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Summary of Contents for Duda Solar SC5815
- Page 1 Duda Solar Water Heating Systems Operation and Maintenance Manual Duda Energy LLC 1112 Brooks St SE Decatur, AL 35601 Phone Contact: 256-340-4866 www.DudaEnergy.com...
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Page 2: Table Of Contents
Table of Contents General Information ........................... 5 Local Standards ............................5 Qualified Installer ............................ 5 Warnings and Cautions ........................... 5 Pressure Release & Relief Valve ......................6 Water Quality............................6 Metallic Corrosion ........................... 7 Connection of Piping ..........................8 Freeze Protection of the Closed Loop System ..................8 Freeze Protection of the Copper Heat Pipes ................... - Page 3 Tubing ..............................26 Electronic Controller ..........................26 Controller display ..........................26 Controller ............................26 Backup Heating function ........................28 System Set-up ........................... 28 Solar water Tank ........................... 29 Mounting Feet ..........................29 Temperature/Pressure Relief ......................30 Cold water Inlet Port ......................... 30 Lower Circulation Loop Ports ......................
- Page 4 Slope Roof Installation ........................45 Bracing .............................. 46 Flat Roof or Ground Installation ......................46 Wall Mounting ..........................47 Installing the Components to the Frame ....................47 Mounting the Manifold ........................47 Piping & Automatic Air Vent ......................48 Insulation ............................48 Charging the System .........................
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Page 5: General Information
General Information Please read this manual in its entirety prior to installing your Duda Solar water heater. This manual covers the general installation of the solar water heater but may not be a complete resource for the full installation or safety requirements for performing an installation. These systems should be installed in accordance with all local building codes. -
Page 6: Pressure Release & Relief Valve
Pressure Release & Relief Valve Caution: The closed system solar loop must operate at less than 87 psi and have an expansion tank installed to accommodate expansion from the working fluid. Caution: The closed loop system design must eject fluid at no more than 113 psi. -
Page 7: Metallic Corrosion
1000 2 Year or Less The Duda Solar water heating tank is initially equipped with a magnesium anode rod. Magnesium anode rods dissolve into the water as they corrode and provide healthy minerals to the water supply. Alternatives to the magnesium rods are aluminum or zinc-aluminum combinations. The aluminum-type rods are nobler than magnesium rods and will last a little bit longer than magnesium rods. -
Page 8: Connection Of Piping
The evacuated tubes and heat pipes are not normally susceptible to damage in mild cold climates. The standard Duda Solar copper heat pipes (0.6mm thickness) are rated for -10°C (14°F) operating temperatures. It is generally acceptable for the heat pipes to endure 5–10°C (9-18°F) lower than their rated minimum operating temperatures for intermediate periods. -
Page 9: Srcc Certification & Collector Specifications
SRCC Certification & collector specifications The Duda Solar Water Heater Collectors are OG-100 SRCC Certified. They are one of the most efficient solar water heaters in the market. They have a very high performance in both warm and cold weather due to its excellent design in manifold technology and quality evacuated tubes. -
Page 14: Manifold Connections
Manifold Connections There are two connections on the manifold, an inlet and an outlet. The fluid can flow in either direction. The flow of the fluid should be oriented so that the outlet of the manifold is also where the solar collector temperature sensor is installed. -
Page 15: Snow Loading
Snow Loading In areas where significant amounts of snow accumulation can occur, it is recommended that the solar collectors be elevated. Please refer to local and other regulations regarding snow loading precautions. Storage Tanks Tanks must be installed in accordance with local building codes. Use additional braces or straps when installing the tank in earthquake zones. -
Page 16: Equipment Supplied By Duda Energy For A Complete System
Tank Coil – Coils or heat exchangers are immersed inside of the solar tank which permits transfer of heat from the closed loop pressurized system to the water. These coils are ½” or ¾” OD copper tubing coils which keep the solar loop working fluid from mixing with the domestic water. ... -
Page 17: Tools & Materials Needed
Nitrile/NBR/Buna/EPDM or other high temperature resistant pipe insulation Aluminum Pipe Wrap for protection of insulation exposed to weather Copper wire for extending connections to the solar collector temperature sensor Compression fittings for connecting the system components to the piping ... - Page 18 Solar water heater vacuum tubes are a state of the art technology which were originally used only in commercial applications but have now become affordable as the ultimate use in energy conservation for both residential and commercial applications. The following diagram displays an overview of the system and how it operates: Duda Energy Closed Loop Solar Water Heater System...
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Page 19: Explanation Of Components
Explanation of components Solar collector The solar collector consists of the manifold, vacuum tubes and frame. Warning: Ensure the roof is structurally secure before installing the solar collector. If in doubt, consult an engineer or the local building inspector. The roof must be able to support the weight of the collector with tubes installed and able to withstand any additional weather loads such as snow and wind. -
Page 20: Accessory Frame Construction
Accessory Frame Construction Below are photos of the solar collector frame to reference when building the frame. For the flat roof stands, the back legs on the frame are optional and can be removed if you wish to mount the collector flush to the roof. Our slope roof frames may also be used for flush to the roof installations and also have the special ability of mounting underneath the tiles on a tile roof for a leak-proof design. - Page 21 Side Angle of Flat Roof / Ground Stand Flat Roof / Ground Stand with manifold mounted and tube holders in place (ready for tubes)
- Page 22 Slope Roof Frame Front View of Slope Roof Frame Back-Side View of Slope Roof Frame...
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Page 23: Working Station
Supplemental strapping should be used in high wind and hurricane areas. Working Station The Duda Solar Water Heater System comes with the SR961s working station or its equivalent. The SR961s working station is an advanced device which circulates the working fluid of the closed loop with a varying flow rate from the collector to the tank based on collector, tank and return temperature coming from the tank. -
Page 24: Electrical Installation
SR961s Working Station A 3–speed German WILO star RS high temperature fluid pump with pressure gauge, pressure relief valve, flow meter, shut-off valve(s), check valve and charging valves are incorporated into the system. The pump station is encased with a foam insulation that helps retain heat. The metal casing helps protect electronic components from getting damaged by external forces. -
Page 25: Mounting The Electronic Controller
The pressure relief valve is located at the top right of the working station enclosure. It has a knob which is used to test its functionality and for manual draining. A drain hose or pipe should be attached to this valve so that if the valve opens, fluid can be directly to an appropriate container. -
Page 26: Tubing
On these mechanical flow meters is typically a tempering valve which can be used to restrict the flow of the fluid to the suction side of the pump. This valve should normally be set to full open (vertical position) by use of a flat head screwdriver unless the application requires higher temperature fluid to approach the tank (not normal). - Page 27 Note: Apply some thermal conducting paste to the tip of the probe to aid in rapid temperature detection with the sensor. Properly Secured pt1000 sensor The 2 gray wire sensors are to be installed into the top and bottom ports on the solar tank. T2 is the bottom sensor;...
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Page 28: Backup Heating Function
tee to allow insertion into the pipeline. The controller can then sense when the pipe has cooled off in order to operate the circulation pump to provide the pipes with more hot water. Copper Thermowell Backup Heating function Our tanks come with a manual thermostat for electric water heating backup. The controller has a backup heating function as well which can be used for this electric water heating element or another backup source such as an external gas heater. -
Page 29: Solar Water Tank
cools down and the solar water tank drops 2°C below the set maximum temperature (for the SR961s). For instructions on how to set up this feature, please refer to the working station manual. This method may not be preferred if tank overheating is likely to occur often, such as with an oversized collector or during the summer in southern locations when hot water consumption is not high. -
Page 30: Temperature/Pressure Relief
Attach the bottom plastic or rubber feet to the tank so it stands a few inches from the floor. Screws are provided in the tank packaging. Bottom of Duda Solar Tank with Threaded Holes for Mounting Feet & Drain Port Temperature/Pressure Relief The T/P valve should be installed into the T/P port or top of the tank. -
Page 31: Lower Circulation Loop Ports
Lower Circulation Loop Ports The solar loop is to be connected so that the return from the collector passes through the hot circulation inlet and out the hot circulation outlet to the working station. Caution: Do not over-tighten the nut that holds the upper and lower coils in place. Doing so can twist the copper coil which will restrict fluid flow within the coil. -
Page 32: Bottom Temperature Sensor Port
Elbows used on Solar Loop Connections to Tank to Prevent Thermo Siphon Effects Bottom temperature Sensor Port The bottom temperature sensor port is for detecting the temperature of the water which the bottom coil heats via the solar loop. This is recognized as T2 on the controller. Apply a little bit of the thermal conducting compound supplied with the manifold and slide it into this port. -
Page 33: Upper Circulation Loop Ports (Optional)
There is a water heating element pre-installed into the tank. It is usually a 3000w/220 VAC element. A 220v/240v AC power source should be used to activate this element for proper usage. This element can be easily removed and replaced with any element of your choosing from a local plumbing store which utilizes a 1” screw thread type connection. -
Page 34: Hot Water Outlet
The anode rod port already has a new magnesium rod pre-installed. This rod should be checked regularly for corrosion and be replaced as needed to ensure a long lasting life to the tank. The rod can be replaced with an aluminum rod if the water supply is very hard water or with a zinc-aluminum rod if the water has a sulfur dioxide smell. -
Page 35: Thermostatic Mixing Valve
when the tank needs to be serviced. Connect an elbow directly to the drain port, run piping far enough out from under the tank and install a valve for easy draining access. The valve should be able to eject water to the drain pan or have a garden hose fitting attached so that a garden hose can be used to direct draining water outside. - Page 36 1” Thermostatic Mixing Valve Connected to Hot Water Outlet and Cold Water Inlet The thermostatic mixing valve must be used in a solar water heater to prevent scalding at the faucet. Since the sun can vary based on weather and time of year, solar systems will experience anywhere from mild to extreme hot water.
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Page 37: Duda's Flex Tubing / Corrugated Stainless Steel Tubing
Example of Thermostatic Mixing Faucet Example of Thermostatic Mixing Shower Duda’s Flex Tubing / Corrugated Stainless Steel Tubing A special tool is required to flatten the corrugations on the end of the tubing. There are a few different types of tools available. -
Page 38: Step 2: Flatten The Corrugations Using The Special Fitting Tool
Slide the fitting you will use over the end of the tubing with the threads facing the end of the fitting. Leave enough room so you can clamp the tubing. Step 2: Flatten the corrugations using the special fitting tool Place the tubing into the clamp which holds the tubing in place in the special tool for flattening the corrugations. -
Page 39: Step 4: Pull The Fitting Forward
Once the ending corrugations are flattened as shown in the above photo, apply the c-ring between the last flattened corrugation and the first unflattened corrugation as shown in the above photo. Once in place, crimp the c- ring closed. This C-ring will prevent the fitting from coming off the tubing. Step 4: Pull the fitting forward Pull the fitting forward so it is against the c-ring. -
Page 40: Step 6: Attach To Your Piping
Apply the washer to the inside of the fitting. The photo shows a Teflon washer which is generally acceptable for most solar installations. Step 6: Attach to your piping Thread the fitting end onto the pipe you are attaching to. Do not use Teflon tape or any pipe dope. The seal is made by the washer. -
Page 41: Installation
Installation Transport Unpacking and Inspection The system will arrive on a pallet. Before signing for delivery, inspect each box to be sure that there is no damage. If there is any damage, have it noted on the bill of lading. Signing for the bill of lading without noting any damage waives the consignee’s right to a damage claim with the carrier. -
Page 42: Electrical Requirements
Note: Local codes and requirements in your area may require the installation of your water heater be accomplished in a way that the bottom element is elevated from the floor at least 18 inches. Important: the solar water tank should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. -
Page 43: System Design
2000 2500 3000 3500 4000 4500 5000 5500 System Design The Duda Energy split solar water heater is the most efficient design on the market which provides freeze protection in most climates. The design of the heat pipes allow for working ambient temperatures as low as -40°C (- 40°F). -
Page 44: Direction And Angle Of Installation
Pressurized Split Solar System with Dual Coil Tank NOTE: Due to variances in types of controllers, working stations and system designs, the above system design should be observed as a baseline to follow during installation, and the final set-up of your system design may vary slightly such as the location of the charging valves, working station and ports used for the hot water outlet on the tank. -
Page 45: Mounting The Frame
Also, since the sun rises from the horizon, which is 90°, and rises to no more than 0° in non-tropical areas throughout the year, the standard Duda Solar 37° and 45° frames are considered ideal for efficient solar water heating. -
Page 46: Bracing
CAUTION: Do no install the vacuum tubes until the unit has been mounted properly, the pipes have been attached and system properly charged with fluid and tested for leaks. Be sure that the pump and valves operate properly. Keep the solar tubes away from exposure to sunlight until ready to install. Failure to do so will void warranty. CAUTION: Install only in the late afternoon or early morning or wear protective gloves while installing the units. -
Page 47: Wall Mounting
If the frame is to be mounted on the ground it needs support from a concrete base. Affix the frame base to the concrete using appropriate concrete fasteners with stainless steel bolts or screws. When attacking the frame to a flat roof use appropriate sized stainless steel bolts or screws to affix the unit to the surface. -
Page 48: Piping & Automatic Air Vent
Piping & Automatic Air Vent Install the piping which will connect the tank coils to the manifold. We recommend using Duda’s Flex Tubing, which is stainless steel flexible tubing. This tubing has high temperature resistance, loses heat much slower than copper, and is very easy to install due to its flexible properties. -
Page 49: Charging The System
The SR961s is the most common working station for Duda Solar Systems. It has a check valve after the pump and 2 charging valves. The top charging valve should be the inlet from the submersible pump and the bottom valve should be the outlet for discharging fluid/air. -
Page 50: Installing The Vacuum Tubes
Direction of flow when charging the solar system with an SR961s Working Station Installing the Vacuum Tubes Ensure that the manifold holes for the heat pipes are clean. If there is any debris or rough edges, using a half round file to clean it and remove any foreign debris. NOTE: Vacuum tubes will heat the heat pipes rapidly. - Page 51 Good Tube with Metallic Bottom (Existing Vacuum) Bad Tube with White Bottom (Vacuum Lost) Prior to installing the vacuum tube into the manifold, apply some thermal conducting paste to the sides and tip of the heat pipe. This will ensure full contact with the manifold (no air pockets) for optimum heat transfer and will also make removal of the heat pipes much easier in the future.
- Page 52 Coat the Condenser with Thermal Paste Prior to Insertion into the Manifold What Condenser Looks like After Removing from Manifold with Applied Thermal Paste To install the tube, pull the heat pipe about 6 inches out of the tube so that you can hold onto the heat pipe by hand without touching the condenser.
- Page 53 until it bottoms out. Once it bottoms out, slide the vacuum tube up so that the heat pipe goes back into the vacuum tube until the vacuum tube is flush against the manifold. Pulling the copper heat pipe out of the tube so it can be pushed in by hand Pushing the tube up against the manifold once copper heat pipe is inside the manifold hole Once the tube is in place, unscrew a tube holder and slide it onto the bottom of the tube.
- Page 54 Your style of tube holders may vary. There is a screw on type which will require that you unthread it completely to put it onto the tube. Then snap it down to the bottom frame of the collector and then thread it back on until the tube is tight.
- Page 55 Screw bottom piece into tube holder to fasten tube tightly to manifold Completely Fastened Tubes...
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Page 56: Reflectors
Clamshell Style Tube Holder Reflectors Reflectors are optional but provide increased sunlight absorption while the sun is directly overhead. Sunlight which normally passes in-between the tubes will bounce off the bevels on the reflector and into backs and sides of the tubes. -
Page 57: Maintenance
Side view of collector Maintenance Cleaning Your Duda Solar water heater system should remain clean from occasional rainfall. The round vacuum tubes naturally resist collection of dust and debris that transfers through the atmosphere. Leaves Leaves and limbs should be removed when they accumulate on the system. The debris blocks the sun energy and causes a buildup of moisture that can cause decay of the roof surface. -
Page 58: Anode Rod Maintenance
If the water heater tank is left unused for long periods of time (over two weeks) a small quantity of hydrogen gas will have built up in the top of the tank. WARNING: This gas is highly flammable and in order to dissipate it safely, we recommend that the hot water tap be opened for several minutes to allow the gas to pass safely through the pipes. -
Page 59: Warranty
-Check the pressure of the closed loop system. It should be approximately 25 psi or higher if the system is heating. If it has overheated, the pressure will be much higher and needs to be allowed to cool before normal operation may resume. -Follow the recommendations of the controller manual and check the temperature of T1.
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