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VELUX Solar Water Heating System Installation

VELUX Solar Water Heating System Installation. SAFETY. Be alert and aware of all jobsite risks Take steps to prevent injuries due to: Falling off the roof Work site clutter Electrical shock Hot water scalding Flying debree Sharp edges Weather. AGENDA. System Selection

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VELUX Solar Water Heating System Installation

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  1. VELUX Solar Water HeatingSystem Installation

  2. SAFETY • Be alert and aware of all jobsite risks • Take steps to prevent injuries due to: • Falling off the roof • Work site clutter • Electrical shock • Hot water scalding • Flying debree • Sharp edges • Weather

  3. AGENDA • System Selection • Pre-Installation Inspection • Installation Procedures • Collector Installation • Tank & B.o.S. Installation • System Commissioning • Routine Maintenance • Basic Troubleshooting

  4. VELUX Solar Water HeatingSystem Selection

  5. U.S. WATER HEATING SYSTEM GEOGRAPHY Key Heavy Electric Market Heavy Gas Market Heavy Boiler Market • U.S. water heating market consists of 3 primary system types for residential hot water. Note: Hawaii and Florida are the primary markets for “OPEN” solar water heating systems.

  6. VELUX SOLAR SYSTEM OFFERING • Indirect solar water heater with electric backup • Direct replacement for electric water heaters • Primary solution for hot climates and electric water heater markets • Indirect solar water heater with heat exchanger backup • Direct replacement for indirect water heater/boiler systems • Primary solution for northeast and mountain regions • Indirect solar preheat system • Direct integration with electric water heaters • Direct integration with gas water heaters • Primary solution for gas water heater markets • * Systems and utilize the same tank type 1 2 3 1 3

  7. SYSTEM 1 – INDIRECT ELECTRIC AUXILIARY Collectors Flashings/connector tube Flextubes Air separator Pump station/controller Expansion tank Solar storage tank Mixing valve Temperature sensor 1 2 3 4 5 6 7 8 9 1 9 HW CW 2 1 2 4 3 8 5 7 6 Electric Auxiliary with Thermostat 3 Solar loop

  8. SYSTEM 2 – INDIRECT W/BOILER AUXILIARY Collectors Flashings/connector tube Flextubes Air separator Pump station/controller Expansion tank Solar storage tank Mixing valve Temperature sensor 1 2 3 4 5 6 7 8 9 2 9 HW CW 1 2 2 4 3 8 5 7 6 AuxiliaryHeat Exchanger 3 Backup heat source (by others) Solar loop

  9. SYSTEM 3 – INDIRECT SOLAR PREHEAT Collectors Flashings/connector tube Flextubes Air separator Pump station/controller Expansion tank Solar storage tank Mixing valve Temperature sensor 1 2 3 4 5 6 7 8 9 3 HW CW 9 1 2 2 8 4 3 5 7 6 3 Solar loop Existing gas or electric water heater

  10. COMPONENT SELECTION - COLLECTOR SIZING • U.S. systems • Ideal size = 10-15 ft2 per person 10-15 ft2 per = approximately 80% solar fraction = approximately 50 ft2 collector area = approximately 75 ft2 collector area

  11. COMPONENT SELECTION -TANK SIZING • U.S. systems • Typical tank = 1.5 gal. per ft2 collector area = approximately 80 gallons = approximately 120 gallons

  12. SYSTEM OPTIMIZATION - SOLAR FRACTION • U.S. systems • Ideal size = 90% -100% sf in summer months • Solar Fraction by Month • 2 collector/80 gallon system • 4 person household

  13. VELUX SOLAR SYSTEMS • Systems/Components: • Collectors • Flashings • Tank • Expansion tank • Pump station • Controller • Thermostatic mixing valve • Microbubble air separator • Glycol (liquid) • Piping adapters IMPORTANT: ZFM Flextubes are NOT INCLUDED in kits

  14. VELUX SOLAR SYSTEMS • System Kits Available: • System kits available with U12 collectors only • System kits with electric auxiliary heat will be shipped from inventory • System kits with boiler auxiliary heat are special order • Systems with S06 and M08 collectors are custom design/special order only

  15. VELUX SOLAR SYSTEMS Flextubes Available:

  16. Decide on a system kit according to costumers needs Number of persons in household Type of roof (shingle or tile) Type of auxiliary heat (electric/preheat or boiler) Order additional panel if needed Determined by geography, orientation, and pitch Order flextubes according to distance from collectors to tank WHAT TO ORDER? • Example: • 5 person home • Shingle roof • Electric auxiliary heat • 25’ collector-tank distance • Order: • 1 x CLI U12 SK0L318 (Kit) • 2 x ZFM 010 (10m/30’ flextubes)

  17. VELUX Solar Water HeatingPre-installation Inspection

  18. PRE-INSTALLATION CHECKLIST • Site Inspection • South facing roof • Un-shaded roof • Review Local Building Codes • Electrical • Plumbing • Installation Location • Placement • Orientation • Roof Pitch • Roof Survey • Roofing material • Condition of roof • Plumbing Requirements • Cold in stub out • Hot out stub out • Electrical Requirements • Power line stub outs • Circuit panel and breaker

  19. ORIENTATION • South facing is ideal but not essential • Orientation 45 degrees from South – minimal efficiency loss (<5%) • East or West facing – efficiency loss up to 30%

  20. ROOF PITCH • Between 15 & 90 degrees from horizontal is acceptable • Minimum 3/12 pitch (15 deg) required • Maximum 20/12 pitch (60 deg) recommended for optimal performance 1111111111111111111111111111111111111111111111111111

  21. SOLAR IRRADIATION – ORIENTATION/PITCH 4 Person DHW System (typical at 40 Latitude) Green = recommended pitch and orientation range for optimal performance

  22. VELUX Solar Water HeatingInstallation ProceduresCollector Installation

  23. INSTALLATION PROCEDURES - COLLECTORS • Pre-installation preparation • Open collector packaging • Check for all components • Carefully read installation instructions

  24. INSTALLATION PROCEDURES - COLLECTORS • Prepare the Roof • Carefully remove shingles • Layout collector locationon roof • Nail temporary collectorsupport to roof • Mark flextube penetrationlocations

  25. INSTALLATION PROCEDURES - COLLECTORS • Drill holes for flextubes • Verify there are no roofjoists or obstructionsprior to drilling

  26. INSTALLATION PROCEDURES - COLLECTORS • Carefully place collectors on roof • Place collector against temporary support • Secure collector top support flange to roof

  27. VELUX Solar Water HeatingFlextubes

  28. INSTALLATION PROCEDURES - FLEXTUBES • Identify ZFM flextube connections • Identify pump station end (end with red/blue tabs) • Identify collector end of flextube(end with cone shape) • Attach flextubes to collectors • Connect cone shaped end to collector • Tear off blue tab from flextubeconnected near temperature sensor • Tear off red tab from other flextube

  29. INSTALLATION PROCEDURES - FLEXTUBES • Install ZFR flextube connectors • ZFR flextubes are used between collectors • ZFR flextubes have cone shaped connections both ends • Lift collector 3-4 inches to ease installation • Tighten nuts securely • Insulate all flextube connections

  30. INSTALLATION PROCEDURES - FLEXTUBES • Install collector temperature sensor • Fill sensor port with couplant provided • Insert sensor into sensor port • Route sensor cable along side of collector • Connect sensor cable to extension cable • Route extension cable through roof opening

  31. VELUX Solar Water HeatingFlashing System

  32. INSTALLATION PROCEDURES - FLASHINGS • Secure collector to roof • Use self-tapping screws provided • Carefully remove temporary collector support

  33. INSTALLATION PROCEDURES - FLASHINGS • Open packaging for flashings • Carefully read installation instructions • Install all flashings and shingles • Procedure is same as VELUX Skylights and roof windows

  34. INSTALLATION PROCEDURES - FLASHINGS • Cover collectors using collector packaging • Collectors should remain covered until after the system is fully commissioned

  35. VELUX Solar Water HeatingInstallation ProceduresStorage Tank

  36. INSTALLATION PROCEDURES - TANK • Intall heat exchanger and domestic fittings on tank • Use pipe tape and pipe dope on all fittings • Tighten 2-1/2 turns past hand tight • Install drain valve and T&P relief valve • Use pipe tape and pipe dope on all fittings • Tighten 2-1/2 turns past hand tight • Route flextubes and collector sensor wire to tank • Carefully place storage tank in predetermined location • Allow adequate space for pump station • Allow adequate space for expansion tank

  37. VELUX Solar Water HeatingInstallation ProceduresPump Station

  38. INSTALLATION PROCEDURES – PUMP STATION • Install microbubble air separator to pump station • Must be connected to top left connection on pump station(hot supply from collectors) • Mount pump station to the wall next to tank • Locate flextube with red tab (hot supply from collector) • Cut this flextube to length – to connect to air separator • Connect to air separator (tighten ¼ turn past hand tight) • Locate flextube with blue tab (cold return to collector) • Cut this flextube to length – to connect to top right connection on pump station • Connect to pump station(tighten ¼ turn past hand tight)

  39. INSTALLATION PROCEDURES - PUMP STATION • Install ZFM-002 flextubes between pump station and tank • Cone end of flextubes must be cut-off for this procedure • Connect heat exchanger supply • Connect one flextube to bottom left connection of pump station • Cut to length and connect other end to top heat exchanger connection • Connect heat exchanger return • Connect other flextube to bottom right connection of pump station • Cut to length and connect other end to bottom heat exchanger connection • Secure flextubes to wall with support clamps provided

  40. VELUX Solar Water HeatingInstallation ProceduresTemperature Sensors

  41. INSTALLATION PROCEDURES – TEMP SENSORS • Connect tank temperature sensor to tank • Locate and remove sensor access panel on tank • Remove insulation • Connect sensor to sensor stud with nut provided • Cover sensor with insulation and attach access panel

  42. INSTALLATION PROCEDURES - TEMP SENSORS • Connect collector temperature sensor • Remove front cover from control pad • Connect collector temperature sensor to terminals S1 • Connect tank temperature sensor • Connect tank temperature sensor to terminals S2 • Attach front cover to control pad

  43. VELUX Solar Water HeatingInstallation ProceduresExpansion Tank

  44. INSTALLATION PROCEDURES – EXPANSION TANK • Install expansion tank bracket • Attach one end of flex connector securely to pump station • Adjust flex connector as needed • Mount expansion tank bracket to wall • Install expansion tank • Attach expansion tank to expansion tank bracket • Tighten securely

  45. VELUX Solar Water HeatingInstallation ProceduresBalance of System

  46. INSTALLATION PROCEDURES – B.O.S. • Install mixing valve • Connect “mixed” port to hot water supply to home • Connect “cold” port to cold water supply to home • Connect “hot” port to hot water from solar system

  47. INSTALLATION PROCEDURES - TANK/B.O.S • Insulate all exposed connections and piping

  48. INSTALLATION PROCEDURES - TANK/B.O.S • Connect auxiliary heat • Connect electrical supply to electric element on systems equipped with auxiliary electric heat • Connect boiler supply and return to heat exchanger on systems equipped with auxiliary boiler

  49. VELUX Solar Water Heating Commissioning System

  50. COMMISSIONING SYSTEM • Mix glycol 40% propylene glycol solution • Mix 2 gallons glycol to 3 gallons clean tap water in a clean graduated container • Mix approximately 6.5 gallons solution for a 2 collector system • Mix approximately 10 gallons solution for a 3 collector system • Transfer all solution to a large container

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