INSTALLER TRAINING COURSEMODULE 1 BASIC SOLAR THERMAL

Introduction to SHW Earth Energy Resources US Solar Radiation Why Go Green Why SHW

SHW Technology SHW Components Different Types of SHW Systems

Sizing Solar Domestic Hot Water System Solar Fraction (SFn) and Sizing Guidelines Sizing Dependencies SHW Sizing Other Factors

Auxiliary Heating Basic considerations Preheating Dual Tank Systems

BASIC SOLAR THERMALCOURSE OUTLINE

The mission of the Helio Partner program is to ensure thatHeliodyne installing contractors have acquired the knowledgeand skills to effectively promote Heliodyne products, successfully install Heliodyne products, and to provide lasting customer support to end-users thereby representing the Heliodyne brand in the best possible way and in additionincrease for the dealer: productivity, customer satisfaction,repeat sales and referrals.

BASIC SOLAR THERMALHELIO-PARTNER MISSION

Step 1. Successful completion of in person training or completion of on-line training with 100% passing score on the exam portion. Step 2. Submit to Heliodyne current copy of applicable contractor’s license and proof of liability insurance. Minimum: $1,000,000.00 Step 3. Complete successful installation of a Heliodyne Pro system with proof of performance through Heliodyne’s on-line web monitoring system. Step 4. Sign and return Helio Partner agreement.

BASIC SOLAR THERMALBECOMING A HELIOPARTNER

Helio Partners will have added visibility on the Heliodyne web site dealer locator. The Heliodyne logo will appear nextto Helio Partner’s listing. Homeowners and business owners will be drawn to Helio Partners because they will know that partners have successfully completed training, have installed Heliodyne products, and carry adequate licensing and insurance. Helio Partners will receive preference in receiving leads and referrals that come from trade shows, advertising, and directcontact with Heliodyne.

BASIC SOLAR THERMALHELIOPARTNER BENIFITS

BASIC SOLAR THERMALSolar Resources

BASIC SOLAR THERMALPrograms, Legislation and other Support

• Higher fuel prices• 30% federal tax credit• Tax credits• Grants and cash rebates• Obama stimulus package

Go to: www.dsireusa.org

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BASIC SOLAR THERMALU.S. Solar Hot Water Industry Growth

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INTRODUCTION TO SHWEARTH ENERGY RESOURCES

Solar Energy

World Annual Consump.

Uranium

Gas

Oil

Coal

INTRODUCTION TO SHWEARTH ENERGY RESOURCES

INTRODUCTION TO SHWWHY SOLAR HOT WATER

IT’S SUITABLE FOR ALL REGIONS

SHW ( HELIODYNE) GOBI 410Output/day: 22.7 kWhArea: 80 ft2 (2 panels)Installed Cost: $7,000

PV (SHELL SQ 165-PC)Output/day: 22.3 kWhArea: 456 ft2 (18 panels)Installed Cost: $30,000

Hawaii

Alaska

IT’S THE MOST COST-EFFECTIVE RENEWABLE WAY TO HEAT WATER

Solar hot water systems perform efficiently all over the US, from Hawaii to Vermont, and Alaska to Florida.

Introduction to SHW Earth Energy Resources US Solar Radiation Why Go Green Why SHW

SHW Technology SHW Components Different Types of SHW Systems

Sizing Solar Domestic Hot Water System Solar Fraction (SFn) and Sizing Guidelines Sizing Dependencies SHW Sizing Other Factors

Auxiliary Heating Basic considerations Preheating Dual Tank Systems

BASIC SOLAR THERMALCOURSE OUTLINE

1. Collector2. Controller3. Pumps4. Heat Exchanger5. Storage Tank6. Tempering Valve7. Expansion Tank8. Air Vent9. Pressure Relief

Valve10. Auxiliary Energy

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3

4

10

5

6

7

SHW TECHNOLOGYSYSTEM BASICS AND COMPONENTS

8

9Heat transfer fluid is pumped through the collectors, heated by the sun and circulated to the heat exchanger. The fluid exchange heat to the water in the storage tank and returns to the collector to be reheated. This repeats as long as there is sun or until the tank is charged

SHW TECHNOLOGYCOLLECTORS

THREE TYPES OF COLLECTORS

Unglazed Collectors

Vacuum Tube Collectors

Flat Plate Collectors

BASIC SOLAR THERMALTypes of Thermal Collectors

Evacuated Tube Collectors

Flat –Plate Solar Collectors Unglazed Tube-mat Collectors

Integrated Collector Storage Collectors

85%

of Market

15%

of Market

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BASIC SOLAR THERMALComparing Collector Technologies

Source:Home Power magazine

SHW TECHNOLOGYCOLLECTORS

UNGLAZED COLLECTORS

PRO Easy to install Inexpensive Short Payback period

CON No insulation Efficiency sensitive to wind

and ambient temperature Low temperature range (75°F - 95°F ) Aesthetics  May be considered visually

unpleasing Low durability

Unglazed collectors are typically made of plastic tubes combined into an absorber and used for residential pool heating to extend the pool season

SHW TECHNOLOGYCOLLECTOR

VACUUM TUBE COLLECTORS

PRO Works well at high temperature ranges > 220°F Good for high temperature industrial applications

CON May be considered aesthetically unpleasing Relatively higher maintenance Sensitive to loosing vacuum High installation complexity Relatively expensive Relatively fragileDouble wall glass tube with vacuum

in between or a glass tube with a top seal and a pumped vacuum containing an absorber. The vacuum efficiently insulate the absorber minimizing collector heat loss and sensitiveness to wind and ambient temperature

BASIC SOLAR THERMALEvacuated Heatpipe Technologies

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The sealed tube contains a small amount of alcohol which vaporizes when heated and condenses when cooled

SHW TECHNOLOGYCOLLECTOR

FLAT PLATE COLLECTOR

PRO Simple and proven technology Low maintenance Highly durability High Performance in Cold and Hot Climates Cost-effective (More energy per Dollar) Easy Installation

CON Relatively heavy to carry Limited temperature range of up to 220°FConsists of an insulated weather

sealed metal box containing the absorber and closed with a transparent cover typically made of tempered glass. Frame

Glass

Insulation

Absorber

BASIC SOLAR THERMALFlat Plate Collector

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Features:• Extruded aluminum frame• Copper or aluminum absorber • Black paint or blue sputtering• Life expectancy of over 25 years• Rated by SRCCInstallation: Weight: 120 - 160 lbs. full

SHW TECHNOLOGYCOLLECTOR ABSORBER VARIOUS SURFACES

BLACK PAINT Low cost solution Recommended for warm climates with high

solar radiation α = 0.85

ε = 0.25

BLACK CHROME First generation selective surface Tough surface Recommended for cool climates α = 0.95

ε = 0.12

BLUE SPUTTERED State of the art technology Optimal heat absorption with minimal emission Suitable for all types of installations and regions Recommended for cool climates

α: Absorptivity A measure of an object's ability to absorb incident energyε: Emissivity The ability of a material to hold or release heat

α = 0.95

ε = 0.05

BASIC SOLAR THERMALResidential Flush-Mount Arrays

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BASIC SOLAR THERMALResidential Tilt-up Arrays

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BASIC SOLAR THERMALResidential Ground Mounted Array

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BASIC SOLAR THERMALSmall Commercial Systems

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BASIC SOLAR THERMALLarger Commercial Systems

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BASIC SOLAR THERMALData Monitoring

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Types of monitoring• Manually read gauges• Controller with digital display• Wireless remote monitoring• Web based monitoring

SHW TECHNOLOGYCONTROLLERS

T1

T2

The controller senses the temperature in

the collector and the bottom of the

tank and start/stop the pump at

various differential temperatures ∆T.

Pump start setting is usually at 18°∆T,

while pump stop setting is usually at

5°∆T. ∆T start/stop settings are different

to avoid continuous start/stop of the

pump

Design Considerations

Stagnation/Overheating Protection

Provides high limit shut-off by turning off the pump

when a preset tank temperature has been

reached (Typically 180°F)

Other Types Timers Differential pressure

SHW TECHNOLOGYPUMPS

The pumps main function is to circulate

the liquid in the solar loop from the

collectors to the tank or heat exchanger

and back into the collectors. Pumps in

closed loop systems are usually fitted

with a cast iron housing whereas pumps

in open loops with direct contact to the

portable water are fitted with bronze

housing to avoid corrosion

Design Considerations

Pumps needs to cope with the desired static

pressure of the system and overcome the

pressure losses in the pipes, collectors and

water heater and at the same time ensure an

adequate flow rate in the solar loop

Flow Rate

The flow rate in a solar loop is typically set at

0.025 GPM per ft2 of collector

Other Types Variable Speed Pump

Keeps a proper temperature in the collectors,

while using minimum electricity

SHW TECHNOLOGYHEAT EXCHANGERS

THREE TYPES OF HEAT EXCHANGERS

Tube-In-TubeHeat Exchangers

Brazed PlateHeat Exchangers

Tube and Shell Heat Exchangers

SHW TECHNOLOGYHEAT EXCHANGER

TUBE HEAT EXCHANGER

Common tube heat exchanger designs are coil-in-tank, tube in tube, wraparound-tube and tube in shell. Heat transfer occurs when one fluid moves through the inner tube while a second fluid moves in a different direction on the outside of that tube.

PRO Low Flow Rate Less Electricity Not

Costly To Operate Fewer Joints Low fouling factor Good option for high

SFn > 70%

Resistant to high pressure

CON Relatively big in size Has to be insulated

Primary feed

Secondaryfeed

Tubes

Shell

SHW TECHNOLOGYHEAT EXCHANGER

PRO Relatively small in size Relatively inexpensive High efficiency

CON Big fouling factor Thus, sensitive to water

quality Should not be used with SFn above 40%

Higher maintenance required

FLAT PLATE HEAT EXCHANGER

Composed of multiple, thin, slightly-separated plates that have very large surface areas and fluid flow passages for heat transfer. Can be more effective, in a given space, than the shell and tube heat exchanger

BASIC SOLAR THERMALTanks with Heat Exchangers

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SHW TECHNOLOGYEXTERNAL VS. COIL-IN-TANK HEAT EXCHANGER

Heat Transfer Efficiency

External Coil-In-Tank

EXTERNAL HEAT EXCHANGER

Hot-water tank

COIL IN TANK HEAT EXCHANGER

Stores the water heated by the

collector and is typically larger than

regular water heater to allow adequate

accumulation of solar energy

Design ConsiderationsProper tank stratification (hottest water on top, and coldest at the bottom) is important to have maximum solar hot water efficiency. Tall slim tank with a height equal to 3-4 times diameter is optimal.

Choosing a copper or stainless steel tank over an enameled tank can lengthen the service life significantly but price is likely a factor 3-4. Enameled tanks are fitted with sacrificial anodes and if properly maintained can have a satisfactory service life.

Solar storage tanks should have a proper insulation (min. R16) to minimize heat loss.

SHW TECHNOLOGYSTORAGE TANK

The water in a solar storage tank can get very hot (180 oF) so its important to regulate the HW output temperature to prevent scalding. The tempering valve can be set at different HW output temperatures and automatically mixes the hot solar water with the cold water inlet. Typical set temperature is between 120-140 oF

SHW TECHNOLOGYTEMPERING VALVE

Other Types Anti-Scalding Valve

Like the tempering valve it mixes hot and cold water to deliver water at a preset temperature but functionsalso as a safety valv by closing off the flow if the hot or cold mixing supply fails

From Storage Tank

From Cold Water Line

To FixturesM

SHW TECHNOLOGYEXPANSION TANK

Design ConsiderationsExpansion tank should be designed upon a ratio of the total volume of fluid in system and allow for total potential thermal expansion of fluid

The expansion tank absorbs excess water pressure, and provides overpressure protection which could otherwise damage the plumbing structure or exhaust fluid through the pressure relief valve. Normally pre-charged by manufacturer to a set psi.

DIAPHRAGM

BLADDER

Diaphragm Expansion Tank Sensitive to correct install (Has to be in

vertical position) Relatively large in sizeBladder Expansion Tank The flexible bladder maintains a

constant pressure on the fluid while allowing it to expand and contract as it heats and cools

Not sensitive to correct install Smaller in size

Air valves are either manually operated or automatic and is mounted in the flow to allow air to escape. Air valves should be installed vertically in pipe air locks and/or at the highest point in the solar loop. Air locks will restrict flow of the fluid and reduce the heat transfer in the solar loop.

SHW TECHNOLOGYAIR VENT

Design ConsiderationsSince air valves are typically installed at the collector return the fluid can be very hot (up to 430 oF when stagnating). The air valve thus needs to be compatibility with this temperature. Most standard automatic air valves jams after a few months which is fine since all the air is usually out by then. When refilling its recommended to replace the air valve.

Other Types Micro-bubble air vents

The pressure relief valve protects system components from excessive pressures. Used to control or limit the pressure in the system which can build up by a temperature upset. For solar loops its usually set at 125-150 psi. Offers a higher degree of reliability and is often required through regulations

SHW TECHNOLOGYPRESSURE RELIEF VALVE

Design ConsiderationsMandatory in closed solar loops and should

have a pressure rating lower than other ratings of system components, typically 125 psi

Other Types Temperature-pressure relief valve

Protects system components from

excessive pressures and temperatures.

Typically set at 150 psi and 210°F

SHW TECHNOLOGYTYPES OF SYSTEMS

Thermosyphon

Drain Back

Fully Flooded(Indirect)

Fully Flooded(Direct)

BASIC SOLAR THERMALTypes of SHW Systems

• Open Loop Batch• Non-freeze climates• Lowest cost

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SHW TECHNOLOGYTYPES OF SYSTEMS

THERMOSYPHONPRO No pump required No controller required Less space required Relatively inexpensive

CON Tank exposed to external environmental

condition Efficiency Reduction Aesthetics  May be considered visually

unpleasing Not suitable for cold climates Strong support structure needed Sensitive to poor water quality (scaling) Not Scalable

The thermosyphon system uses natural convection to circulate the liquid in a vertical closed-loop which allows it to operate without a pump or control. Tank will need to be positioned above the solar collector for the natural convection to occur

BASIC SOLAR THERMALIntegrated Collector Storage (ICS)

(also called a batch collector system)

• Simple installation (few parts)

• Mild freeze protection available

• Very economical

• Good for the tropical climates

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BASIC SOLAR THERMALChinese ICS Solar Water Heaters

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SHW TECHNOLOGYTYPES OF SYSTEMS

FULLY FLODDED (DIRECT)

PRO Simple and well proven technology Easy to install Cost effective Moderately scalable

CON Pump and controller required Not applicable in climates with temperatures

below 42oF Sensitive to poor water quality (scaling)

The heat transfer fluids in the solar loop stays fully flooded. In warm regions the heat transfer fluid is typically the portable water coming directly from the storage tank or water heater.

SHW TECHNOLOGYTYPES OF SYSTEMS

DRAIN BACK

PRO Provides overheating protection Protects collectors from freeze damage

CON Requires drain back reservoir Can be more complicated to install All pipes

and collectors have to drain back to reservoir Limited to maximum height of pump Limited Scalability

The heat transfer fluid in the collector loop drains into a tank or reservoir whenever the solar pump stops. When drained the system is protected from overheating. In cold climates with freezing, potable water can be used in the collectors as they drain at night or when there is no sun

SHW TECHNOLOGYTYPES OF SYSTEMS

FULLY FLOODED (INDIRECT)

PRO Simple and well proven technology Easy to install Cost effective Easily scalable

CON Pump and controller required Care need to be taken to avoid freeze damage System sizing is critical to avoid overheating

The heat transfer fluids in the solar loop stays fully flooded. In cold regions the heat transfer fluid is typically an antifreeze such as propylene glycol to avoid freeze damage to the collectors. As such the heat transfer from the solar loop to the storage tank is done indirectly using a heat exchanger

Introduction to SHW Earth Energy Resources US Solar Radiation Why Go Green Why SHW

SHW Technology SHW Components Different Types of SHW Systems

Sizing Solar Domestic Hot Water System Solar Fraction (SFn) and Sizing Guidelines Sizing Dependencies SHW Sizing Other Factors

Auxiliary Heating Basic considerations Preheating Dual Tank Systems

BASIC SOLAR THERMALCOURSE OUTLINE

BASIC SOLAR THERMALHot Water Usage

TERMINOLOGY

SIZING SOLAR SYSTEM FOR DHWSOLAR FRACTION (SFn) AND SIZING GUIDELINES

Hot Water Demand = Solar Energy + Aux Heating

Consumption Production

Solar Fraction Considerations SFn of 100% will overheat and create

problems in the summer season An undersized system will not provide a

feasible rate of return on investment

A SFn of around 60-80% is optimal

Solar EnergySolar Energy

Hot Water DemandHot Water Demand

Aux EnergyAux Energy

Hot Water Demand

Solar Energy

Aux Energy

SFn =Solar Energy

Hot Water Demand

Space heating requirements of small low energy house

En

erg

y re

qu

irem

ent

or

gai

n (

%)

Space heating requirements of large house

DHW requirements

Solar yield from160 ft2 collectors

Solar yield from 54 ft2 collectors

SIZING SOLAR SYSTEM FOR DHWSIZING DEPENDENCIES

HOT WATER CONSUMPTION

Load Type (Showers, Baths & hot tubs, Hot water appliances)

Patterns (Morning/Night peaks vs. continuous consumption)

Users (Number of people living in the household)

OTHER FACTORS

Shading (Trees, Buildings)

Space Limitations

COLLECTOR

Tilt of the collector

Orientation in relation to due south

Collector efficiency

LOCATION

Solar Radiation (Intensity)

Climate (Clouds, Fog, etc)

Seasonal Variations (Sun path during seasons, Day Vs. Night)

Design Assumptions:

Domestic hot water temperature 120°F

Glazed flat plate collector with good efficiency

Tilt angle 35° (Optimum)

Orientation Due South (Optimum)

SIZING SOLAR SYSTEM FOR DHWSHW SIZING TO VARIOUS HW LOADS

SFn = 58.6%

Sizing Storage Capacity

1.5 Gl/ft2 of Collector

up to

2.0 Gl/ft2 of Collector

Sizing Collector Array

10 ft2/Pers: Low Hot Water Demand (15 Gl/Pers)

12 ft2/Pers: Average Hot water Demand (20 Gl/Pers)

14 ft2/Pers: High Hot Water Demand (25 Gl/Pers)

Example: Base case (used in following slides)

4 Person Household

Average Consumption (20 Gallons/Person)

GOBI glazed high selective absorber

Location: Boston, MA.

Sizing:

Array: 4 x 12 = 48 ft2 2 GOBI 406

Storage: 48 x 1.5 = 72 Gl 80 Gl

SIZING SOLAR SYSTEM FOR DHWSFn SENSITIVINESS TO COLLECTOR ORIENT.

Change the Orientation to Southeast or Southwest

SFn = 56.5% Base case SFn of 58.6%

Minor deviations from a due south collector orientation does not have a significant

impact on Solar Fraction

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Design Assumptions:

Base case

Impact on SFn when changing collector orientation to Southeast/Southwest

Impact on SFn when changing collector orientation to East/West

Change the Orientation to East/West

SFn = 41.0% compared to Base case SFn of 58.6%

Significant deviations from due south will require a relative larger collector array from

base case. A factor 2 on East/West orientations provides an adequate SFn. Storage

capacity should be calculated as if collectors were due south, however, using 2 Gl/ft2

SIZING SOLAR SYSTEM FOR DHWSFn SENSITIVINESS TO COLLECTOR TILT

NoteMin. tilt in mild areas is 10° to ensure that rain water drains off the collector. In cold, snowy regions min. tilt is 30° to avoid heavy snow loads on the glass

NoteMin. tilt in mild areas is 10° to ensure that rain water drains off the collector. In cold, snowy regions min. tilt is 30° to avoid heavy snow loads on the glass

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Design Assumptions:

Base case Impact on SFn with a collector tilt of

+/- 20% Impact on SFn with a collector tilt of

10o or 90o

Change the Collector Tilt to 28o or 42o

SFn = 52% Base case SFn of 58.6%

Minor deviations from an optimum tilt of 35o does not have a significant impact on the SFn

Change the Collector Tilt to 10o or 90o

SFn (10o)= 43.0% and SFn (90o)= 31.0% compared to Base case SFn of 58.6%

Significant deviations from optimum tilt will require a relative larger collector array from

base case. A factor 2 on 10o or 90o provides an adequate SFn. Storage capacity should

be calculated as if collectors were due south, however, using 2 Gl/ft2

SIZING SOLAR SYSTEM FOR DHWSFn SENSITIVINESS TO GEOGRAPHICAL LOC

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Design Assumptions:

Base case

Impact on SFn when changing geographical location further north

Impact on SFn when changing geographical location to a mild region

Impact on SFn when changing geographical location to a tropical regionChange the Geographical location to Vermont (White River Junction)

SFn = 50% Base case SFn of 58.6%

Minor correction to collector array required especially if orientation and/or tilt is also slightly off

Change the Geographical location to California (San Francisco)

SFn = 66% Base case SFn of 58.6% No corrections needed

Change the Geographical location to Hawaii (Honolulu)

SFn = 84% Base case SFn of 58.6%

Solar fraction is on the high side and could cause over heating problems. Changing the

collector absorber surface from high selective to black paint would be beneficial

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SHW systems need full sunshine to operate at

peak performance

Shading should be avoided at all times and in

particular between 10 am – 2 pm

SIZING SOLAR SYSTEM FOR DHWOTHER FACTORS

Take in consideration deciduous roof

structure, and shading (trees, chimneys, etc)

Roof conforms to current building codes for

loading

Sun Path

Roof Structure

Introduction to SHW Earth Energy Resources US Solar Radiation Why Go Green Why SHW

SHW Technology SHW Components Different Types of SHW Systems

Sizing Solar Domestic Hot Water System Solar Fraction (SFn) and Sizing Guidelines Sizing Dependencies SHW Sizing Other Factors

Auxiliary Heating Basic considerations Preheating Dual Tank Systems

BASIC SOLAR THERMALCOURSE OUTLINE

AUXILIARY HEATINGPREHEATING

SRCC requires installation of isolation valves to ensure that the solar system can be taken out for service without interrupting the hot water supply.

Tempering valves are typically installed between the two tanks to prevent the HW high temp limit fuses to blow if the solar water is too hot.

Electrical

The solar storage tank is installed in the supply line to the water heater (WH) preheating the water. If the solar supply temperature is above the WH set temperature the heating element will not come on. If not it will heat the water to the desired hot water temperature as normal. The solar controller and the WH controller operates independently

Gas Design Considerations

SHW SYSTEM WITH ELECTRICAL OR GAS WATER HEATERS

AUXILIARY HEATINGSINGLE TANK SYSTEMS

In a standard 2 element electric hot water heater the bottom element should be disconnected. The top element can be connected to power and can serve as an auxiliary heater for the top third of the storage tank

The top element will reheat the top of the tank irrespectively of possible solar gains.

Collector feed tube connects to cold water supply. Collector return tube should ideally exhaust below heating element separately from the hot water supply line to ensure that cold or luke warm water from the solar system does not feed directly into the hot water supply.

SHW SYSTEM WITH ELECTRICAL BACKUPDesign Considerations

The electric heating element functions as back-up when solar energy is not available or when hot water demand exceeds the solar-heated supply

Solar Heat Transfer Appliance

AUXILIARY HEATINGSINGLE TANK SYSTEMS

SHW SYSTEM WITH INSTANTANEOUS (ON DEMAND) WATER HEATERS

The solar storage is installed in the supply line to the on demand heater. If the temperature is above the WH set temperature, the on demand heater will not come on. If it isn't, the WH will heat the water to the desired hot water temperature as normal. The solar controller and the on the demand controller operates independently

On demand heater has to be designed for high water inlet temperature coming from the solar system. If it can’t, it’s recommended to install an automatic temperature sensitive by pass valve around the on demand heater.

The on demand heater has to be modulating i.e. heating to a preset hot water output temperature only. Standard incremental heating is not recommended.

Design Considerations

AUXILIARY HEATINGSINGLE TANK SYSTEMS

Using a bottom fired gas water heater as a solar storage tank with gas as a back up requires an electrical ignited burner which can be connected to a solar controller priority relay or the normally open terminal on relay #2 on the Heliodyne Delta T Pro controller.

A pilot flame burner does not work.

SHW SYSTEM WITH GAS BACKUP

The solar heat transfer appliance is connected directly to the gas water heater provided it has the required storage capacity.

Sol

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eat T

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fer

App

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Design Considerations