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Solar Water Heating Appliance
Installation Manual
Pre-Heat Appliance
1, 2, 3 & 4-Collector Pre-heat Appliances
(EWRA1, EWRA2, EWRA3, EWRA4)
1, 2, 3 & 4-Collector Pre-heat Appliances
(EWRA1-DWHX, EWRA2-DWHX, EWRA3-DWHX, EWRA4-DWHX)
Energy Kinetics Inc.
51 Molasses Hill Road
Lebanon, NJ 08833
Tel: (908) 735-2066
Toll-free: 1-800-323-2066
Fax: (908) 735-2068
www.energykinetics.com
EnerWorks Inc
969 Juliana Drive
Woodstock, ON N4V 1C1
Canada
Tel: (519) 268-6500
Fax: (519) 268-6292
info@enerworks.com
www.enerworks.com
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Table of Contents
Summary of Contents for ENERGY KINETICS Smart Solar EWRA1
- Page 1 Pre-Heat Appliance 1, 2, 3 & 4-Collector Pre-heat Appliances (EWRA1, EWRA2, EWRA3, EWRA4) 1, 2, 3 & 4-Collector Pre-heat Appliances (EWRA1-DWHX, EWRA2-DWHX, EWRA3-DWHX, EWRA4-DWHX) Energy Kinetics Inc. EnerWorks Inc 51 Molasses Hill Road 969 Juliana Drive Lebanon, NJ 08833 Woodstock, ON N4V 1C1...
- Page 2 EnerWorks authorized dealer or warranty is void. CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
- Page 3 The EnerWorks Pre-Heat Appliance is the first system in North America to achieve the Canadian Standards Association (CSA) certification (CSA F379.1). This certification does not imply endorsement or warranty by CSA. © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
- Page 4 Any damage due to ingress of rain is not covered by warranty. It is best to store both the EnerWorks Solar Collectors and the EnerWorks Energy Station in a cool, dry place. Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 5: Table Of Contents
5.2 Preparation of heat transfer fluid..............34 5.3 Charging Appliance with heat transfer fluid............34 6 – Collector Flashing and Leaf guard Installation.............37 6.1 Side flashing for 1-collector Appliances............39 © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 6 Exploded Views......................46 Controller operation....................49 Product & Installation Registration Form ...............52 Maintenance Log.......................53 Residential Site Survey ....................54 Tool and Supply Checklist ..................56 Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 7: Safety
All persons working on roofs should have successfully completed a fall-safety course and should be properly equipped with appropriate safety equipment. © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 8: Enerworks Pre-Heat Solar Water Heating Appliance
Even in summer months, additional heat from the back-up heater may be required. For more information on Appliance components and function, please see the Owner Manual. Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. -
Page 9: Appliance Schematic
Pre-existing or auxiliary hot water tank or on- demand heater Pressure relief valve (inside cover) Thermosiphon loop feed (from storage) Fig.2.2 – EnerWorks Pre-Heat Solar Water Heating Appliance (with optional leaf-guard). © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 10: Appliance Selection And Sizing
Denser cool water from household pipes tends to sink into storage tanks. Tank manufacturers install heat trap valve, gasket or flapper to limit this convective flow and associated heat losses Fig.2.4.2.1 10 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 11 Space may be required for a 2 gal US (7.8 L) expansion tank to be mounted on side of solar storage tank or on wall (4.9.2 Supplemental expansion tank). 11 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
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Page 12: Recommended Work Sequence
3 – Recommended Work Sequence Power or gas supply to existing water heater is turned off; tank is drained as required. Solar storage tank is positioned. 12 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 13 Product & Installation Registration Form included with (Fig.3.1) Owner Manual and in Appendices. Serial numbers are required for warranty service. Serial number Fig.3.1 – Energy Station Label. 13 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
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Page 14: Pre-Heat Appliance Installation
Charging port, supply to system Cold (mains) water inlet from charging pump and reservoir Heat transfer fluid filter (in lower Thermosiphon loop, hot water to storage manifold) from Energy Station 14 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 15 Follow all codes and regulations. Before installing the EnerWorks Energy Station, shut down power or gas to existing hot-water heater and drain tank. 15 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
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Page 16: Energy Station Installation
( ). Thread sealant or Fig.4.2.1 Teflon tape is not required as gasket ensures water-tight seal. Do not over-tighten or gasket may be damaged. 16 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 17 Thermist by releasing air from expansion tank). Fig.4.2.2 – Thermistor clamped to corrugated copper pipe close to lower manifold. Pressure gauge Expansion tank Schrader valve 17 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
- Page 18 Energy Station must be at least 1¾” (50mm) off floor to allow for service. See, 9 – Scheduled Maintenance. 18 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 19: Thermosiphon Loop Installation
4. Remove protective plug from top port of upper manifold. Loosely thread ¾” MNPT x ½” sweat fittings into ¾” FIP port at Fig.4.3.1 – Brass tee connected to 19 - top of solar storage tank © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 20 Damage to back flush valve may occur if hot solder or flux drips down into valve – do not perform any soldering of copper in place 20 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
- Page 21 16. Hot outlet of solar storage tank (remaining port of ¾” sweat tee) is to be fitted to cold inlet of existing water heater. ¾” copper pipe may be used or install supplied ¾” x ½” sweat reducer to use ½” copper pipe ( Fig.4.4.3 21 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
- Page 22 EnerWorks Solar Water Heating Appliance Remove thermometer from well before soldering. Do not install thermometer until soldering is complete and well is cool. 22 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 23: Water Connections - Bypass Valves
Maintenance valve positions ( Fig.4.4.1 Solar storage tank Back-up Cold mains water supply heater To Energy Station Hot water to home Solar-heated water To back-up water heater 23 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 24 EnerWorks Solar Water Heating Appliance Fig.4.4.1 – Bypass valve configuration. 24 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 25: Water Connections - Cold Mains Supply
EnerWorks recommends that all water lines, hot and cold be insulated to minimize heat loss and condensation. 25 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 26: Water Connections - Solar Storage Hot Outlet
Check local codes and regulations regarding installation of anti-scald valves and set point requirements. This installation may have to undergo inspection – check local codes and regulations. 26 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. -
Page 27: Filling Tanks With Water
(copper or plastic straps are recommended). Do not compress insulation when bundling or securing lines. 27 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 28 Expansion tank may also be attached to wall with appropriate screws (not included). Ensure access to expansion tank and to Schrader valve is maintained for charging and maintenance procedures. 28 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 29: Controller Connections
Energy Station expansion tank. Using a pressure gauge, ensure that air pressure in expansion tanks is 25 psi. Adjust, if necessary, with a bicycle pump or air compressor. 4.10 Controller connections 29 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 30 Similarly, connect red wire descending from top of tank to red wire 30 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 31: Appliance Control Wire Connections
(even though collectors are covered, they will be hot), proceed with Energy Station Controller connections If a short or open connection is perceived, (Fig. 4.11.1). check for and correct faulty connections. 31 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 32 Common (5 Com) Factory-installed storage tank thermistor wire connections (blue) to Common (5 Com) and to Storage (7 Stor) Fig.4.11.2 – Controller thermistor connections 32 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 33: Charging Appliance
Leak test must not be rushed. Take this time to prepare the heat transfer fluid, to educate homeowner on Appliance operation, to complete Product & Installation Registration Form, and/or to begin clean up. 33 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 34: Preparation Of Heat Transfer Fluid
Air must be completely purged from system. Collectors must remain covered until charging is complete. Uncovered collectors will get very hot. Fluid pumped through uncovered collectors will flash boil, placing 34 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 35 Supply-line Charge pump (from reservoir to pump and Appliance) Return-line Reservoir with heat (from Appliance) transfer fluid Fig.5.3.1 – Charging Kit and fluid reservoir 35 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
- Page 36 (An alternative is to apply a 4.5-5 kΩ resistor to Source and Common terminals at bottom right of Controller, under cover. This will simulate a hot collector and unit should turn on.) 36 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 37: Collector Flashing And Leaf Guard Installation
Collector flashing and leaf guard are designed for pitched roof installations only. Flashing and leaf guard should not be installed on rack-mounted collectors due to increased wind loads. 37 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 38 EnerWorks Solar Water Heating Appliance Before installing flashing and leaf guard confirm no leaks at panel(s), insulate line-set, and record collectors Serial Number(s)) 38 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 39: Side Flashing For 1-Collector Appliances
Side flashing may also be used on multi-collector installations to hide C- channel. 1. Slide center-flashing between collectors in collector side-wall grooves. Upper length should overlap lower length to ensure proper rain and snow shedding ( Fig.6.2.1 39 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 40: Leaf Guard Installation
Leaf guard for one and two-collector Appliances is optional and is of benefit to prevent leaves and debris from gathering around and behind collectors. Leaf guard includes thin lengths 40 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. -
Page 41: Appliance Start-Up
4. Remove plastic foil cover from collectors. 5. Check Energy Station operation and Controller display to ensure Appliance is working properly. 41 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 42: Final Steps
Follow charging procedure as outlined in sections 5.2 Preparation of heat transfer fluid and 5.3 Charging Appliance with heat transfer fluid. 42 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. -
Page 43: Troubleshooting
If resistance is 0 Ω, there is a short circuit, Table 10.2.1). if resistance is infinite or if there is an error reading, there is an open circuit – check for broken wires or connections. 43 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 44: Pump
- this will cool storage tank and pump should come back on. 4. Thermostat of over-temperature control may have to be manually reset. Remove solar storage tank upper element cover and push red reset button on thermostat. 44 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. -
Page 45: Noisy Pump
Station, additional expansion capacity may be necessary. Install supplemental expansion tank (4.9.2 Supplemental expansion tank). 5. Check operation of stagnation-control damper. 6. Recharge with fluid and purge air. 45 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 46: Exploded Views
EnerWorks Solar Water Heating Appliance Exploded Views Fig.A.1 – Energy Station – exploded view 46 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 47 EnerWorks Solar Water Heating Appliance Fig.A.2 – Expansion tank & upper manifold – exploded view Fig.A.3 – Lower manifold – exploded view 47 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
- Page 48 EnerWorks Solar Water Heating Appliance 48 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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Page 49: Controller Operation
Maximum Storage temperature since item was last cleared Minimum Storage Minimum Storage temperature since item was last cleared HEAT Number of relay running hours since item was last cleared 49 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... - Page 50 Altering any default PRGM setting other than the operating mode or temperature units will void the warranty. 50 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
- Page 51 If an error message is displayed, check associated sensor and connections. Error Description Source (solar panel) sensor error Source Err open/short circuit Storage (tank) sensor error Storage Err open/short circuit Table 9. Thermistor resistance vs. Temperature 51 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
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Page 52: Product & Installation Registration Form
EnerWorks Solar Water Heating Appliance Product & Installation Registration Form 52 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. -
Page 53: Maintenance Log
EnerWorks Solar Water Heating Appliance Maintenance Log 53 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual... -
Page 54: Residential Site Survey
EnerWorks Solar Water Heating Appliance Residential Site Survey 54 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc. - Page 55 EnerWorks Solar Water Heating Appliance 55 - © 2011 EnerWorks Inc. - Page Energy Kinetics Inc. / Installation Manual...
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Page 56: Tool And Supply Checklist
EnerWorks Solar Water Heating Appliance Tool and Supply Checklist 56 - Installation Manual / Energy Kinetics Inc. - Page © 2011 EnerWorks Inc.
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