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_______________________________________________________________________________
SRCC OG-300 Certified Solar Water Heating System
Free
Hot
Water Collector 5000 Series – Freedom 5002, 5003
Type: AC Circulating Pump and Differential Control
Installation, Operation and Maintenance Manual
The solar energy system described by this manual, when properly installed and maintained, meets the minimum
standards established by the SRCC. This certification does not imply endorsement or warranty of this product by
SRCC.
Version 2011.02
_______________________________________________________________________________
Free
Hot
Water
2146 Bering Dr. San Jose, CA 95131 Tel: 408 218 3660 Fax 408 872 4142
2011044A - Liberty - 4002 XG
2011044B - Liberty - 4003 XG
2011047A - Liberty - 4002 XE
2011047B - Liberty - 4003 XE
www.FreeHotWater.com
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Table of Contents
Summary of Contents for Free Hot Water Freedom 5003
- Page 1 _______________________________________________________________________________ SRCC OG-300 Certified Solar Water Heating System Free Water Collector 5000 Series – Freedom 5002, 5003 2011044A - Liberty - 4002 XG 2011044B - Liberty - 4003 XG 2011047A - Liberty - 4002 XE 2011047B - Liberty - 4003 XE Type: AC Circulating Pump and Differential Control Installation, Operation and Maintenance Manual The solar energy system described by this manual, when properly installed and maintained, meets the minimum...
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Page 2: Table Of Contents
Table of Contents Safety Information ..............................3 Transport Note ..............................4 Installation, Operation And Maintenance Manual ....................5 Introduction ............................... 5 System Description ............................6 Specifications ..............................6 Freeze Protection .............................. 7 Tools Needed ..............................8 Collector Specifications ............................9 Collector Certification OG100 ......................... -
Page 3: Safety Information
Page 3... -
Page 4: Transport Note
Attention: Do not lift the collectors by the connections and or the screw threads Page 4... -
Page 5: Installation, Operation And Maintenance Manual
The FREE HOT WATER solar water heating system uses the sun’s energy as a source of heat to produce hot water for domestic household use. Designed to meet the certification requirements of SRCC 0G-300, FREE HOT WATER solar water heating systems are reliable, and can typically generate from 50% to 80% of your annual household water heating needs from the sun. -
Page 6: System Description
FREE HOT WATER solar collectors and flashings allow for a low profile, roof integrated, solar panel installation. The FREE HOT WATER collector is made up of copper tubes and a plate that is covered with a highly selective absorber coating; this assembly is enclosed in a well insulated aluminum frame or “box” and covered with low-iron tempered glass glazing. -
Page 7: Freeze Protection
Solar Storage Tank All FREE HOT WATER solar water heating systems will include a solar storage tank with the solar heat exchanger located in the bottom section of the tank to heat the entire water volume of the tank. The tank contains a thermometer located on the outside of the tank so you will know the temperature in the tank. -
Page 8: Tools Needed
It is the owner’s responsibility to protect the system in accordance with Free Hot Water’s instructions if the ambient air temperature approaches the specified freeze tolerance limit. -
Page 9: Collector Specifications
Absorber Capacity 1.1 gal. Intelligent Design Deep Drawn Aluminum Tray Manifold 3/4 - Risers 3/8 Selective Absorbent Coating Free Hot Water item #: FHWC-FC-50221 Thermal Insulation Rockwool Gross Area: 2.070 m2, 22.28 sf Tempered Low Iron Glass Net Aperture: 1.85 m2, 19.91 sf Suitable for Closed &... -
Page 10: Collector Certification Og100
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Page 11: Pressure Drop And Flow Rates
Pressure drop and flow rates Mass flow rate To ensure the performance of the collector, a specific flow rate of .5 gallons per minute is to be selected up to a collector panel size of approximately 27 sq. ft. Pipe diameters Dimensions table with a specific flow rate of .5 gallons per minute Collectors Up to 6... -
Page 12: General Closed Loop System Schematics
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Page 14: Precautions
Precautions For safety reasons you should only fill the collectors when there is no direct irradiation from the sun (covering the collectors can be an option). Especially in regions exposed to frost, for flat plate collectors you should use a mixture of anti freeze with water (40% anti freeze). - Page 15 Only operate the bleeding valve if the temperature of the heat transfer fluid is < 140° F. When bleeding the system, the collectors must not be hot! Cover the collectors and, if possible, bleed the system in the morning. See Material Safety Data Sheet on page 45 for safety information. Check heat transfer fluid The heat transfer fluid must be checked every two years with regard to its antifreeze and pH value.
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Page 16: Collector Orientation
Free Hot Water solar collectors must be installed at a minimum pitch of 15 degrees from horizontal, and for optimal performance, the recommended pitch is between 15–60 degrees. The collector should be mounted as close to the storage tank as possible to minimize heat loss in the piping runs. -
Page 17: Installation Steps For Roof Mounting
Installation Steps for Pitched Roof Mounting 1. Locate and mark the roof rafters into which the solar collector mounting brackets will be mounted (one way to find rafters is to see the “tails” at the edge of the roof). 2. To create a set point for plumbing and level installation, measure the distance from the edge of the roof to the desired mounting points and mark the points where the collector mounting brackets will be installed (fig 1.2). - Page 18 Fig 1.3 5. Using a hole saw, cut the hole (penetration) for the 2 hoses or pipes from step 3. 6. If using flex hose: before connecting the hose, measure, cut, and lay out the hose, including enough length for 8’ of hose above the roof. Pull the hose through the hole. 7.
- Page 19 Fig 1.5 Fig 1.6 Fig 1.7 10. Pre drill mounting bracket screw holes into rafter or other appropriate mounting substrate (one hole per bracket) using a 7/16” drill bit. 11. FOR ONE BOTTOM BRACKET ONLY, apply Solarflex in bracket screw holes, on roof surface where bracket will be placed, and on bracket surface that will be facing down.
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Page 20: Recommend Anchor Points
Fig 1.90 18. Place collector on profiles, checking to make sure it fits and lines up appropriately. Recommend Anchor Points 19. Once collector fits and lines up appropriately, apply AT 60 to ½” bolts for collector and fasten collector to profiles using ½” bolts and washers. 20. - Page 21 21. Connect collectors with each other (if installing more than one collector) and with storage tank, using flex hose or copper pipe and compression fittings. Note: * Tighten compression fittings gently by hand and then 1.25 turns with a wrench. Avoid over- tightening as this can damage the flex hose or copper tubing.
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Page 22: Flat Roof Installation Instructions
Flat Roof Installation Instructions 1. Locate and mark the roof rafters into which the solar collector mounting Frame will be mounted (one way to find rafters is to see the “tails” at the edge of the roof). 2. To create a set point for plumbing and level installation, measure the distance from the edge of the roof to the desired mounting points and mark the points where the collector mounting frame (fig 2.2) will be installed (fig 2.1). - Page 23 4. If you have more than one bank of 3 collectors you will need to use the FHW expansion band as illustrated in fig 2.5 Fig 2.5 5. At the end of every bank please connect to the main as described in fig 2.6 Fig 2.6 ...
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Page 24: Installing The Solar Tank
The main goal of producing the Free Hot Water SST Tanks is heating and storing potable hot water in a main pressure storage tank using solar energy. Potable hot water is stored in the main water storage tank separately from the heating liquids in the coils. - Page 25 The type of water heater to choose (single or double coil) depends on the heater and if you are planning to extract heat. For example, if the tank will be heated with a solar system, Free Hot Water single coil water heater would be appropriate.
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Page 26: Basic Plumbing Connection Diagram
Not all valves are supplied with the water heater. The above diagram describes valves for a mains pressure arrangement; however the tank could also be fitted to a low pressure system. Free Hot Water tanks are equipped with a service circulation port. -
Page 27: Commissioning
It is highly recommended running the solar system via the Free Hot Water coil on a close loop arrangement. Open loop solar is also possible using the Service Circulation port for the solar return instead of the Coil Hot port, and branching of the Cold Inlet instead of using the Coil Cold port. -
Page 28: Regular Care
Every 5 years - maintenance: A qualified plumber should replace the TPR valve, of the water heater and should clean coils of the tank via the clearing door. Regular Care – Service Person Anode Replacement Free Hot Water SST Disconnect the power supply to the water heater Drain approximately 5 to 10 lt. -
Page 29: Anode Replacement
(5) on the other side, and install nut over anode behind the beam gear side. 10. Locate flange gasket through inlet of the tank. Replace gasket if needed 11. Locate flange exactly central side of the tank flange. Fasten nuts in a cross tightening order as per page 18. - Page 30 Replacement water heater or parts provided under this warranty does not carry a new warranty. The unexpired warranty remains effective. Free Hot Water is only liable for the water heater and will not assume directly or indirectly any other obligations in connection with the product.
- Page 31 WARRANTY Free Hot Water will repair or if necessary replace a defected water heater or parts failed due to faulty manufacturing as per the following schedule: Durability Free Hot Water SST meets the requirements of the US Building Code for durability given that:...
- Page 32 Water quality according to this manual Change of Ownership This warranty extends beyond the original purchaser of the water heater. Standard Installation Standard installation includes all connections as per this manual and any other connections approved by Free Hot Water service desk. The water heater is installed where delivery and access is standard.
- Page 33 Page 33...
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Page 34: Pump Station And Controller
Pump Station and Controller Solar controller: The solar controller, turns on or off solar loop circulator depending on the heat gained in the solar collectors. The controller will also limit over heating in the solar collectors and overheating in the solar storage tank. Locate the collector hot supply - the hot supply pipe must be cut to length using a tubing cutter and connected to the pump station. -
Page 35: Mounting
Mounting the insulation box Measurements 150x425x150. Box with a special bracket to fasten the unit and with the groove for the cable. Cover with the opening for the cable press. (The cable press must be positioned towards the down, see the picture). Side opening for the security unit. -
Page 36: Options
Pump Station Options – 2 way Ball valve on the supply way (thermometer with red ring and Scale 0-250F) with "Sola/' check ball. (Ball valve on the return way (thermometer with blue ring and scale 0-250F) with "Solar" check ball. Pressure Relief Valve - The security unit, CE and TUV approved, protects the installation from the overpressures. - Page 37 Model with the vent air The vent air is a device that divides continually the air that can be in circulation together with the fluid. The air goes to the upper part of the vent air and it can be eliminated through the special drain while the installation is working.
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Page 38: Installing The Expansion Tank
Installing the Expansion Tank • Follow all instructions and local codes during the installing of this product. • Tanks are pre-charged to 12psi (83 kPa) and should be charged to the system pressure prior to installation in the system. Caution: Do not exceed the maximum pressure rating of the tank. After installing the ETX/ETSX 2.1 Expansion Tank •... -
Page 39: Solar Thermal Controller
Solar Thermal Controller Combining practical design with a feature rich, crystal clear operator guidance system, and sophisticated control in an extremely user-friendly package. Users are presented with programming and operational information, in graphical or plain written text formats. The STDC is designed to offer OEMS, installers and system designers an extremely compact, low cost, entry level platform capable of managing any one of 8 pre-programmed solar thermal system types in a single product. - Page 40 Solar Controller Installation Install the controller only in dry areas and under the ambient conditions. Carry out the following steps 1-8. 1. Unscrew cover screw completely 2. Carefully pull upper part of housing from lower part. 3. Set upper part of housing aside, being sure not to touch the electronics when doing so. 4.
- Page 41 Controller Installation Select necessary program/hydraulics Open controller as described above. Strip cables by 55mmmax., insert, fit the strain relief devices, strip the last 8-9mm of the wires. Open the terminals using a suitable screwdriver (see right) and make electrical connections on the controller (s. D.1 D.20) Refit upper part of housing and fasten with screw.
- Page 42 Examples of key controller functions: = enlarge/shrink values ▼/▲ = scroll menu down/up yes/no = approve/reject Info = additional information Back = to previous screen = confirm selection Confirm = confirm setting Setup Wizard The first time the controller is turned on and after the language and time are set, a query appears as to whether you want to parametrise (establish parameters) the controller using the commissioning help or not.
- Page 43 When operating mode “Manual” is activated, the current temperatures and the selected parameters are no longer considered. There is a danger of scalding or serious damage to the system. The operating mode “Manual” may only be used by specialists for brief function tests or during commissioning! 5.
- Page 44 Starting the commissioning help guides you in the correct order through the basic settings necessary for commissioning, and provides brief descriptions of each parameter in the display. Pressing the “esc” key takes you back to the previous value so you can look at the selected setting again or adjust it if desired.
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Page 45: System Pressure Guide
System Pressure Guide Height from Expansion Solar System Collectors to Tank Operating expansion tank Pressure Pressure 14.50 19.00 15.40 19.90 16.30 20.80 17.20 21.60 18.10 22.50 19.00 23.40 19.90 24.30 20.80 25.20 21.70 26.00 22.60 26.90 23.50 27.80 24.40 28.70 25.30 29.60 26.20... -
Page 46: Charging The System
Charging the System With a pressurized solar heating system an issue that the installer must be concerned about is getting the air out of the system. If the installer leaves too much air in the propylene glycol/water solution there can be problems including: pump cavitation, vapor lock, air lock, system noise, decrease in efficiency, overheating and premature system discharge. - Page 47 Propylene Glycol Material Safety Data Sheet Notification MANUFACTURER: Houghton Chemical Corporation (Safe-T-Therm) ADDRESS: 52 Cambridge Street, Allston, MA 02134 EMERGENCY TELEPHONE: (617) 254-1010, 1-800-777-2466 or Chemtrec 1-800-424-9300 CHEMICAL NAME & SYNONYMS: Non-toxic Antifreeze CHEMICAL FAMILY: Propylene Glycol Based FORMULA: Trade Secret CAS REGISTRY NUMBER: Not applicable for blended product DOT SHIPPING CLASSIFICATION: Not Regulated PRODUCT NUMBER: 510787, 520787, 550787, 560787...
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Page 48: Propylene Glycol Material Safety Data Sheet
Eye Contact: Irritation may result. Skin: No significant signs or symptoms expected. Inhalation: This material is not expected to be a respiratory hazard except if aspirated. If swallowed, can enter lungs and cause damage. Ingestion: If more than several mouthfuls are swallowed, abdominal discomfort, nausea, and diarrhea may occur. Aspiration during ingestion or vomiting may cause lung damage. - Page 49 heat transfer fluid in preventing corrosion has been proven both in use and in extensive laboratory testing. Using ® SAFE-T-THERM in place of brine solutions or uninhibited glycol/water solutions lowers maintenance costs and improves heat transfer efficiency. ® SAFE-T-THERM heat transfer fluid has been formulated with ingredients which are generally recognized as safe (GRAS) by the FDA for use as an aqueous heat transfer medium for closed primary and secondary refrigeration and cooling systems.
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Page 50: Labels
Free Water Label Set Instructions: The following labels must be attached to the relevant valves in the system in order for it to be considered OG-300 compliant. This page should be laminated, each label cut from it, punched in the margin at the right hand side and affixed to the appropriate valve with a wire tie, plastic ties are inappropriate due to high operating temperatures. - Page 51 Collector Array Isolation RETURN Valve Valve is normally open during operation. It is closed to isolate the storage tank should the storage tank need servicing or replacing. When closed the circulating pump is isolated from the solar collector loop piping. Never shut these valves while the circulating pump is in operation.
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Page 52: Systems Parts List
4002 4003 5002 5003 7002 7003 Collectors Systems Parts List Model # Liberty Freedom Independence Roof System (included based on system) Pitch Flat Pitch Flat Pitch Flat Pitch Flat Pitch Flat Pitch Flat Flat Collector, 4000 Series - SRCC#-2010086A FHWC-FC-40220 Flat Collector, 5000 Series - SRCC#-2010087A FHWC-FC-50221 Flat Collector, 7000 Series - SRCC#-2010020A &... -
Page 53: Trouble Shooting
Glycol / Distilled Water Mix For 3/4" pipe per 100' Basic calculation Trouble Shooting A properly maintained solar water heating system can provide years of dependable trouble free service. It is suggested that routine preventive maintenance program be established and followed by the end user with his contractor. - Page 54 Nature of trouble Possible cause Service System undersized. Reduce rate of hot water use. Defective element. Not enough hot water. Check amperage, replace element. Defective thermostat or wired incorrectly. Check wiring or replace. Solar system controller incorrectly installed. Check Installation. Leaking plumbing or open hot water Make sure all faucet(s) are closed and check faucet(s).
- Page 55 Nature of trouble Possible cause Service Normal when weather changes. None. Check sensor connections - Refer to Sensors connected to wrong controller manual “Installation” section. terminals. Pump operates intermittently. Check sensor resistance - Refer to controller Improper system “switch-on” or manual “Control parameter”...
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Page 56: Vacation Planning
Vacation Planning Solar water heaters can build up very high temperatures when there is no daily draw on the system. Your Free Hot Water solar water heating system controller is programmed to protect your system from overheating. When leaving your home for extended periods of time, no special shut down procedures are required. The best way to protect your system is to make sure power is always on and to keep the system in normal operating mode. -
Page 57: Maintenance Notes
Maintenance Notes Notes Page 57... -
Page 58: Installer Information
Installer information Installers name:__________________________________________________ Company:_______________________________________________________ Address 1:_______________________________________________________ Address 2:_______________________________________________________ City: State: Zip:___________________________________________________ Phone number:___________________________________________________ Fax number:_____________________________________________________ E-mail:__________________________________________________________ Installation information Collectors: Model number: Serial number:_____________________________ 1.___________________ 2.___________________ 3.____________________ Tank: Gallons: Existing:_____________________________________________ Orientation: Pitch:________________________________________________ Installed date:____________________________________________________ Guarantee and Warranty No liability will be assumed for use other than for the intended purpose or for inadmissible alteration of installation components or consequences thereof;... -
Page 59: Collector Warranty Certificate
Page 59...
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