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Direct Connect 30

SRCC OG-300 Certified Solar Water Heater System

Installation, Operation and Maintenance Manual

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DIRECT CONNECT 30

DOMESTIC SOLAR WATER

HEATING SYSTEM

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

The Direct Connect 30 solar water heating system has gone through an extensive technical and performance review by the

Solar Rating & Certification Corporation (SRCC). The installation of Direct Connect 30 system is to be performed by

properly licensed and experienced professional contractors in accordance with SRCC Standard OG-300, “Operating

Guidelines and Minimum Standards For Certifying Solar Water Heating”, and must conform to applicable federal, state

and local regulations, codes, ordinances and standards governing the installation of solar water heating systems.

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 the SRCC.

OG-300 system certification for the Direct Connect 30 system is granted to Sunvelope® Solar Inc. by the SRCC. It may

not be used for any commercial purpose without the prior written consent of Sunvelope®. Sunvelope® must approve any

deviation from the specified materials and methods described in this manual in writing in order not to void components’

manufacturer warranties.

The inherent Envelope design of the patented collector used in the Direct Connect 30 solar water heating system protects

system against freeze damage to temperatures as low as -40ºF (-40ºC). This system should not be installed in areas where

the annual ambient temperature has ever fallen below -40° Fahrenheit (-40° Celsius).

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This product certified by:

Solar Rating & Certification

Corporation™

www.Solar-Rating.org

Sunvelope Solar.

96 Glen Carran Cir. #105

Sparks, NV 89431

USA

Solar Energy Factor

(SEFD) SRCC Cert. No. Model No.

1.99 30004157 DIRECT CONNECT 30

The installed system is marked above

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TABLE OF CONTENTS

Safety Information

A. Introduction

B. System Description and Operation

C. General Installation Requirements

D. System Installation Requirements

E. System Start Up Procedures

F. System Operation

G. Shut Down Procedures

H. Summer Vacation Procedures

I. Maintenance and Troubleshooting

J. Direct Connect 30 System Component Parts

K. System Operating Parameters

Appendix A. OG-300 Approved Primary Components

Appendix B. Direct Connect 30 OG-300 Labels

Appendix C. Sunvelope® Solar Collector Product Warranty

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IMPORTANT SAFETY INFORMATION

READ ALL INSTRUCTIONS BEFORE USING.

DANGER - WATER TEMPERATURE SETTING

Water temperatures above 125°F can cause severe burns or death from scalding. Maximum water temperatures

occur just after the heating element(s) has shut off. To find hot water temperature being delivered, turn on a hot water

faucet and place a thermometer in the hot water stream and read the thermometer. The following chart may be used as a

guide in determining the proper water temperature for your home.

TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

TEMPERATURE TIME

125° F 1/2 to 2 minutes

130° F About 30 seconds

135° F About 10 seconds

140° F Less than 5 seconds

145° F Less than 3 seconds

150° F About 1 1/2 seconds

155° F About 1 second

The temperature of the water in the heater can be regulated by setting the temperature dial on front of the mixing valve

or thermostat. There is a Hot Water SCALD Potential if the mixing vale or thermostat’s temperature is set too high.

WARNING

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For your safety, the information in this manual must be followed to minimize the risk of fire or explosion, electric shock,

or to prevent property damage, personal injury, or loss of life. Be sure to read and understand the entire Installation,

Operation and Maintenance Manual before attempting to install or operate this solar water heating system. Pay particular

attention to the Safety Instructions. Failure to follow these warnings could result in serious bodily injury or death.

Should you have problems understanding the instructions in this manual, or have any questions, STOP, and get help

from a qualified service technician.

FOR INSTALLATIONS IN THE STATE OF CALIFORNIA California Law requires that residential water heaters must be braced, anchored or strapped to resist falling or horizontal

displacement due to earthquake motions. For residential water heaters up to 52 gallon capacity, a brochure with generic

earthquake bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street, Suite 5100,

Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater dealer. However, applicable local codes

shall govern installation. For residential water heaters of a capacity greater than 52 gallons, consult the local building

jurisdiction for acceptable bracing procedures.

SAFETY PRECAUTIONS Have the installer show you the location of the circuit breaker and how to shut it off if necessary. Turn off the circuit

breaker if the water heater has been subjected to overheating, fire, flood, physical damage or if the ECO fails to shut off.

Read this manual entirely before installing or operating the water heater.

Use this appliance only for its intended purpose as described in this Installation, Operations and Maintenance

Manual

Be sure your appliance is properly installed in accordance with local codes and the provided installation

instructions.

Do not attempt to repair or replace any part of your water heater unless it is specifically recommended in this

manual. All other servicing should be referred to your installing contractor or Sunvelope® Solar Inc.

READ AND FOLLOW THIS SAFETY INFORMATION CAREFULLY.

SAVE THESE INSTRUCTIONS

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A. INTRODUCTION

Solar water heating systems are climate and site specific appliances. Different types of solar systems are installed in

accordance with regional weather and water quality conditions. System performance varies as a function of the household

hot water load, including daily showers, laundry and kitchen uses, the average ground water and ambient air temperatures,

the home’s roof pitch and orientation, and, of course, the seasonal intensity of solar radiation. These variables, some of

which change from home to home on the same neighborhood street, will determine how much energy the Sunvelope Direct

Connect 30 system will generate each year of operation.

The Direct Connect 30 solar water heating system is an “Active Open Loop System” system meaning that water flows

directly through the hot water solar collector, using a DC pump powered by a solar panel to circulate water in the system.

This manual provides a basic “solar water heating primer”. Our goal is to familiarize you with the proper installation,

operation, and maintenance of your Direct Connect 30 solar water heating system. This system is required to be installed

by properly licensed solar or plumbing contractors in accordance with SRCC Standard OG-300 and all applicable national,

state and local codes, ordinances and regulations governing solar installations as well as good trade practices. Failure to

follow the procedures and practices described in this manual may void manufacturer warranties for specific component

parts.

This manual covers installations utilizing one Sunvelope® Solar collector with a single 50-gallon electric water heater

tank. Frequent reference will be made throughout this manual to specific component parts. The placement of each

component in the system is depicted in Figure 1.

B. SYSTEM DESCRIPTION AND OPERATION

The Sunvelope® Direct Connect 30 solar hot water system is designed with many unique features, safeguards and controls.

Figure (1) is a basic schematic drawing showing the general location of these features, showing an active “open loop”

configuration. Potable water is the only approved heat transfer fluid that can be utilized in the Direct Connect 30 system.

The key components in the Direct Connect 30 solar water heating system include the patented FPE-30 Sunvelope® solar

collector, Sunvelope® Pump Station which includes a circulation pump, a 10 watt PV panel to power circulating pump

and a High Temperature Limit (HTL) switch. The electric hot water tank, expansion tank and mixing valve may be

supplied as part of the system or supplied separately.

FIGURE 1

SYSTEM SCHEMATIC

Collector PV Panel

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Figure 1 System Schematic

The simple and elegant design of the patented Sunvelope® FPE-30 collector makes it possible to install open loop systems

in hard freeze areas. The Sunvelope® FPE-30’s freeze resistance has been tested in accordance with ISO 9806:2013. The

FPE-30, in conjunction with the recommended PEX tubing, corrugated stainless tubing and recommended connections,

enables a system that will not be damaged by freezing or static flow conditions.

The Sunvelope® FPE-30 collector is 3’ X 10’ and features a patented envelope type absorber plate in which the water

inside the envelope is in direct contact with the entire internal surface. This allows for very high flow rates while providing

an optimal temperature differential across the collector. Additionally, due to the greatly increased surface contact area,

when the temperature of the water inside the collector rises, the efficiency of the collector drops and self modulates the

high temperature potential as long as the flow is continuous. The Sunvelope® FPE-30 collector is fitted with an attached

thermistor and High Temperature Limit switch (HTL) which will shut off the PV powered DC pump at the factory preset

temperature of 170°F. Because the thermistor is installed on the back of the absorber plate, the high limit will not permit

the pump to restart as long as the collector temperature is above 170 degrees F. Corrugated stainless tubing is used for the

first 3 feet past the collector outlet on the hot side to protect the PEX from potentially high temperatures. Additionally, a

Pressure Relief Valve (PRV) set at 100 PSIG is installed between the corrugated stainless tubing and PEX tubing in the

return loop of the collector. This sub assembly is called the TPI (Temperature and Pressure Isolator) and can be seen in

figure 2. The NP-60 and NP-70 PEX tubing, as manufactured by NIBCO or equal, is rated for temperatures of 180 degrees

F at 100 psi. As an alternative to PEX, stainless steel 304 corrugated tubing manufactured by Falcon Stainless (S12C-

10012EP), can be used as suitable piping in hot climates.

Expansion Tank

Tank

Pump Station

Return into T&P

Mixing Valve

HTL Switch

Supply from Boiler Drain

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Figure 2 TPI (Temperature and Pressure Isolator)

The standard Pump Station is compact and designed to reduce installation time and complexity. The Pump Station features

a DC powered, variable speed pump that is powered by a 10-watt solar PV panel. The pump varies speed according to

the available solar insolation thus providing a self-modulating continuous flow which maximizes efficiency in the desirable

temperature range while minimizing over temperature potential. The Pump Station also includes a built in Joule digital

monitoring system, a check valve (back flow preventer), isolation valves at one end, and isolation/purge valves at the other

end. The Joule monitoring system, which includes a flow meter, two built-in temperature sensors, and the AMBR edge

router for internet connection, also has the capability of adding temperature and AC current sensors to monitor the water

heater tank.

NOTE: For areas or customers where internet is not available, analog Pump Station is available with analog read outs.

The analog Pump Station comprises a DC pump and check valve, Calleffi flow meter, two temperature wells with dial

thermometers, isolation valves, isolation/purge valves and connectors. The Analog Pump Station delivers the same

functionality as the standard Pump Station, but does not requiring internet connection.

The electric water heater tank requires a mixing valve (tempering valve) for scald protection against high temperature

water.

The system is designed to be compatible with a standard and readily available 50 gallon electric water heater tanks.

C. GENERAL INSTALLATION REQUIREMENTS

C.1 Permits:

Installing contractor shall obtain all required permits and approvals.

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C.2 Codes, Ordinances and Standards:

The installation shall conform to all federal, state and local regulations as well as all codes, ordinances and standards

governing the installation of solar water heating systems. The installing contractor shall adhere to sound building safety

and trade practices. Special consideration must be given to building code requirements for roof loading and the penetration

of structural members and fire rated assemblies.

C.3 Shading Considerations:

The collectors should be located in an area of the roof that will not be shaded for the majority of the day all year round in

order to maximize hot water production. Adjacent buildings and trees should be checked for possible winter shading. In

addition, the collector should not be shaded by any permanent obstacle between 9:00 a.m. and 3:00 p.m. on any day of the

year in order to maximize hot water production.

C.4 Roof and Site Inspection:

Before the installation, the contractor shall inspect the condition of the roof and notify the homeowner of any existing roof

damage or necessary repairs.

C.5 Structural Considerations:

The collectors must be located in a structurally sound area of the roof. Penetrations into structural members must not

compromise the structural integrity of the structural member. All structural member penetrations must comply with

applicable codes.

The collector mounting method must be capable of maintaining the required tilt and azimuth of the collector under the

expected dead loads, wind loads and snow loads for the location.

C.6 Building Envelope:

Penetrations through the building envelope (including roof, walls or floor penetrations) must not impair the enclosure

function and must meet applicable codes and best practices.

Roof penetrations whether for structural mounts or pipe penetrations must be sealed and leak proofed as per applicable

codes and National Roofing Contractors Association practices.

Building penetrations must not allow vermin intrusion.

C.7 Fire-Rated Assemblies:

Penetrations through fire-rated components must not reduce the fire resistance of the assembly below code.

C.8 Building Materials:

Building materials adjacent to solar components must not be exposed to elevated temperatures.

C.9 Confirmation of Installation Site:

The homeowner and contractor shall confirm the location of all roof and ground mounted components in advance of the

installation.

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C.10 Fluid Identity and Toxicity:

The Direct Connect 30 system uses potable water as a heat transfer fluid, which is directly heated in the collector. Use of

toxic heat transfer fluids is prohibited.

C.11 Maintenance and Servicing:

When installing the system, make sure that all the components are accessible and easy to reach. Provide for clear access

to the electric water heater tank, pump station, and mixing valve. Make connections with PEX connectors or other

approved connections.

D. SYSTEM INSTALLATION REQUIREMENTS

D.1 Collector Orientation and tilt

The performance of solar water heating systems in the Northern Hemisphere is optimized when the collector is mounted

facing True South. However, performance suffers very little when the collector is oriented no more than 45° East or West

of True South.

The FPE-30 Collector can be mounted flush or slightly raised and parallel with the roof. It can also be mounted raised to

an angle of latitude plus 15 degrees to maximize winter efficiency and minimize over heat potential in summer. If raised

to an angle it should always be mounted landscape to reduce wind loads. It can be oriented perpendicular to, parallel to,

or at an angle with the slope of a roof to achieve proper Southerly orientation.

NOTE: The outlet of the collector must be at the high point of the collector. Collectors are manufactured in two

configurations to accommodate installation. Specify which orientation is required when ordering.

D.2 Mounting Procedures

The collector should be mounted as close to the electric water heater tank as possible to minimize heat loss in the piping

runs.

Collector shall be mounted in landscape orientation. The PV panel may be mounted on either end or in the middle or even

away from the collector as long as the collector and the PV panel share the same orientation and tilt angle. Differences in

orientation, tilt angle or shading between the collector and the PV panel will result in sub-optimal performance of the

system.

NOTE: The collector has a top and bottom. Be sure to mount the side of the collector that has the High Temperature

Limit switch (HTL) slot, at the top.

Figure 3 Typical Installation

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Be sure to read the plumbing procedure in Section D.3 prior to mounting the collectors.

Tilt-Up Mounting Option: For the tilt-up installation option the collector requires a minimum of three legs connected

to swivel clips at the collector (as shown below) and bolted to feet connected to the roof.

Figure 4 Swivel Clip and Top Bracket

The legs are 1.5” square aluminum tube with holes at the bottom which are connected to the channel feet with a 2” long

¼-20 bolt. At the top of the square tube use one of the 10” long aluminum channels over the square tube to adjust the

length so the collector is evenly mounted at the proper angle. Slide the channel over the 1.5” square tube, on the end of

the square tube without a hole. The back feet can be moved closer or back from the bottom feet to adjust the collector to

the desired angle. The square tube legs can also be shortened if necessary. Sunvelope® recommends latitude plus 15

degrees from horizontal to maximize hot water production. Once the desired angle is achieved, use self-drilling screws to

attach the channel to the leg.

Figure 5A Swivel Clip 5B Mounting Foot

Three feet connect to swivel clips at the bottom of the collector and attach to the roof. The most important structural

consideration is to securely anchor the collector and the Sunvelope® mounting hardware to the structural members of the

roof with an approved roof attachment method. Roof connections can usually be made at the roof trusses by sliding the

connector clips to align correctly. More connectors and legs may be used in high wind or snow load areas. If it is not

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possible to align with trusses you must attach to blocking under the roof sheet. 5/16” lag screws are recommended long

enough to allow 2 ½” engagement into roof member. Engineering may be required for lag screw requirements. Consult

a Structural Engineer and or building department about loading and local codes and requirements.

If the region is subject to hurricane conditions, additional steps may be required to secure the collector and mounting

hardware to the structural members. In certain areas of the country, local building codes may require collector wind load

testing or prescribe specific mounting procedures. Consult your local building department.

The collector should be raised from the roof surface to allow for rainwater and debris to pass under the collectors and for

proper ventilation of the roofing material. There should be at least 1 ½” of clearance between the roof surface and the

bottom of the solar collectors. Local codes may require greater clearance.

Preserving the integrity of the roof membrane is the most important roofing consideration. Ensure that all roof penetrations

required to plumb and mount the solar collector are properly flashed and sealed in accordance with best roofing practices.

Figure 6A Roof Attachment 6B Flush Mount Foot

BEST PRACTICE – Mounting

Snap a line at the location where you want the bottom of the collectors. You must stay 3’ above the edge of the roof.

Using lag screws, screw 3 of the channel feet to the roof in line with each other to provide the support at the bottom of the

collectors.

The feet at the ends of the collector should be 6” to 12” from the end of the collector at each end. The middle leg or legs

should be as evenly spaced as possible with the two ends. The PV panel may mount as shown in Figure 1 or in any

alternative location as long as it shares the exact solar resource. Pre drill and use silicone seal under the feet to seal the

lag screws from leaking.

Once the front (bottom) feet are mounted, determine the spacing between the feet at the bottom of the collector and the

feet at the bottom of the legs. The best way to determine this is to attach the bottom of the collectors to the front feet with

the ¼-20 bolts provided.

Note: Be sure that the bottom fitting in the back of the collector is connected with a ½” brass 90° fitting on the stub in the

back of the collector before mounting the collector.

Place one of the 10” channels over the square tube leg with 3” minimum overlap. Then use one of the legs with the 10”

end channel at the top of the leg but not attached yet and lift the collector to the desired angle and hold the leg from the

top of the collector to the roof. Mark the location of the back foot and snap a line parallel to the bottom of the collector.

Screw all the back legs to the roof using silicone seal under the foot to seal the lag screws. Lag screws must penetrate a

strut or a blocking.

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Now you can finish mounting the collector. Hold the collector at the desired angle and with the bottom of the square tube

held in place with a 1/4-20 bolt, and a top clip in place on the collector frame; you can slide the channel up or down the

leg to adjust the angle exactly. Then repeat with the other legs being careful to align the collector top at the same angle

on both ends. Make final attachment channel to 1 1/2 inch square tube with self-drilling screws.

Flat Mounting Option: Use six "Flat Mount Feet" attached to collector (see figure 5-B) where they can connect to roof

trusses. Start 6" to 12" from ends and maintain maximum span of 4' between feet. Plumbing connections can be made

underneath the collector but on top of the roof for appearance.

D.3 Collector Loop Plumbing

The collector loop must be plumbed using ¾” PEX tubing, rated for potable water, and lead free brass, bronze or stainless

steel fittings. Use of galvanized steel, CPVC or PVC is prohibited. Pre-insulated ¾” PEX tubing, insulated with ¾” wall

closed cell insulation tubing with a R value of 2.6 Btu/hr-ft2 °F or greater, can be supplied by Sunvelope®. This optional

material is cost effective and significantly reduces installation time. If using PEX, use type PEX rated for potable water.

Alternatively, 1/2" corrugated stainless steel coil with 3/4" EPDM insulation and control wire (as manufactured by Falcon

Stainless) can be used in lieu of PEX tubing in locations with occasional freeze exposure and minimum temperatures

above 25 degrees F (- 4 degrees C).

The inlet (return) and outlet (supply) fittings are on opposite corners of the collector. The collector is mounted landscape,

and if the outlet is on the right at the top from the back of the collector, it is a right hand collector, and vice versa.

If the collector is mounted parallel to the slope of the roof or at an angle other than horizontal, the outlet MUST be at the

high point of the collector.

Both the plumbing fittings are located in the back of the collectors and are male copper adapters silver brazed onto stainless

steel stubs. The best practice is to use a ½” brass elbow threaded onto the male adapter at the bottom of the. Screw a male

PEX adapter into the elbow. Sunvelope® recommends using 5 wraps of Teflon tape on the male threads. The elbow with

the PEX adapter should point toward the opposite end of the collector. Thread the elbow on the lower fitting before

mounting the collector.

Once the elbow is in place, attach the mounting clips into the feet and secure with the ¼”-20 bolts and nuts provided.

At the top of the collector, screw the female ½” NPT fitting which is attached to the 3’ corrugated stainless tubing supplied,

onto the ½” male adapter on the collector outlet. This is the hot side or return side, and can be connected after the collector

is fully mounted.

Connect the pressure relief valve to the return side of the collector loop, between the corrugated stainless tubing and the

PEX at the transfer connection. Set pressure setting at 100 PSIG. Sunvelope® provides pre-assembled corrugated stainless

tubing pigtails with a ½” female connector at one end and the pressure relief valve at the other end. The female end screws

onto the male fitting at the outlet of the collector. Use ½” male pipe to PEX adapter to connect to the tee with the pressure

relief valve and to the Pump Station.

All vertical piping between the back tank and the collector shall be supported at each story or at maximum intervals of ten

feet (10’). Hangers and supports can be used to prevent sagging of the piping. Hangers must be installed in a manner that

do not damage or inhibit insulation. Although the Direct Connect 30 system does not require any slope for drainage since

the system is pressurized (does not rely on drainage for normal operation), the best practice is to slope for drainage to

allow the system to be easily emptied for service. The system utilizes domestic water pressure to fill and purge the system

Allowance should be made for expansion and contraction of piping due to changes in temperature of the water and piping.

Use flexible pipe supports and avoid long straight piping runs. Include bends and elbows to allow for expansion such as

swing joints at the collector inlet & outlet.

The installation of all horizontal and vertical piping must not reduce the performance or rating of any structural member

or fire rated assembly. Adhere to all applicable local codes and ordinances.

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D.4 Pipe Insulation

WARNING: HOT PIPES MAY CAUSE BURNS IF TOUCHED. ENSURE THAT ALL PIPES AND FITTINGS

ACCESSIBLE TO THE PUBLIC ARE WELL INSULATED. COMPONENTS ACCESSIBLE TO PUBLIC TRAFFIC MUST

BE KEPT BELOW 140ºF OR CLEARLY LABELLED WITH AN APPROPRIATE WARNING.

The collector loop piping, plus any interconnecting hot water piping shall be well insulated with a high quality flexible

closed cell insulation to minimize heat loss. In addition, the final 5 feet of metallic cold water supply pipe leading to the

system, or the length of piping which is accessible if less than 5 feet, shall also be insulated. The insulation shall have a

maximum operating temperature of 220°F or higher and a minimum thermal resistance of R-2.6. The wall thickness of the

pipe insulation should be ½” or thicker. A 1” wall thickness is required for exposed piping in all areas prone to annual

hard freeze conditions. When it comes to pipe insulation the rule is simple: thicker is better.

To the extent possible, slide the insulation material over the pipe without cutting or taping. All butt joints must be sealed

with contact adhesive. The use of rigid polyethylene pipe insulation is prohibited. The temperatures generated by the

collector in the summer months or under static conditions can melt this type of material.

Any above ground exterior pipe insulation shall be protected from UV degradation and moisture damage. Use EPDM UV

resistant insulation (available from Sunvelope®) above the roof or a UV protectant wrap such as “Venture Clad”.

D.5 PV Panel Mounting and Wiring

Mount the PV panel which is supplied to the collector at either end or alternate position if desired, maintaining the same

orientation and tilt angle as the collector. The side shields must be vertical as shown in Figure 2.

Connect the PV panel to the High Temperature Limit switch (HTL) provided and installed at the factory on the back of

the PV panel. The wires at the high limit switch are marked “to Pump Station”. Connect the high limit switch to the Pump

Station. Always connect colors red to red and black to black wires. Install the thermistor connected to the HTL switch on

the back on the collector in the slot provided. The low voltage wiring used to connect the PV panel to the Pump Station

shall be a minimum18 AWG. The wiring should be two conductor, stranded, PVC insulated, with a PVC UV rated jacket

suitable for exterior use. See note 3 in Figure 7. Sunvelope® can supply pre-insulated and wired PEX tubing.

NOTE: Do not connect the PV panel wires to the DC Pump in the Pump Station until the system is fully charged and

purged of air.

D.6 Pump Station

Mount the Pump Station in the orientation shown in figure 6, on a wall near or in the electric water heater tank and in an

accessible location. Preferably mount to a stud but if one isn’t available use adequate sheet rock mounting to support the

weight. Looking at the Pump Station the left hand fittings are the supply side to the collectors and the right side fittings

are the return side from the collectors. See the markings on the label. All 4 ball valves and the two purge/drain valves

should be in the closed position.

Route the PEX tubing from the corrugated stainless tubing pig tail to the Pump Station. Connect one end to the corrugated

stainless tubing and the other end to the top return outlet of the Pump Station as marked.

Route the tubing from the bottom of the collector at the elbow to the pump side of the Pump Station as marked. Connect

to the PEX or other approved tubing connector at the bottom of the collector and to the pump side at the top of the Pump

Station as marked.

Connect PEX or other tubing from the ¾” brass tee fitting at the bottom of the tank at the drain valve to the bottom pump

side of the Pump Station.

Then connect the return side of the Pump Station at the bottom of the Pump Station to the ¾” brass tee fitting at the T and

P valve.

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FIGURE 6

PUMP STATION

SUPPLY

Figure 7 Pump Station Schematic

RETURN

T Flow Purge Valve

T Flow Purge Valve

Thermo Well Tee

Back Flow Preventer

Flow Sensor

Variable Speed DC Pump

Thermo Well Tee

Ball Valve

Ball Valve

¾” PEX to Tank Bottom

¾” PEX to Tank at T&P Valve

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D.7 Electric Water Heater Tank

When installing the electric water heater tank make sure that all the components are accessible and easy to reach. Ensure

that there is clear access to the tank, pump station, mixing valve and expansion tank. Use only brass nipples and unions,

and copper and brass fittings, in plumbing water heater tank and expansion tank. The use of galvanized fittings or nipples,

CPVC or PVC piping is prohibited.

Use standard connections to the city cold water supply line and the home hot water feed lines.

The 3/4” cold water supply line to the water heater tank shall be insulated with R-2.6 or greater pipe insulation to a

minimum distance of 5’ behind the storage tank, or to the wall if closer than 5’.

A boiler drain must be installed at the lowest point in the system to serve as a drain valve for manual draining, tank

flushing, and maintenance.

A brass shut-off isolation valve, allowing isolation from water supply to the electric water heater, must be installed in the

cold water supply line, ahead of the electric water heater and expansion tank connection.

A high quality thermostatic mixing valve is a required component in all OG-300 certified systems and should be plumbed

in line with brass union connections for ease of future repair or replacement. The mixing valve shall be standard ASSE

1017 approved. The specified mixing valve should have an operating range between 95°F and at least 120°F. The mixing

valve shall include a set point of 120°F delivered water temperature.

WARNING: SCALDING CAN OCCUR WITHIN FIVE SECONDS WHEN WATER TEMPERATURES

APPROACH 140° F. DESPITE THE INSTALLATION OF A MIXING VALVE, ALWAYS EXERCISE

CAUTION WHEN OPENING A HOT WATER FIXTURE OR FAUCET IN YOUR HOME.

To maximize solar heat capture from your Direct Connect 30 system, Sunvelope® recommends disconnecting the bottom

water heating element. To disconnect bottom heating element of the electric water heater tank, shut off power to the water

heater. Remove the access covers over the heating elements. Fold insulation outwards, or if the insulation is plastic foam,

just remove the insulating block and set it aside. Remove the plastic thermostat cover found under this insulation that

protects the thermostat electrical connectors from touching the water heater thermostat cover, and then disconnect the

electrical wires connected to the water heater element. Insulate the electrical wires with wire nuts.

All electric water heater tanks used with this system must have a minimum of R12 external insulation. An exterior

insulation blanket may be used to satisfy this requirement.

D.8 Expansion Tank

The expansion tank is used to accept expansion of the potable water as it heats, preventing a pressure increase and

subsequent dumping from the pressure relief valve. For the Direct Connect 30 installation, a 3.2 gallon expansion tank is

specified as suitable capacity. Use only high temperature expansion tanks rated up to 200°F.

The expansion tank is to be pre-charged to 45 psi.

Connect the expansion tank to the cold water supply line, between the water heater isolation valve and the water heater.

Use only “drinking water safe” copper, brass, or PEX fittings and piping in plumbing the expansion tank. The use of

Teflon tape on the threaded fittings is recommended.

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D.9 Electrical Requirements

The DC pump inside the Pump Station is powered by a 10 watt PV panel, which is mounted in an unshaded area outside

at the same orientation and tilt angle as the collector. No other power source is required to operate the water heating portion

of the Sunvelope® system.

The Energy Heat Meter included in the Pump Station to capture temperature and flow data does require an electrical outlet

within 6ft of the pump station.

E. SYSTEM START UP PROCEDURE

E.1 Charging and Purging the System

Once the piping is completed, the system is ready to be charged. First connect a garden hose to the purge valve hose

connection on the Pump Station on the return side. Use a good quality hose and use extreme care; the discharged water

may be EXTREMELY HOT. Make sure the end of the hose is in a location where the discharge will not cause any damage.

NOTE: The collector is usually super-heated and will generate steam. Be sure everyone is a safe distance from the end

of the hose.

The system is now ready to connect power from the PPV panel to the DC Pump in the Pump Sation. Leave the ball valve

on the return side of the Pump Station closed and open the purge valve to the hose. Open the ball valve on the supply side

of the top of the Pump Station and leave the purge valve closed. Then slowly open the ball valve from the tank at the

bottom of the Pump Station supply side through the pump and to the collector until the flow is full. Leave the flow full

until the system is purged. You can tell when the system is fully purged when the return temperature cools to around 100

degrees F and you hear no air bubbles or steam. Then open the valve from the top of the tank to the Pump Station while

leaving the purge valve open for a second or more. Close the purge valve and examine the entire system for leaks. All 4

ball valves should be fully open and the purge valves should be closed and the caps screwed in place.

The system is now ready to connect to the DC power from the PV panel and HTL switch.

F. SYSTEM OPERATION

Once the Direct Connect 30 system is properly installed and connected, the DC pump in the Pump Station will

automatically modulate its speed to match the available solar irradiance, which in turn will control the flow rate thru the

solar collector and the amount of heat produced by the system. The heat collected by the solar hot water system will be

used to heat the water going to the electric water heater tank, reducing or eliminating the need for the electric water

heater to turn on.

The Pump Station’s integrated monitoring incorporates four system status LEDs. The yellow LED indicates flow; this is

only lit when the system detects flow though the Pump Station. The red LED indicates that the monitoring system is

ON. The green LED reports that all temperature probes are reporting. Lastly, the blue LED indicates a link between the

monitor and the AMBR edge router.

To determine whether the solar hot water system is working, go into the Energy Dashboard of the monitoring solution;

compare the Supply Temperature with the Return when the solar loop pump is running. The Return temperature from the

collector on a sunny day should be at least 4° F warmer than the Supply temperature going up to the collector.

In order to utilize the electric water heater as a backup to the solar hot water system, leave the circuit breaker on to the

electric water heater tank and set the tank thermostat to the lowest acceptable temperature setting. The electric resistance

heating element will come on only when the tank temperature falls below the thermostatic set point. If the solar heated

water entering the tank is warmer than the thermostatic set point, the electric heating element will not come on.

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G. SHUTDOWN PROCEDURES

The Direct Connect 30 solar water heating system is designed so that the key components can be isolated for emergency

repairs or routine maintenance. By shutting the shut off valve installed in the incoming water line (Figure 7), the entire

system can be isolated from the cold water supply line. In the case of a leak immediately shut this valve and call your

installation contractor for service.

The collector loop can be quickly drained if a leak is detected or for routine maintenance. First, disconnect the DC power

pump in the Pump Station from its DC power source. Next, close both ball valves (supply and return) in the bottom of the

Pump Station to isolate the collectors loop. Then attach a hose to the T Flow Purge Valve on the return side of the Pump

Station. Use a good quality hose and use extreme care. Make sure the end of the hose is in a location where the discharge

will not cause any damage. Open the valve to drain the system.

NOTE: The collector is usually super-heated and will generate steam. Be sure no one is in range of the end of the hose.

CAUTION: THIS WATER MAY BE EXTREMELY HOT!

H. SUMMER VACATION PROCEDURES

Solar water heating systems can build up very high temperatures during summer months if there is no periodic draw on

the system. The Sunvelope Direct Connect 30 system has excellent over temperature protection features so it is

recommended to simply close the shut-off valve in the cold water supply of the electric water heater tank and allow the

system to operate normally. When user returns, just open the valve to the tank.

If for any reason the user desires to drain the collector loop the pump should be disconnected. The two top ball valves

with purge/drain valves should be closed. Hoses should be connected to the two purge valves, either simultaneously or

one at a time, and the purge valves opened to release the water in the loop. Once the water is fully drained the purge valves

may be close again. To recharge the system, follow the instructions in Section E-1, Charging and Purging the system.

I. MAINTENANCE AND TROUBLESHOOTING

The following simple procedures are intended to optimize the performance of the Direct Connect 30 system and also to

extend the life of the primary components:

I.1 Electric Water Heater Tank Flush

The electric water heater tank should be flushed annually to minimize sediment buildup on the bottom of the tank. If you

live in an area with high mineral content in your water, flush the tank on a semi-annual basis. Open the drain valve on the

bottom of the water heater tank and flush a sufficient volume of water to eliminate the sediment. It is also possible to flush

the entire system including the collector by connecting a hose to the purge valve at the return side of the Pump Station.

Close the ball valve and purge there.

I.2 Electric Water Heater Tank Anode Rod Replacement

Typically constructed from magnesium, anode rods are installed in “glass lined” electric water heaters to inhibit

corrosion. The anode rod is consumed so that the tank lining is not. By changing the anode rod after the fifth year of

system operation, and every three to five years thereafter, it is possible to extend the life of the electric water heater tank.

Periodic replacement of the anode rod in the backup water heater tank can significantly extend the tank life. System

temperatures and water quality affect the rate at which the anode rod is consumed. In general: the higher the average

system temperature the faster the rate of corrosion.

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I.3 Collector Glass Cleaning

If you live in a dusty climate it is beneficial but not necessary to wash off the dirt that settles on the collector glass once

every two months. Normal rain and snow is usually sufficient to maintain collector reasonably clean. Clean glass allows

the collector to maintain a high level of thermal performance.

I.3 Pipe Insulation Maintenance

Check the exterior pipe insulation annually and patch or repair any exposed surfaces or degraded areas. Repair as

necessary with manufacturer’s recommended jacket or coating or a high quality exterior latex paint.

I.4 System Leaks

If you detect a water leak in the solar loop piping or in the water heater tank, follow the Shutdown Procedures in Section

G, and contact your installation contractor for additional troubleshooting and repair support.

I.5 Pump Failure

Use the flow meter in your monitoring system or check the analog flow meter when the sun is shining directly on the PV

panel (no shading). If you are not getting hot water and the flow reading is zero, the pump may not be operating and

may need to be replaced. Contact your installation contractor for service.

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J. DIRECT CONNECT 30 SYSTEM COMPONENT PARTS

Figure 7 below depicts the key components of the Direct Connect 30 system:

Figure 8 System Schematic

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Table 1 System Components

Number in Figure #7

Component Manufacturer Catalog # Quantity

1 Solar Collector Sunvelope® FPE-30 1

2 Pump Station Sunvelope® SPA-15 1

3 Electric Water Heater Tank, 50 gallons

Rheem or comparable XE40M06ST45U1 1

4 Expansion Tank, 3.2 gallons Amtrol ST-8 1

5 PV 10W panel Dasol DS-A18-10 1

6 High Temperature Limit Switch (HTL) and thermistor

Wangwanqui 261247778904 1

7 Solar loop piping - PEX tubing encased in ½" PEX-foam insulation

Uponor, NIPCO, EverPEX or equal

F6040750, NP60/70, 64766

varies

8 Pressure Relief Valve Watts 530C 1

9 Shutoff Ball Valve Webstone Ball valve 1

10 Boiler flush valve Included as part of Electric Water Heater

N/A 1

11 Mixing Valve Honeywell-Sparco AM100C-UT-1LF 1

12 Temperature and Pressure Relief Valve

Included as part of Electric Water Heater

N/A

K. SYSTEM OPERATING PARAMETERS

K.1 Collector Loop Pressure

The pressure in the solar collector loop should be within 0 – 80 PSIG.

K.2 Collector Loop Temperature

The temperature in the collector loop should not exceed 170 degrees F.

K.3 Circulation Flow Rate

The flow rate in the collector loop should be 0.5 – 2 GPM while the pump is operating (clear days from 9AM to 6 PM).

K.4 FPE-30 Collector’s Dry and Fill Weights

Dry Weight: 141 lbs.

Fill Weight: 145 lbs.

K.5 Tank Temperature and Pressure

Refer to tank manufacturer’s specification label for tank maximum working temperature and pressure.

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APPENDIX A

DIRECT CONNECT 30 OG-300 APPROVED COMPONENTS

Primary Components Manufacturer Model Number

Solar Collector Sunvelope® FPE-30

Collector Mounting Hardware Sunvelope® LS-30

Electric Water Heater -50 gallon Rheem XE50M06ST45U1

Whirlpool E1F50RD045V

AO Smith ENT-50

Pump Station (including PV panel,

HTL switch and DC pump)

Sunvelope® SPA 15

Expansion Tank Amtrol ST-8

Other Components Description

Thermostatic Mixing Valve The thermostatic mixing valve shall have a bronze, brass or stainless steel body

with a rated maximum working temperature no less than 200oF and a rated

maximum working pressure no less than 125psi. The range of temperature set

points shall be at least 18ºF (10ºC) and shall include a set point of 120ºF (50ºC).

The Thermostatic Mixing valve shall be third party listed and certified to one of

the following ASSE standards: ASSE 1016; ASSE 1017; ASSE 1070.

Ball Valves Ball valves shall be of bronze, brass or stainless steel construction. Maximum

working temperature shall be no less than 200oF and maximum working pressure

shall be no less than 125 psi.

Boiler Drains Boiler Drains shall be of bronze, brass or stainless steel construction. Maximum

working temperature shall be no less than 200oF and maximum working pressure

shall be no less than 125 psi.

Pressure Relief Valve

The pressure relief valve shall be of bronze, brass or stainless steel construction

with a pressure setting between 30psi and 100psi. The pressure relief valve shall

be set to discharge at a pressure below the maximum design pressure of all other

components in the collector loop.

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APPENDIX B

DIRECT CONNECT 30 SYSTEM & COMPONENTS LABELS

FLUID IDENTIFICATION THE HEAT TRANSFER FLUID USED IN THIS SYSTEM IS WATER. NO OTHER FLUID SHALL BE USED THAT

WOULD CHANGE THE ORIGINAL CLASSIFICATION OF THIS SYSTEM. BE EXTREMELY CARFUL WHEN

DRAINING THIS FLUID. IT MAY BE DISCHARGED AT A VERY HIGH TEMPERATURE AND PRESSURE.

FREEZE LABEL THE DIRECT CONNECT 30 SYSTEM IS PROTECTED FROM FREEZING BY THE INHERENT DESIGN OF THE

SOLAR COLLECTOR. WHEN PROPERLY INSTALLED AND OPERATED THE SYSTEM IS PROTECTED TO

TEMPERATURES AS LOW AS -40 DEGREES F.

BOILER FLUSH VALVE (COMPONENT #9) – WATER HEATER TANK DRAIN VALVE VALVE 11 IS NORMALLY CLOSED. WHEN OPENED IT IS USED TO DRAIN THE WATER HEATER TANK. BE

EXTREMELY CARFUL WHEN DRAINING THIS FLUID. IT MAY BE DISCHARGED AT A VERY HIGH

TEMPERATURE AND/OR PRESSURE.

PUMP STATION’S T FLOW PURGE VALVE (RETURN SIDE) VALVE IS NORMALLY CLOSED. WHEN OPENED, IT IS USED TO CHARGE AND DRAIN THE SOLAR

COLLECTOR LOOP PIPING. THE HEAT TRANSFER FLUID USED IN THIS SYSTEM IS WATER. NO OTHER FLUID

SHALL BE USED THAT WOULD CHANGE THE ORIGINAL CLASSIFICATION OF THIS SYSTEM.

UNAUTHORIZED ALTERATIONS TO THIS SYSTEM COULD RESULT IN A HAZARDOUS HEALTH CONDITION.

BE EXTREMELY CAREFUL WHEN DRAINING/PURGING THIS FLUID. IT MAY BE DISCHARGED AT A

VERY HIGH TEMPERATURE AND/OR PRESSURE.

SHUTOFF SUPPLY ISOLATION VALVE (COMPONENT #8) THIS VALVE IS NORMALLY OPEN AND ALLOWS POTABLE WATER TO FILL THE WATER HEATER TANK.

WHEN CLOSED THE SOLAR STORATANK IS ISOLATED FROM THE PRESSURIZED CITY COLD WATER

SUPPLY LINE PIPING.

PRESSURE RELIEF VALVE (COMPONENT #11)

THE PRV WILL AUTOMATICALLY OPEN AND DISCHARGE FLUID OR AIR IN THE EVENT OF THE

COLLECTOR LOOP PRESSURE EXCEEDING THE MAXIMUM WORKING PRESSURE OF THE SYSTEM.

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APPENDIX C

FPE SERIES COLLECTOR PRODUCT WARRANTY

1. GENERAL: The patented Sunvelope®

Solar FPE Series Collectors are warranted to be free from defects

in parts and workmanship under normal use and service including freezing.

2. THE EFFECTIVE DATE: The effective date is the completion date of original installation if properly

documented; or the date on the building permit for installation of your Collector plus thirty (30) days.

Installation of a collector without a building permit voids warranty.

3. APPLICABLE WARRANTY PERIOD: Subject to proof of purchase of your collector, the

Applicable Warranty period is ten (10) years from the Effective date.

4. EXCLUSIONS: This Warranty will not apply:

To damage from abuse, accident, fire, flood, wind or other event beyond control of the manufacturer;

To defects or damage caused by the use of any component, attachment, or device not authorized in writing

by Sunvelope®

Solar, Inc.;

To a collector which has been moved from its’ original installation location;

To a collector that has been modified in any way;

To damage caused by negligence or vandalism;

To Collectors with structural attachments not authorized by the manufacturer;

5. LABOR, SHIPPING AND PROCESSING COSTS: This Limited Warranty does not cover any labor expenses

for service, repairs, reinstallation, permits, or removal and disposal of defective component part(s). All such

expenses are the responsibility of the Customer. This limited Warranty does not extend to any shipping cost,

transportation cost, or delivery expenses.

6. HOW TO MAKE A CLAIM: To obtain Warranty Service, contact Sunvelope®

Solar Inc. The ORIGINAL

DATED RECEIPT OR OTHER PROOF OF PURCHASE AND DATE OF INSTALLATION, accompanied by

the model and serial numbers are required. Please be prepared to provide proof that the Collector meets the

Limited Warranty requirements.

7. EXCLUSIVE WARRANTY – LIMIT OF LIABILITY: This Limited Warranty is the only Warranty for

products provided by Sunvelope®

Solar, Inc. No outside parties are authorized to make any warranties for or

on behalf of Sunvelope®

Solar, Inc. ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED PREVIOUSLY. THE DEALER’S SOLE LIABILIY, WITH RESPECT TO ANY DEFECT, SHALL BE SET FORTH IN THIS LIMITED WARRANTY, AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGE FROM WATER LEAKAGE) ARE EXCLUDED. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESDRIPTION ON THE FACE HERE OF. Some states do not allow limitations on how long an implied warranty lasts, or for exclusion of incidental or consequential damages so the above limitations or exclusions may not apply to you.

8. This limited warranty gives you specific legal rights, and you may also have other rights, which vary from state

to state.