the anode.
f. Close the drain valve. Open a hot water fixture to allow air to escape. Open the cold water supply to the
heater and allow the tank to fill.
g. Check your anode and drain valve for leaks.
h. Turn the water heater and, if applicable, solar controller electricity on.
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Maintenance continued-
4. Sediment (Annual, but harsh water quality may dictate more frequent service) - Depending on water
conditions, a varying amount of sediment may collect in the tank. Levels requiring service are indicated by a
small temperature difference in the supply and return lines (See also “Scale” below). Repeated flushing usually
clears such material. As a preventive measure, water should be drawn from the tank at the drain valve until it
runs clear.
5. Scale (Annual) - Hard water may cause scale to build-up on the outside of the heat exchanger coil. A water
softener will prevent this problem (See also “Sediment” above). Symptoms would be reduced recovery
capacity or reduced temperature differential between solar collector supply and return lines. Repeated flushing
should resolve the problem.
6. Solar Controller -The solar controller manufacturer may have a recommended maintenance procedure. Refer
to the installation and operation manual that was received with the solar controller.
7. Solar Collector Panels - The solar collector panel manufacturer may have a recommended maintenance
procedure. Refer to the installation and operation manual that was received with the solar collector panels.
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SECTION IX
TROUBLESHOOTING GUIDE
PROBLEM
No hot water at
faucet
CAUSE
ECO on thermostat tripped
SOLUTION
Determine if ECO trip is a result of excessive solar heat or
electric element. Correct or replace as necessary. Depress red
“RESET” button on thermostat
Improper thermostat setting
or calibration
Adjust tank thermostat to appropriate setting
See Section VII
Circulator does not pump
fluid through solar collector
Check electrical connections
Check that proper valves are open
Check that system is bled
Replace as necessary
Electrical problem (Control,
wiring, etc.)
Check fuse and replace
Check circuit breaker and reset (if applicable)
Check power supply
Scale build-up
If solar controller, collectors, circulator, and tank are operating
satisfactorily, coil may have scale coating. See Section VIII:
Maintenance
Clogged cold water filter
Thermostat set too high
Clean or replace filter or strainer
Adjust thermostat setting. See Section VII
Water at faucet
too hot
Improper system plumbing
Compare plumbing to Section V
Improper system wiring
Mixing Device temperature
set too high
Compare wiring to Section VI
Adjust Mixing Device setting. Refer to Mixing Device
instructions.
Insufficient hot
water
Thermostat setting too low
Undersized solar collectors
Adjust thermostat to higher setting. See Section VII
Review calculations for proper collector surface area,
orientation and available sunlight
Faulty solar sensor or solar
controller
Check connections, power and sensor resistance. Replace as
necessary.
Peak use of hot water is
greater than tank storage
capacity
Determine peak usage and compare to tank capacity
Circulator does not pump
fluid
Check electrical connections
Check that proper valves are open
Check that system is bled
Replace as necessary
Faulty tank thermostat
Replace thermostat
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SECTION X
PARTS LIST
PART NAME & DESCRIPTION
1. Hole Closure
11. Element Gasket
2. Hex Head Anode
12. Thermostat with ECO (89T33)
13. Thermostat Mounting Bracket
14. Heating Element
15. Thermostat Protector (Large)
16. Access Cover
3. Integrated Mixing Device
4. Hot Water Outlet/Anode
5. Cold Water Inlet Diptube
6. Electrical Outlet Cover
7. Conduit Grounding Cover
8. Escutcheon
17. Exchanger Escutcheon
18. Thermostat (59T)
9. T&P Relief Valve
10. ¾” Plug
19. Lower Thermostat Protector
20. Brass Drain Valve
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Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on
the rating plate of the water heater.
Provide the part name, model, and serial numbers of the water heater when ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE
WATER HEATER ARE WARRANTED.
Manufactured under one or more of the following U.S. Patents: RE.34,534;B1 5,341,770; 4,416,222;
4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983; 4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696;
5,092,519; 5,115,767; 5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952; 5,660,165; 5,682,666; 5,761,379;
5,943,984; 5,954,492; 5,988,117; 6,142,216; 6,395,280; 6,684,821; 7,007,748; 7,063,132
Other U.S. and Foreign patent applications pending. Current Canadian Patents:
1,272,914; 1,280,043; 1,289,832; 2,045,862; 2,092,105; 2,107,012; 2,108,186; 2,112,515
Complete the following information and retain for future reference:
Model No:________________________________________
Serial No: ________________________________________
Service Phone
Days: _________________ Nights:___________________
Address:_________________________________________
Supplier:_________________________________________
Supplier Phone No: ________________________________
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SECTION XI
--NOTES—
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SECTION XI
--NOTES—
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