Solar Handbook

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10 Industrial Parkway Woburn, MA 01801
Ph. 781-721-0303 Fax 781-721-9119
www.capcosupply.com
REV. 4
Thermal Solar Table Of Contents

VITOSOL Installation Guide 1-12

VITOSOL Flat Plate Installation Instructions 13-34

Viessmann Solar Packages 35-36

Caleffi idronics 37-90

Caleffi 2-80 Solar Package 91

2-Panel 80 Gal. Tank Simulation 92-96

Caleffi 3-120 Solar Package 97

3-Panel 120 Gal. Tank Simulation 98-102

Solar Project Check List 103-104

Sizing a Solar System for DHW 105-106

SRCC Ratings 107-110

Solar Costs with Incentives Example 111

Cost Analysis versus Oil 112

Tax Incentives 113-116

Application Drawings 117-119

So|ar hot vater heating systems

F|at p|ate and vacuum tube so|ar co||ectors
lnsta||ation Cuide
2
V|essmann So|ar Systems
V|toso| so|ar co||ectors
F|at |ate or vacuum tube co||ectors?
eIore you beg|n the |nsta||at|on, make sure you have:
A Vitoso| vacuum tube or I|at p|ate co||ector kit
o o
High-grade, veatherprooI insu|ation suitab|e Ior high temperatures
SuIIicient equipment and manpover to get the co||ectors onto the rooI
Detai|ed Viessmann lnsta||ation, Service and Operating lnstructions
Techn|ca| overv|ew
V|toso| 100, SV1
F|at |ate co||ector
V|toso| 300, SP3 2m (20 tubes)
2
Vacuum tube co||ector
V|toso| 300, 3m 30 (30 tubes)
2
Vacuum tube co||ector
Gross area 27.2 It
2
/2.53 m
2
30.5 It
2
/2.83 m
2
45.6 It
2
/4.24 m
2
D|mens|ons (in)
(WxHxD)
42 x 94 x 3.5 55 x 78! x 4 83 x 78! x 4
We|ght (|bs) 99 99 150
A
B
C
D
D1
E
F
C
H
H1
H2
So|ar pane| and rooI mounting hardvare
F|exib|e connection pipes (optiona|)
Fast air vent c/v shut-oII va|ve
So|ar-Divicon pumping station
Pressure re|ieI va|ve and pressure gauge
Expansion tank
Air separator
System Ii|| maniIo|d
So|ar contro|
So|ar pane| temperature sensor
So|ar storage tank temperature sensor
NoIe: 3o/ar sIorage Iank can a/so be a sing/e-
coi/ Iank Ior preheaI / reIroIiI sysIems
Viessmann is a vor|d |eader in hot vater heating techno|ogy and renevab|e energy systems vith over 30 years oI
experience in so|ar hot vater heating. Severa| thousand Viessmann so|ar co||ectors have been insta||ed in North America
since their introduction in 2000.
Vitoso| so|ar co||ectors are made Irom the highest qua|ity materia|s Ior |ong-term re|iabi|ity and exceptiona| eIIiciency. ln
addition to se|ecting the right equipment, it is important that the so|ar co||ectors are insta||ed proIessiona||y, using the
correct Iittings to ensure maximum perIormance and saIety.
F|at p|ate co||ectors are oIten the most economica| option Ior domestic hot vater (DHW) and indoor poo| heating
systems. They provide exce||ent year-round perIormance, are easy to insta||, and come vith a variety oI mounting
options. Due to their so|id construction, additiona| assistance may be required to |iIt the I|at p|ate co||ector into p|ace.
Vacuum tube co||ectors are idea| Ior co|d, norther|y c|imates. They are oIten the best option Ior combined DHW / space
heating supp|ement systems. The individua| tubes can be rotated Ior optima| a|ignment to the sun. The header and
tubes can be carried onto the rooI as individua| components Ior easy insta||ation.
Copper or stain|ess stee| pipe vork (no p|astic - temperatures can reach 180 C/350 F)
Boi|er
Storage Tank
120v
3
V|essmann So|ar System Packages
V|toso| 100 F|at P|ate Co||ectors
1-p|ate co||ector kit
Suitab|e Ior 1-2 person househo|ds
2-p|ate co||ector kit
V|toso| 300 Vacuum Tube Co||ectors
20-vacuum tube co||ector kit
30-vacuum tube co||ector kit
Sh||ng
The Vitoso| 300 vacuum tube co||ectors are unassemb|ed and shipped in separate boxes.
The vacuum tubes are packaged separate|y in sets oI 10/box.
Pequ|red Comonents
1 x Vitoso| 100, SV1 7188 383
1 x S|oped rooI hardvare Z003 097
1 x Cenera| connection set 7317 005
1 x Sensor ve|| set 7174 993
Pequ|red Comonents
2 x Vitoso| 100, SV1 7188 383
1 x lnterconnection pipes 7317 062
1 x Sensor ve|| set 7174 993
Pequ|red Comonents
1 x Vitoso| 300, SP3 2m
2
SK00251
Pequ|red Comonents
1 x Vitoso| 300, SP3 3m
2
SK00252
IMPOPTANT
Th|s document does not re|ace the manuIacturer's |nsta||at|on |nstruct|ons. P|ease read th|s gu|de |n con[unct|on w|th
the |nsta||at|on |nstruct|ons su||ed w|th the roduct. Insta|| necessary ||It|ng equ|ment and com|y w|th a|| a||cab|e,
|oca| hea|th and saIety regu|at|ons. Incorrect|y |nsta||ed so|ar co||ectors can be dangerous!
Viessmann current|y oIIers severa| so|ar co||ector combinations to suit the needs oI diIIerent DHW |oads. Viessmann
a|so provides custom sizing Ior various |oads, using the Viessmann ESOP So|ar Simu|ation SoItvare. P|ease ca|| your |oca|
Viessmann sa|es representative or so|ar distributor Ior more inIormation.
The maniIo|d header and a|uminum mounting rai|s vith tube co||ectors are packaged together.
4
A So|ar-D|v|con DN-20
Part No. 7134 799
C
Bui|t into So|ar-Divicon
D
Part No. 7143 535
E
Part No. 7134 450
c/v 2 x 10K sensors
TyIocor-HTL So|ar F|||
Part No. 7316 098
rass E|bow c/w sensor we||
Part No. 7175 213
Insta||at|on F|tt|ng Set
Part No. 7134 449
Comonents Pequ|red Ior Indoor Insta||at|on
E Basic so|ar contro| CL30
A So|ar-Divicon pumping station
B
C
Automatic air vent
System Ii|| maniIo|d
D Expansion tank
Vitoce||
Sing|e- or dua|-coi|
DHW storage tank
Automat|c A|r Vent
System F||| Man|Io|d
Exans|on Tank 25 Ltr.
So|ar Contro| GL30
The main components required Ior indoor insta||ation are shovn be|ov. P|ease make sure to have a|| the parts
|isted beIore starting the insta||ation.
A|so avai|ab|e in DN-25
mode| c/v high head pump
Bui|t into So|ar-Divicon
c/v manua| key and hose
Pequires " copper Iitting
adaptor supp|ied in
lnsta||ation Fittings Set.
Avai|ab|e in 5 tank sizes
Ior diIIerent system needs.
5.3 USC / 20 Ltr. Jug
Non-toxic propy|ene g|yco| / vater
premixed so|ar I|uid
Do not add water
Shipped separate|y Ior Vitoce||
300 tanks
lnc|uded vith Vitoce||-B 100 tanks
Contains metric to " copper
adaptors and Iittings to connect a||
so|ar components
1 set required per system
5
Mount|ng Pa||s and
Mount|ng P|ates
1 Co||ector K|t
Part No. 7188 479
2 Co||ector K|t
Part No. 7188 480
T-o|ts Accessor|es Pack
1 Co||ector K|t
Part No. 7175 265 (pkg oI 4)
2 Co||ector K|t
Part No. 7179 234 (pkg oI 6)
Genera| Connect|on Set
Part No. 7317 005
Interconnect|on P|es
Part No. 7317 062
Co||ector Mount|ng C||s c/w T-bo|ts
1 Co||ector K|t
Part No. 7194 423 (pkg oI 4)
2 Co||ector K|t
Part No. 7194 424 (pkg oI 6)
Sensor We|| Set
Part No. 7147 993
PooI rackets
1 Co||ector K|t
Part No. 7181 515 x 4
2 Co||ector K|t
Part No. 7181 515 x 6
F|ex|b|e Sta|n|ess Stee| P||ng
Part No. 7316 252
Comonents Pequ|red Ior Outdoor Insta||at|on
V|toso| 100 F|at P|ate Co||ector
Mount|ng Hardware K|ts Ior S|oed PooIs
1 Co||ector Kit Part No. Z003 097
2 Co||ector Kit Part No. Z003 098
Co||ector Hydrau||c Connect|ons Comonents
V|toso| 100, SV1
Part No. 7188 383
A Vitoso| 100
B PooI bracket
C
A|uminum
mounting rai|
MounIing kiIs Ior 3 Io 1O co//ecIors and I/aI rooI rack hardvare are a/so avai/ab/e. ConIacI a Viessmann so/ar
disIribuIor Ior deIai/s.
Co||ector mounting hardvare is so|d in kits containing the individua| pieces shovn be|ov. Make sure to have a||
necessary components beIore starting the insta||ation.
Pequires 2 x " copper
adaptors, supp|ied in lnsta||ation
Fittings Set.
1 set required per co||ector array.
Pequired Ior connecting 2
p|ates together (set oI 2)
Optiona|, not inc|uded vith system
packages.
Pre-insu|ated, I|exib|e stain|ess stee|
piping c/v compression coup|ings
" x 3.2 It.
6
Mount|ng Pa||s
Part No. 7186 256
T-o|ts Accessor|es Pack
Part No. 7175 265 (pkg oI 4)
Fasten|ng Set
Part No. 7188 864
PooI rackets
Part No. 7181 515 x 4
Genera| Connect|on Set
Part No. 7188 914
Interconnect|on P|es
Part No. 7188 920
F|ex|b|e Sta|n|ess Stee| P||ng
Part No. 7316 252
Comonents Pequ|red Ior Outdoor Insta||at|on (Cont|nued)
V|toso| 300 Vacuum Tube Co||ector
Mount|ng Hardware K|t Ior S|oed PooIs
Co||ector Hydrau||c Connect|ons Comonents
20-tube co||ector: Part No. SK00251
30-tube co||ector: Part No. SK00252
V|toso| 300, SP3
A ManiIo|d
B PooI bracket
C Tubes
D A|uminum
mounting rai|s
E Tube ho|ders
Consists oI 3 boxes
ManiIo|d. Part No. 7188 860
2 x Vacuum tubes (box oI 10). Part No. 7194 178
Consists oI 4 boxes
ManiIo|d. Part No. 7188 861
3 x Vacuum tubes (box oI 10). Part No. 7194 178
Co||ector Kit - Part No. Z003 335
Co||ector mounting hardvare is so|d in kits containing the individua| pieces shovn be|ov. Make sure to have a||
necessary components beIore starting the insta||ation.
Pequires 2 x " copper
adaptors, supp|ied in
lnsta||ation Fittings Set.
1 set required per co||ector.
Pequired Ior connecting 2
co||ectors together (set oI 2)
c/v insu|ation
Optiona|, not inc|uded vith system
packages.
Pre-insu|ated, I|exib|e stain|ess
stee| piping c/v compression
coup|ings. " x 3.2 It.
7
Outdoor Insta||at|on Stes
Hea|th and SaIety
F|at P|ate and Vacuum Tube Co||ector Insta||at|on
(Stes 1 5)
PooI racket Mount|ng Screws
Part No. 7317 114
Pos|t|on|ng
1. Set up necessary |iIting and
saIety equipment.
2. Measure rooI, mark co||ector
area, and |ocate rooI joists.
3. Attach rooI brackets to rooI
joists vith mounting screvs.
4. Ensure mounting screvs
penetrate joists 2.5".
5. Sea| a|| rooI penetrations
vith suitab|e sea|ant / cau|king.
/or I/aI p/aIe insIa//aIion
conIinue on nexI page.
/or vacuum Iube sysIems
Iurn Io page 1O.
Washer
Mounting
bracket
Si|icone
sea|ant
Lag bo|t
Min.
6.3 cm/
2.5 in.
For a|| insta||ations (vacuum tube and I|at p|ate co||ectors) Io||ov the Iirst Iive steps be|ov, then continue vith the
re|evant section. lndoor insta||ation and commissioning are detai|ed on page 11.
At a|| stages oI the insta||ation be sure to abide by app|icab|e, |oca| hea|th and saIety regu|ations, and insta|| a||
necessary |iIting and saIety equipment prior to insta||ation. Pemember that the I|at p|ate co||ectors veigh 99 |bs each!
ln addition to Iinding the best
position to capture the suns
energy, p|ace the co||ectors vhere
you can pass the piping through
the rooI easi|y Ior interna|
connection.
80mm / 3.1"
Longer screvs may be required
Ior some rooIs.
lnc|uded vith a|| mounting
hardvare kits.
8
Outdoor Insta||at|on Stes (Cont|nued)
V|toso| 100 F|at P|ate Co||ector Insta||at|on
(Stes 6-1B)
6. Fix a|uminum rai|s to brackets. 7. Measure and position mounting
p|ates onto a|uminum rai|s.
8. Hoist I|at p|ate co||ectors onto
rooI, in accordance vith Hea|th
and SaIety regu|ations.
9. Position I|at p|ate co||ector on
mounting p|ates.
10. Secure I|at p|ate co||ector to
a|uminum rai| vith c|amping
11. lnsert brass p|ug Iittings into
the I|at p|ate co||ector and
secure vith stain|ess stee|
L|It|ng stras
Avai|ab|e as an accessory
Part No. 7188 503
IMPOPTANT
c|ip.
bo|t.
Vitoso| I|at p|ate co||ectors are
designed Ior quick and easy
insta||ation. Once the a|uminum
rai|s and mounting p|ates are in
p|ace, the p|ates vi|| be a|igned
correct|y and Iirm|y insta||ed.
This Irees up both oI your
hands to Iasten the co||ectors
vith the c|amps.
Brass connection Iittings vith
O-rings simp|iIy I|uid
connections and e|iminate
|eaks. Use the supp|ied
|ubricant to ease insta||ation.
The I|at |ate co||ectors are
su||ed w|th reI|ect|ve covers.
Leave these |n |ace unt|| the
ent|re system |nsta||at|on |s
com|ete.
9
12. For a 2-p|ate insta||ation,
insert I|exib|e connection pipe
betveen p|ates, (use supp|ied
grease).
13. S|ide p|ate in and c|amp both
co||ectors to rai|. Ensure
I|exib|e connector stays
centered.
14. lnsert supp|y and return
Iittings into top and bottom
connections oI p|ate.
15. Secure brass Iittings vith
stain|ess stee| c|amps.
16. Connect T-piece vith sensor
ve||. Use copper adaptors to
connect to supp|y and return
pipes.
17. Pass supp|y and return
pipe-vork through suitab|e
rooI I|ashings.
18. Externa| insta||ation is nov
comp|ete.
Turn Io page 11 Ior indoor
connecIions and
commissioning.
10
V|toso| 300 Vacuum Tube Co||ector Insta||at|on
(Stes 6-16)
8. Attach tube holders to rails.
14. nsert tubes into header by
spreading apart header springs.
Rotate towards south if required.
11. For two collectors insert
interconnection pipes, clip in
place and insulate.
6. Attach rails to roof brackets.
13. Remove top cover of header.
9. nsert U-bend pipe to header and
clip in place. nstall insulated cover.
10. nsert brass supply and
return connection pipes, and clip
in place.
12. Pass supply and return
pipework and sensor wire
through roof flashings.
16. External installation is now
complete.
7. Attach header to rails.
15. Secure tubes with rubber
clips.
o
IMPOPTANT
Vitoso| vacuum tube co||ectors are
designed Ior easy insta||ation. lI
necessary, rotate the individua| tubes
tovards the south (25 max.) Ior
best perIormance.
Do not |nsta|| vacuum tubes unt|| a||
I|u|d connect|ons are com|ete and
system |s I|||ed and deaerated. Insta||
the vacuum tubes |n the even|ng or on
a c|oudy day. The t|s get very hot!
11
Indoor Insta||at|on Stes
A. Connect supp|y and return piping
to the So|ar-Divicon pumping
station.
E. Set the system pressure.
Connect PPV discharge pipe to
an overI|ov container.
D. Check and adjust nitrogen
pressure in the expansion tank.
B. Connect So|ar-Divicon to the
so|ar storage tank. lnsta||
expansion tank (ensure
connection pipe is on top).
F. Check and adjust I|ov rate.
Thorough|y I|ush system to
remove debris.
Fi|| system vith so|ar I|uid.
Vent a|| air.
Set system pressure.
Adjust expansion tank pressure.
Set system I|ov rate.
Adjust contro| settings.
Once the outdoor insta||ation is
comp|ete, Iit the air vent at the high
point in the rooI space, then
comp|ete steps A-F. (So|ar-Divicon
not exact|y as shovn).
Comm|ss|on|ng
Correct initia| commissioning
ensures |ong, troub|e-Iree so|ar
system operation. Once everything
is connected and vired comp|ete
the Io||oving.
P|ease reIer to the Vitoso| Service
and Operating lnstructions (Part No.
5285 771) Ior detai|ed
commissioning inIormation, system
pressure settings, and system I|ov
rate settings Ior a|| Vitoso| products.
C. Pump TyIocor so|ar I|uid into system using a I|oor standing or hand Ii|| pump.
Thorough|y vent air Irom system.
Techn|ca| Suort
P|ease contact us iI you require advice on
se|ecting, positioning or insta||ing your
Viessmann so|ar products. To |earn more
about Vitoso| so|ar co||ectors or other
Viessmann heating systems, join us Ior a
Viessmann Academy training seminar!
Brochures and technica| documents
re|ating to design, insta||ation, start-up
and service can be dovn|oaded Irom our
vebsite.
North Amer|can and
Canad|an Head OII|ce
Viessmann ManuIacturing
Company lnc.
Water|oo, ON Canada
Te|. (519) 885-6300
Fax (519) 885-0887
vvv.viessmann.ca
U.S. Head OII|ce
Viessmann ManuIacturing
Company (U.S.) lnc.
Warvick, Pl U.S.A.
Te|. (401) 732-0667
Fax (401) 732-0590
vvv.viessmann-us.com
V|essmann Sa|es Center
Lang|ey, BC Canada (604) 533-9445
V|essmann Sa|es OII|ces
Water|oo, ON Canada (226) 338-7038
Toronto, ON Canada (416) 657-4333
Stoney Creek, ON Canada (905) 664-4426
Peno, NV U.S.A. (775) 849-0725
Technica| inIormation subject to change vithout notice.
535 2182 v1.0 10/07 Printed in Cermany
Installation Instructions
for use by heating contractor
Vitosol-F
Models SV, SH
Flat plate solar collectors for sloped roofs, flat roofs
and freestanding installation
VITOSOL-F
Read and save these instructions
for future reference.
IMPORTANT
Vitosol 100-F
Model SV1
Vitosol 200-F
Model SV2
Vitosol 100-F
Model SH1
Vitosol 200-F
Model SH2
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5285 710 v2.0 03/2008
Notes on Installation
H The entire solar heating system
should be installed in accordance with
the accepted rules of technology,
observing all relevant accident
prevention regulations.
H Employ suitable safety measures to
prevent falls, falling objects and roof
damage due to insufficient load
bearing capacity, e.g. by means of
scaffolding, ladders, cable ties etc.
H The collectors must be securely
mounted so that the mountings can
withstand intense wind conditions.
H Use only stainless steel screws and
bolts when fastening mounting
brackets or frames.
H Although the glass collectors surfaces
are hail-proof, Viessmann recomends
users to include storm coverage in
their building insurance. Our warranty
does not cover storm related damage.
H The collectors should, as far as
possible, be oriented towards the
south. Solar system performance
drops off significantly if collectors
face more than 50 off south.
H The collectors should be mounted
level, or with a slight ascending slope
(approx. / 10mm) towards the
high point of the piping, so that
complete venting is assured.
H An air vent valve (c/w shut-off valve)
should be installed at the highest
point of the solar heating system.
H Filling the solar heating system with
Viessmann heat transfer fluid
Tyfocor-HTL is highly
recommended. Tyfocor-HTL is
supplied pre-mixed and water must
not be added.
Other heat transfer fluids may be
suitable if they have the same
temperature range (-35C to 170C)
and are non-toxic.
H The piping inside and outside the
building should be insulated to avoid
heat loss. Use only high temperature
resistant pipe insulation.
Collector Location
Please refer to the Vitosol System Design Guidelines, Part No. 5167 156 for detailed information on the optimum
alignment and inclination of solar collectors.
Optimum alignment and inclination
The solar collector provides the highest
solar yield over an annual average when
facing south with an inclination of
approx. 30 to 45 degrees
to the horizontal plane. However, the
installation of a solar heating system is
still viable even when the installation
deviates quite significantly from the
above (south-westerly to south-easterly
alignment, 25 to 55 degrees
inclination).
5
2
8
5
7
1
0
v
2
.
0
Use only Viessmann supplied
mounting clips and mounting
hardware. Never drill or screw
directly into collector side frames.
CAUTION
Pool water or potable water cannot
be pumped directly through the
Vitosol collectors. Damage to
collectors caused by corrosion, freeze
damage, or scaling will void warranty.
CAUTION
Installation on Sloped Roofs
8
Overview of System Components
Sloped roof mounting hardware
Roof bracket
Clamping bracket
Joining element for mounting rail
Mounting rail, 46 / 1175 mm or
91 / 2330 mm
Washer, / 8.4 mm
Hexagon screw, M 8 x 10
Mounting plate
Clamping bracket
Locking bolt w/ threaded stud
Hexagon nut
Zinc plated countersunk screws,
3.1 / 80 mm
Hydraulic connection accessories for
one panel array
Interconnection pipes (7248 239)
General Connection Set (7248 240)
consists of:
Pipe clip
Mounting rail end cap
Connecting pipe
Plugs
Compression fitting (elbow),
/ 22 mm, 90
x 4 copper adaptor (part of
installation fitting set 7134 449)
Accessories for one solar heating
system
Sensor Well Set (7174 993)
consists of:
Compression fitting (tee), /
22 mm
Sensor well
Strain relief fitting
Insulation
5
2
8
5
7
1
0
v
2
.
0
Collector, Model SV1 and SV2
Collector, Model SH1 and SH2
1056
1056
2380
2380
Installing the Mounting Frames
Install the panel array level or slightly inclined (approximately / 10 mm) towards the connection side to ensure complete
venting. Always locate an air vent at the highest point in the piping.
Attaching roof brackets on shingled roof
1. The roof brackets should be laid
out as close as possible to the
dimensions shown in the chart on
page 10 for SV collectors, and page
11 for SH collectors.
2. Locate the roof joist by tapping
along the roof to find its general
location (stud finders do not work
well through shingles and roof
sheathing).
3. Pry up the shingles and drill small
pilot holes to locate exact location
of roof joist. If necessary, check
where pilot hole is coming through
roof from inside of attic.
4. Drill pilot holes into center of joist as
shown. Fill the pilot holes and coat
the bottom of roof bracket with
silicone sealant.
5. Attach bracket to roof joist using
appropriate stainless steel lag bolts
or screws (field supplied). Lag
bolt should penetrate the roof joist
at least 2 / 64 mm.
5
2
8
5
7
1
0
v
2
.
0
Correct Incorrect
Source: CANSIA
Source: CANSIA
Lag
bolt
Washer
Mounting
bracket
Silicone
sealant
Minimum
6.3 cm /
2.5 in
Too close
to edge
Drill within
0.2 / 5 mm
of center
The roof bracket must be securely
attached to the roof joist of the
structure. Only use stainless steel
attachment screws.
CAUTION
The 3.1 / 80 mm screws supplied
with the mounting kit may not be
sufficient length for some roof
structures. The installer must ensure
screws will penetrate roof joist
sufficiently, and if not, must provide
longer screws or lag bolts.
CAUTION
10
Installing the Mounting Frames (continued)
Installation dimensions for ten SV collector panels
6. Re-apply shingles, if required, and
ensure all roof penetrations are
thoroughly sealed with silicone
sealant.
7. Continue with mounting rail
installation on page 12.
Dimensions for Model SV collectors
Number 1 2 3 4 5 6 8 10
Dim. A mm
inches
1019
40
1019
40
1019
40
1019
40
1019
40
1019
40
1019
40
1019
40
Dim. B mm
inches
1077
42
1077
42
1077
42
1077
42
1077
42
1077
42
Dim. C mm
inches
39.5
1
68.5
2
79
3
79
3
89.5
3
89.5
3
100
4
110
4
Dim. D
*1
mm
inches
1019
40
A
2038
80
A+A
3115
122
A+B+A
4192
165
A+2xB+A
5269
207
A+3xB+A
6346
249
A+4xB+A
8500
334
A+6xB+A
10654
419
A+8xB+A
Dim. E mm
inches
1098
43
2175
85
3273
128
4350
171
5448
214
6525
256
8700
342
10875
428
Dim. F mm
inches
87.5
3
87.5
3
98
4
98
4
108.5
4
108.5
4
119
4
129.5
5
*1
For static reasons, maintain the stated sequence. Maintain the dimensions A and B as far as possible. Roof brackets may also be offset
if you need to locate roof joist. However, always maintain the overall dimension.
5
2
8
5
7
1
0
v
2
.
0
36 /
923 mm
16 /
154 mm
36 /
923 mm
36 /
923 mm
75 - 82
1900 - 2100 mm
General Information
Notes on Installation
H The entire solar heating system
should be installed in accordance with
the accepted rules of technology,
observing all relevant accident
prevention regulations.
H Employ suitable safety measures to
prevent falls, falling objects and roof
damage due to insufficient load
bearing capacity, e.g. by means of
scaffolding, ladders, cable ties etc.
H The collectors must be securely
mounted so that the mountings can
withstand intense wind conditions.
H Use only stainless steel screws and
bolts when fastening mounting
brackets or frames.
H Although the glass collectors surfaces
are hail-proof, Viessmann recomends
users to include storm coverage in
their building insurance. Our warranty
does not cover storm related damage.
H The collectors should, as far as
possible, be oriented towards the
south. Solar system performance
drops off significantly if collectors
face more than 50 off south.
H The collectors should be mounted
level, or with a slight ascending slope
(approx. / 10mm) towards the
high point of the piping, so that
complete venting is assured.
H An air vent valve (c/w shut-off valve)
should be installed at the highest
point of the solar heating system.
H Filling the solar heating system with
Viessmann heat transfer fluid
Tyfocor-HTL is highly
recommended. Tyfocor-HTL is
supplied pre-mixed and water must
not be added.
Other heat transfer fluids may be
suitable if they have the same
temperature range (-35C to 170C)
and are non-toxic.
H The piping inside and outside the
building should be insulated to avoid
heat loss. Use only high temperature
resistant pipe insulation.
Collector Location
Please refer to the Vitosol System Design Guidelines, Part No. 5167 156 for detailed information on the optimum
alignment and inclination of solar collectors.
Optimum alignment and inclination
The solar collector provides the highest
solar yield over an annual average when
facing south with an inclination of
approx. 30 to 45 degrees
to the horizontal plane. However, the
installation of a solar heating system is
still viable even when the installation
deviates quite significantly from the
above (south-westerly to south-easterly
alignment, 25 to 55 degrees
inclination).
5
2
8
5
7
1
0
v
2
.
0
Use only Viessmann supplied
mounting clips and mounting
hardware. Never drill or screw
directly into collector side frames.
CAUTION
Pool water or potable water cannot
be pumped directly through the
Vitosol collectors. Damage to
collectors caused by corrosion, freeze
damage, or scaling will void warranty.
CAUTION
12
Installing the Mounting Frames (continued)
Installing the mounting rails
Turn the T-slot bolts 90 for all
installation steps.
1. Secure the joining elements into
the mounting rails .
Make sure the mounting rail profile is as
shown. Failure to install the mounting
rail correctly will not allow proper
mounting plate connection.
2. Secure the mounting rails to the roof
bracket. The locking bolt must be
turned 90.
Ensure the upper and lower mounting
rails are square before tightening the
locking bolts. Measure from opposite
corners of the top and bottom rails to
ensure that array is square.
3. Hook the mounting plates into
lower mounting rails according to
the dimensions shown in the
illustrations on pages 10 and 11.
Make sure the mounting plate is
installed with the short bent edge
connecting onto the bottom of the
collector.
5
2
8
5
7
1
0
v
2
.
0
2.
1.
3.
Roof brackets
IMPORTANT
IMPORTANT
IMPORTANT
IMPORTANT
13
Installing the Solar Collectors
Rating plate
(must be on the outside of the
outer collectors)
Interconnecting pipes must be free from
damage and contamination. Lubricate all
plug-in joints (O-ring seals) on the
collectors. Use only the special grease
supplied with the connection set.
On the first and last collector, the side
to which the rating plate is attached
must be on the outside. Ensure that
dimension r is maintained for first and
last collector.
1. Hook the collector into its mounting
plates and lay down onto the
mounting rails .
2. Secure the collector with four
clamping brackets onto the
mounting rails. Tighten the two
outer clamping bolts only. Turn the
grooved bolt 90.
3. Insert the connecting pipe until it
bottoms out inside the collector
connections.
Ensure interconnection pipe is centered
between collector.
Number of collectors 1 2 3 4 5 6 8 10
Dimension r
SV collector
inches
mm
0.8
21
0.8
21
1.2
31.5
1.2
31.5
1.7
42
1.7
42
2.1
52.5
2.5
63
Dimension r
SH collector
inches
mm
0.8
21
1.2
31.5
1.7
42
2.1
52.5
2.5
63
2.9
73.5
3.7
94.5
4.5
115.5
5
2
8
5
7
1
0
v
2
.
0
3.
3.
4x
8.
1.
5.
4.
2.
/
21 mm
Do not stand on the collectors.
CAUTION
IMPORTANT
IMPORTANT
5
2
8
5
7
1
0
v
2
.
0
IMPORTANT
4. Position the second collector as in
step 1.
5. Carefully push the second collector
against the first and insert the
connecting pipes until they are
centered between the collectors.
Distance from the lower edge of the
installed collector should be
/ 21 mm.
6. Install all additional collectors.
Continued on following page.
14
Installing the Solar Collectors (continued)
7. Tighten all clamping brackets.
8. Press the cover caps (part of the
connection set) into the mounting
rails.
9. Remove all labels.
5
2
8
5
7
1
0
v
2
.
0
Arrows on the first and last collector
in a series must point towards the
outside.
CAUTION
Viessmann strongly recommends not
removing the cover foil from the
collectors until after initial start-up in
order to prevent overheating.
CAUTION
Installation on Flat Roofs
or Freestanding Installation
15
Overview of System Components
Legend:
Collector support
Cross brace
Adjustable support, lower part
Adjustable support, upper part (two
part)
Washer, 0.33 / 8.4 mm
Hexagon nut, M8
Hexagon screw, M8 x 20
Support rail (only for flat roofs with
gravel filling)
Retaining plate
Clamping bracket
Connecting brace
Connecting ties
Collector model a b
SV inches
mm
63.8
1620
70.7
1795
SH inches
mm
28.4
722
35.3
897
5
2
8
5
7
1
0
v
2
.
0
3 / 80 mm
4
/
1
0
0
m
m
3
/
7
5
m
m
2 / 50 mm
0.43 /
11 mm
ab
16
Determining the Collector Row Distance z
Legend:
z=Collector row distance
h=Collector height
=Collector angle of inclination
=Solar angle
When installing several collectors in
series, maintain a distance of z.
Example:
Model SV
Toronto is located at approx. 43
latitude.
1. Determine the angle of the sun .
This should be chosen so that the
midday sun December 21 falls on the
second row of collectors without
being obstructed by shadows.
Solar angle :
=90 -23.5-latitude
(23.5 should be accepted as
constant value for northern latitudes)
=90 -23.5-43=23.5
2. Calculating dimension z:
h= 2380 mm (for model SH use
1056 mm)
= 45
= 23.5
z=
2380 sin(180 (45 +23.5))
sin 23.5
z=
2380mm sin111.5
sin23.5
z=5553mm / 218.6
5
2
8
5
7
1
0
v
2
.
0
z
h h
z
=
h
IMPORTANT
17
Installing the Collector Supports and Adjustment of the Angle of Inclination
1. Secure the lower adjustable support
with the cross brace.
2. Secure the upper and lower
adjustable supports in accordance
with the required angle of inclination.
5
2
8
5
7
1
0
v
2
.
0
1.
2.
18
Installing Freestanding Installation (on substructures)
Understructure
1. Mount the understructure (to be
provided on site), e.g. U-channels, at
right angles to and level with the
installation orientation of the
collectors according to the
dimensions shown in the drawing.
2. Position and align the collector
support frames according to the
dimensions shown in the drawing and
secure them to the understructure
using stainless steel bolts (supplied
by others). Use mounting plates as
templates for drilling holes.
3. Secure retaining plates to the
bottom of all collector supports; do
not tighten screws yet.
4. Secure braces onto the retaining
plates between the second and third,
the fourth and fifth supports etc.
Tighten all screws.
5. Secure two connecting ties
diagonally side by side to the
adjustable supports, respectively for
between one and six collectors.
Note:
Only one connecting tie is supplied
for 1 to 6 collectors, two connecting
ties for 7 to 10 collectors.
6. For added stability, attach connecting
ties to each other where they
intersect, using field supplied screw
or bolt.
Collector model X Y
SV inches
mm
23.5
595
18.9
481
SH inches
mm
75.6
1920
18.9
481
8,5
4x
2.
3.
4.
5.
6.
X
Y
5
2
8
5
7
1
0
v
2
.
0
Any welds or connections to the
existing substructure must be
supervised by a professional
structural engineer.
CAUTION
19
Installing Freestanding Installation (on substructures)
Legend
Collector connection
Spacer lip of the connecting brace
Rating plate
7. Position the first collector into the
retaining plates and push right up to
the spacer lip of the connecting
brace.
Install the collector panel so that the
rating plate side of the first and last
collector is on the outside (note
sticker)! If only one collector is to be
installed, connect the piping opposite
the nameplate side.
8. Insert the interconnecting pipes as
far as possible into the collector
connections.
9. Carefully push the next collector up
to the spacer lip and insert the
interconnecting pipes as far as
possible.
between collectors.
10. Click clamping brackets into the
collector edge at the top of all
supports.
11. Secure the connecting brace turned
by 180 to the next brace using
the clamping brackets between the
second and third, the fourth and
fifth supports, etc.
12. Tighten all screws.
5
2
8
5
7
1
0
v
2
.
0
9.1
7.
8.
9.
10.
11.
IMPORTANT
IMPORTANT
IMPORTANT
20
Installing a Freestanding Installation (with weight inserts)
1. Observe the max. load and distance
from the edge of the roof for on-site
substructure.
2. Remove any gravel etc. from the
installation area, cover the surface
with protective building mats or foam
insulation and position concrete slabs
on top of the mats or insulation.
3. Secure the support cross brace (use
as drilling template) onto the
concrete slabs (bolts supplied by
others).
4. Secure retaining plates to the
bottom of all collector supports; do
not yet tighten screws.
5. Secure connecting braces onto
the retaining plates between the
second and third, the fourth and fifth
supports etc.
Tighten all screws.
Collector model X Y
SV inches
mm
23.5
595
18.9
481
SH inches
mm
75.6
1920
18.9
481
3.
4.
5.
4x
Y
X
5
2
8
5
7
1
0
v
2
.
0
A structural engineer must be
consulted to ensure that the existing
roof structure is capable of carrying
the additional weight of the
collectors, insert weights and support
slabs.
CAUTION
21
Installing Freestanding Installation (with weight inserts)
6. Secure the support rails between the
cross braces.
Note:
With an angle of inclination of 25 and
30, the front support rails can be
secured in the center.
7. Apply weights (see tables on
page 23).
8. Secure two connecting ties
diagonally side by side to the
adjustable supports (for up to six
collectors).
9. For added stability, attach connecting
ties to each other where they
intersect, using field supplied screws
or bolts.
8,5
6.
7.
8.
9.
weight insert
5
2
8
5
7
1
0
v
2
.
0
22
Collector connection
Spacer lip
Rating plate
9. Position the first collector into the
retaining plates and push right up to
the spacer lip of the connecting
brace.
Center the distance when fitting only
a single collector.
Install the collector panel so that the
rating plate side of the first and last
collector is on the outside (note
sticker)! If only one collector is to be
installed, connect the piping opposite
the nameplate side.
10. Insert the interconnecting pipes
as far as possible into the collector
connections.
11. Carefully push the next collector up
to the spacer lip and insert the
interconnecting pipes as far as
possible.
between collectors.
12. Click clamping brackets into the
collector edge at the top of all
supports.
13. Secure the connecting brace
turned by 180 to the next brace
using the clamping brackets
between the second and third, the
fourth and fifth supports, etc.
14. Tighten all screws.
5
2
8
5
7
1
0
v
2
.
0
9.
13.
10.
12.
11.
232 mm /
9.1
IMPORTANT
IMPORTANT
IMPORTANT
23
Model SV Secure against slipping
*1
Secure against lifting
*2
Installation height above
ground level
ft.
m
<26
< 8
26 - 66
8 - 20
66 - 328
20 - 100
<26
< 8
26 - 66
8 - 20
66 - 328
20 - 100
Required weight at 25 lbs
*3
kg
694
315
1221
554
1748
793
317
144
670
304
1025
465
kg
1120
508
1856
842
2674
1213
282
128
493
224
762
346
*1
Securing against slipping requires no additional attachment to roof.
*2
Securing against lifting requires additional attachment to roof or structure with wires or cables.
*3
Weights listed are the total of the insert weights and support slabs.
Model SH Secure against slipping
*1
Secure against lifting
*2
Installation height above
ground level
ft.
m
<26
< 8
26 - 66
8 - 20
100<26
< 8
66 - 328
20 -
26 - 66
8 - 20
66 - 328
20 - 100
*3
kg
712
323
1237
561
1764
800
342
155
695
315
1049
476
kg
1085
492
1863
845
2641
1198
291
132
560
254
827
375
*1
Securing against slipping requires no additional attachment to roof.
*2
Securing against lifting requires additional attachment to roof or structure with wires or cables.
*3
Weights listed are the total of the insert weights and support slabs.
Supply and Return Piping Configuration
Vitosol 100
Models SV, SH
Installation of collectors, connection on
alternate sides, max. 12 collectors.
max. 12
B
A
C
28x1
28x1
Installation of collectors, single-sided
connection, max. 10 collectors.
max. 10
B
A
C
28x1
28x1
Supply (hot)
Return
Air vent valve (shut-off type)
5
2
8
5
7
1
0
v
2
.
0
Hydronic Connections
24
Installing the Connection Set and Collector Temperature Sensor
When assembling the locking ring
compression fitting, observe the
following:
H All pipe ends must be square and
deburred.
H Push the union nut and the locking
ring onto the pipe adaptor and lightly
lubricate the threads with oil.
H Push the pipe into the compression
fitting as far as it will go.
H Initially, turn the union nut by hand,
then tighten with an open ended
spanner by another turn.
Do not use annealed copper pipes with
compression fittings.
1.Insert the plug until it bottoms out,
and secure with hose clip .
2.Insert the connection pipes until
they bottom out and secure them with
hose clips .
3.Fit the elbow onto the return
connector at the bottom of the
collector.
4.Fit the tee onto the supply
connector at the top of the collector.
5.Insert the sensor well into the tee
. Hold the tee tightly.
6.Insert the strain relief fitting into the
sensor well.
7.Insert the collector temperature sensor
(supplied with solar controller) until
it bottoms out inside the sensor well,
and secure with strain relief fitting.
8.Insert the 4 copper adaptor into
the compression fittings and make the
connection between the panel array and
the supply and return piping.
9.Install the insulation and secure
with adhesive on its cut faces.
5
2
8
5
7
1
0
v
2
.
0
2.
1.
6.
7.
9.
3. 3. 3. 2.
5.
4.
8.
1.
Hydronic Connections /
Appendix
25
p
Collector Supply and Return Piping
H For the piping connecting the
collectors to the Solar Divicon
pumping station, Viessmann
recommends the use of commercial
copper pipe and bronze fittings, or
non-galvanized steel pipe. PEX or
other plastic pipes are not suitable for
solar collector supply and return
piping.
H Use only high temperature solder or
brazing material when connecting the
copper pipes in the collector piping.
The melting temperature should be
above 450 F / 232 C.
H When laying out the collector array,
ensure that the system can breathe
properly. Do not route pipes above the
collector array.
Refer to the Vitosol System
Design Guidelines for
required flow rates and pipe
sizing parameters for
Vitosol-F collectors.
Solar collector
Solar-Divicon (pumping station)
Collecting tank
Expansion vessel
Solar manual filling pump
System fill manifold valve
Screw-in elbow, comes with
sensor well
Dual-mode DHW tank
I Tank temperature sensor
Air separator
Solar control unit
Flexible connection pipe (optional)
Collector temperature sensor
Fast air vent, c/w shutoff valve
*1
R Return to collector
S Supply from collector
*1
Install at least one air vent valve at the
highest point of the system.
Refer to the Vitosol System
Design Guidelines for more
information on other
installation examples and
system types.
5
2
8
5
7
1
0
v
2
.
0
Do not use galvanized pipes,
galvanized fittings or graphitized
gaskets, or any type of plastic pipes.
CAUTION
Sample System Layout
S
R
T T
T
I
DCW
DHW
The domestic hot water temperature
must be limited to 140F / 60C by
installing a mixing device, e.g. a
thermostatic anti-scald mixing valve.
WARNING
Appendix
26
System Installation
Please refer to the Vitosol
System Design Guidelines
for supplementary notes on
installation examples and
system types.
H The connecting lines must be pressure
and temperature-resistant (observe
the max. shutdown temperature of
the collector).
H To guarantee the satisfactory
operation of the solar heating system,
install the pipes so that complete air
venting is assured.
H At least one fast-acting air vent with
shut-off valve must be installed at the
highest point of the system.
Install an air separator at an acces-
sible point in the piping (e.g. in the
flow of the solar circuit, upstream of
the inlet to the indirect coil of the
domestic hot water tank).
H The system must be equipped with an
expansion tank, safety valve and
circulation pump.
H The Solar-Divicon is equipped with a
safety valve designed for max. 87
psig / 6 bar.
H Use only a diaphragm expansion tank
that is suitable for the application as a
solar expansion tank.
H The expansion tank must be approved
for use in a solar heating system and
must be connected via a heat
insulating loop.
The diaphragms and seals of the
expansion tank and the safety valve
must be suitable for the heat transfer
medium.
Please refer to the Service
Instructions in order to
calculate the inlet pressure
of the diaphragm expansion
vessel.
H Before filling system with solar heat
transfer fluid, thoroughly flush and
clean piping system to remove all dirt,
oils, flux and solder residue.
H Fill the solar heating system with
Viessmann heat transfer medium
Tyfocor-HTL. The Tyfocor-HTL is
supplied as a premixed glycol/water
solution and must not be mixed. The
blow-off and discharge pipes must be
run to an open container capable of
accommodating the total capacity of
the collectors.
H Prior to installing pipe insulation, run a
stranded and protected 18/2 AWG
low voltage sensor wire from the solar
controller to the collector sensor well.
Ensure all wire connections are
soldered and sealed with heat shrink
sleeve connectors (see illustration
below). Cover all wire and
connections with insulation and
jacket.
*1
E.g. HT/Armaflex (temperature resistant up to 175 C) supplied by Armstrong Insulation Products
5
2
8
5
7
1
0
v
2
.
0
Use only red bronze fittings, brass
fittings and copper piping.
Do not use galvanized pipes,
galvanized fittings, graphitized
gaskets or any type of plastic pipe.
CAUTION
Do not carry out any soldering work
at or near the collector.
CAUTION
Components used must be resistant
to the heat transfer medium.
Insulation of external piping must be
resistant to temperature
*1
, UV
radiation and to destruction by birds
(e.g. through the use of metal
sheathing).
CAUTION
Twisted and soldered
Heat shrink sleeve
Heat lightly
Source: CANSIA
Appendix
27
Initial Start-up
Collector
Pressure relief valve
Solar-Divicon
Diaphragm expansion vessel
High-limit safety cut-out
DHW tank
Air vent c/w shut-off
Overflow container
T
Temperature sensors
The collector circuit must be protected
in such a way that at the highest
possible collector temperature
(shutdown temperature) no heat
transfer fluid can escape from the
safety valve, or the air vent.
This is achieved by the appropriate
sizing of the expansion tank and
matching of the system pressure.
Under cold fill conditions, a minimum
static pressure must be maintained. It
can be calculated by the following:
22 psig +0.45 psig x_____h(ft.)
or
1.5 bar + 0.1 x_____h(m)
Commissioning and Adjustment
For commissioning of the solar heating system, refer to the Vitosol Service and Operating Instructions.
5
2
8
5
7
1
0
v
2
.
0
IMPORTANT
The pressure relief valve must be piped
to the overflow container or drain at all
times, since excessively hot fluid can
discharge from the system.
CAUTION
After de-aeration, the air vent c/w
shut-off at top of system must be
closed. To protect the solar system
from overheating in the summer, e.g.
during the holidays, do not shut down.
CAUTION
Viessmann Solar Packages
Single Tank System Package #1
Qty Item # Description
2 7248-395 VISTOL 100-F, FLAT PLATE COLLECTOR
1 7248-239 INTERCONNECTION PIPES BETWEEN COLLECTORS
1 7248-240 GENRAL CONNECTION SET
1 7174-993 SENSOR WELL SET
1 Z003-098 MOUNTING HARDWARE
1 7134-449 INSTALLATION FITTINGS SET
1 7134-799 SOLAR DIVICON PUMPING STATION
1 7134-448 VITOCELL-B 100, STEEL TANK W/ENAMEL FINISH
1 7134-450 BASIC SOLAR CONTROL GL30
1 7248-242 SOLAR EXPANSION TANK
1 7316-789 FAST AIR VENT
1 7316-098 TYFOCOR-HTL
1 NA3540 SOLFLEX CONNECTION PIPING 50' INSULATED
Single Tank System Package #2
1 SK00252 VITOSOL 300-T SP3 SERIES
1 7188-914 VITOSOL 300 GENERAL CONNECTION SET
1 Z003-335 MOUNTING HARDWARE FOR VITOSOL 300
1 7134-448 VITOCELL-B 100, STEEL TANK W/ENAMEL FINISH
1 7316-098 TYFOCOR-HTL
Viessmann Solar Packages
Retrofit Preheat System #1
2 7248-395 VITOSOL 100-F SERIES, FLAT PLATE COLLECTOR
1 7248-239 INTERCONNECTION PIPES VITOSOL 100-F & 200-F
1 7248-240 GENERAL CONNECTION SET VITOSOL 100F & 100F
1 Z003-098 MOUNTING HARDWARE VITOSOL 100
1 7134-799 DIVICON PUMPING STATION
1 7134-162 CVA 79 GAL. DHW TANK
1 7175-213 1" BRASS ELBOW
1 7248-242 SOLARE EXPANSION TANK
1 7316-098 TYFOCOR-HTL SOLAR FILL
Retrofit Preheat System #2
1 SK00252 VITOSOL 300-T SP3 SERIES
1 7188-914 300 GENERAL CONNECTION
1 Z003-335 MOUNTING HARDWARE FOR SITOSOL 300
1 7134-162 CVA 79 GAL. DHW TANK
1 7175-213 1" BRASS ELBOW
3
Solar energy has been used in North American buildings
for decades. The first commercial solar water-heating
device sold in the United States was patented in 1891.
However, widespread use of solar energy in North
America did not transpire because fossil fuels were
readily available and relatively inexpensive throughout the
industrial expansion period following World War II.
This situation quickly changed in the later 1970s following
the Arab oil embargo. At that time, scores of manufacturers
delivered products to the North American market to
capitalize on the fervor to replace conventional energy
sources with renewable energy. Although some of the
solar heating and domestic hot water systems installed
during this time are still functioning today, many have long
since failed, been abandoned or were removed.
The lack of standards and regulation during Americas
first solar era allowed previously untested hardware and
design concepts to quickly enter the market. Government
tax incentives stimulated this trend. The market enjoyed
rapid growth during the early 1980s and then slowly
succumbed to a combination of market forces (expiration
of government tax credits and declining energy prices), as
well as failure of some products to withstand the test of
time. Although a few pockets of activity remained for solar
pool heating and domestic water heating in the sunny
southern markets, widespread national interest in solar
heating was virtually non-existent during the late 1980s
and 1990s as North Americans remained complacent in
the face of low energy prices
TIMES HAVE CHANGED:
Today, North Americans are facing some of the largest
energy price increases in history. Crude oil is selling at
record levels, and energy cost reduction has again become
a high priority for homeowners as well as commercial
building owners. The rapid expansion of solar heating
technology in Europe is quickly making its way to North
America and other areas of the world. Ecological concerns
over global warming, as well as national security issues
associated with oil importation, are also factoring into
energy supply decisions. In short, North America and other
industrialized countries are poised to enter an era where
energy conservation and use of renewable energy sources
will play a major part in their future prosperity.
Here are a few facts that help us realize the potential
impact of renewable energy, now and in the future:
In one second the sun releases more energy than has been
used by mankind since the beginning of recorded history.
In one hour more sunlight falls on the earth than what is
used by the entire population in one year.
In 2006 the renewable energy industries in the United
States generated nearly $40 billion in gross revenue,
while creating nearly 194,000 jobs. *
Source: Management Information Services, Inc. and American Solar Energy Society, 2007.
A major international oil company predicts that renewable
iiiienergy will supply 50% of the world energy by 2040.
Source: NASA
WHAT'S NEW UNDER THE SUN?
4
In the years since the first North American solar era,
manufacturers, both domestic and abroad, have
significantly refined product offering. Modern materials
combined with new production methods now provide
products with long service lives. Improved control systems
provide greater solar collection efficiency. Modular piping
systems speed installation and reduce one-of-a-kind
installations. In short, North Americans are poised for a
new sunrise in the use of solar energy.
This issue of idronics will introduce you to the basic
terminology and system concepts for modern collection
and usage of solar energy. Although solar energy usage
will be briefly discussed in a wide context, the bulk of the
discussion focuses on active solar thermal applications.
CHARACTERISTICS OF SOLAR RADIATION:
Technically, solar radiation is a form of electromagnetic
radiation thats fundamentally similar to radio waves, X-
rays, and even radiant heat emitted by a warm floor.
Although solar energy is produced by nuclear reactions
at the sun, its transmission through space to earth has
nothing to do with nuclear radiation.
What distinguishes solar radiation from other types of
electromagnetic radiation is its wavelength. Approximately
half of the energy in solar radiation lies within wavelengths
that can be sensed by the human eye (e.g., visible light). The
remaining energy lies in the infrared and ultraviolet portion of
the electromagnetic spectrum, as shown in figure 3.
The intensity of solar radiation just outside the earths
atmosphere is approximately 429 Btu/hr/ft
2
. This is more
than 10 times the typical maximum output of a radiant
floor panel. However, the intensity of this radiation is
significantly reduced before it reaches the earths surface
due to absorption by gases, vapors and dust particles
in the atmosphere. Geographic location on the earth, as
well as time of day and time of year, greatly affects the
intensity of solar radiation reaching the earths surface.
Figure 4 shows the intensity of clear day solar radiation
on a south-facing surface sloped at 40 above horizontal
and located at 40 north latitude.
On a clear day, solar radiation is most intense at solar
noon (e.g., that time of day when the sun is highest in the
sky and directly above a polar north/south line).
Before striking the earths atmosphere, solar radiation
travels in straight paths. This is called direct solar
radiation. On a clear day, the majority of solar radiation
striking the earths surface is direct radiation. Because it
Radio Microwave Infrared Visible Ultraviolet X-ray Gamma Ray
10
~3
-7 10
~7
4 10
~7
-10
~8
7 10
~7
-4 10
~7
110
~3
>1
10
~8
10
~12
<10
~12
approximate wavelengths (meters)
The Electromagnetic Sprectrum
solar spectrum ranges from wavelengths of approximately 0.2 to 2.6 micrometers
12 1 2 3 4 5 6 7 11 10 9 8 7 6 5
Clear day solar radiation on 40 sloped surIace
Iacing true south at 40 north latitude
100
200
300
400
5
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solar
noon
sunset sunrise
typical systen operation
(sunner)
typical systen operation
(winter)
0
sunner
winter
Figure 3
Figure 4
5
travels in straight lines, direct radiation is easy
to reflect using polished silver or aluminum
surfaces, or to focus using parabolic mirrors.
If there were no atmosphere, nearly all the
solar radiation reaching the earths surface
would be direct radiation. However, the gas
and vapor molecules in the atmosphere
create a very different scenario. They reflect
a significant portion of the incoming direct
radiation in every direction. The result is called
diffuse solar radiation. Its presence is the
reason we see the sky and objects around us
much differently than how objects are seen in
space where no atmosphere exists. The vast
majority of solar radiation reaching the earths
surface on cloudy days is diffuse radiation.
Because diffuse radiation comes from the
entire sky dome above us, it cannot be easily
focused using mirrors or other reflecting surfaces.
SOLAR ANGLES:
The earth revolves once each day around an axis that
passes through the North and South poles. That axis is
tilted 23.44 with respect to the orbital plane of the earth
around the sun, as shown in figure 5.
The tilt of the earths axis is called the declination angle.
Its the reason that day length changes as the earth makes
its annual orbit around the sun. It also significantly affects
the intensity of solar radiation striking a fixed surface at
any location on earth. We observe this effect as a change
in the suns path across the sky, as seen in figure 6.
The suns position in the sky can be precisely described
using two simultaneously measured angles. The solar
altitude angle is measured from a horizontal surface
up to the center of the sun. The solar azimuth angle is
measured starting from true north (0) in a clockwise
direction (i.e., true south would have a solar azimuth of
180). These angles vary continuously as the sun moves
across the sky. At any given time they are also different
fall equinox
Sept 22/23
spring equinox
March 20/21
summer solstice
June 20/21
winter solstice
December 21/22
Z3.44
declination
angle
Earth's yearly orbit
around the sun
tropic of capicorn
tropic of cancer
N
S
N
S
N
S
N
S
Figure 5
East
West
North South
Mar. 20/21
Sep. 22/23
(equinox)
June 20/21
(summer solstice)
Dec. 21/22
(winter solstice)
ALT
AZI
polar N/S line
AZI = solar azimuth angle
ALT = solar altitude angle
Figure 6
6
Source: National Geophysical Data Center
Figure 7
at different latitudes and longitudes. These angles have
been precisely measured, and when needed, can be
calculated for any time and location on earth. Figure
7 shows a solar path diagram indicating the solar
altitude and azimuth angles for Milwaukee, Wisconsin,
at 42.9 North Latitude. The calculator at the following
Web site can be used to generate a solar path diagram
for any location or time: http://solardata.uoregon.edu/
SunChartProgram.html.
LOCATING TRUE SOUTH:
Solar azimuth angles are always referenced to a true
north line. This is a line at the earths surface thats
exactly parallel with the earths polar axis. Because the
earths magnetic field is not aligned parallel with its polar
axis, there are locations within the continental United
States where the needle of a compass can point as much
as 20 east or west of a true polar North/South line.
The isogonic chart shown in figure 8 shows the deviation of
a magnetic compass needle from true north. For example,
in Boston, the isogonic chart indicates a deviation of
approximately 15.5 west. This implies that true south is
actually 15.5 west of the indicated compass south. In this
case, solar collectors oriented to an uncorrected south
compass direction would actually be facing approximately
15.5 east of true south.
The deviation between compass indicated north/south
and true north/south is called magnetic declination.
It can be precisely determined for any location based
on latitude and longitude using the calculator at the
following Web site: http://www.ngdc.noaa.gov.
The deviation between a true north/south line and
magnetic north/south line varies slightly over time.
This variation is caused by the magnetic properties
of magma flowing deep beneath the earths crust.
Because of this, isogonic charts are typically dated.
Fortunately the deviations over time are relatively minor
and will have essentially insignificant impact on solar
collector installation and subsequent performance.
7
TYPES OF SOLAR THERMAL SYSTEMS:
Any device or combination of components intended
to convert solar radiation into usable heat can be
classified as a solar thermal system. Our discussion of
such systems will be limited to those intended to heat
buildings and/or domestic water.
In a broad context, solar thermal systems
can be classified as either passive or active.
PASSIVE SOLAR THERMAL
SYSTEMS:
Solar thermal systems that collect solar
radiation and deliver it to the heating
load without need of fans or circulators
are called passive systems. A building
with suitable amounts of south-facing
windows combined with internal thermal
mass (concrete walls, floors or water-
filled containers) is itself a passive solar
thermal system. When properly designed,
such a building can reduce the need
for heating energy from conventional
sources by 50% or more. Passive solar
buildings in sunny climates can achieve
even higher fuel savings, all without the
need of fans or circulators.
There are many ways of constructing passive solar
buildings. These include direct gain through windows,
attached sunspaces and trombe walls. One of the
simplest is a direct gain passive building, as illustrated in
figure 9. Light from the low wintertime sun shines through
south-facing windows. Much of the light is instantly
summer
sun
winter
sun
solar energy absorbed
by concrete oor
roof overhang
shades windows
in summer
south-facing
windows
oor releases heat
to room at night
insulated oor slab
Figure 9
Figure 8
8
converted to heat as it strikes the floor and other objects
in the room. Some of this heat immediately raises the
interior air temperature. The rest is absorbed by the
concrete floor slab and other objects in the space. The
absorbed heat is later released into the room as the
interior air temperature cools. Properly proportioned
roof overhangs shade the south-facing windows during
summer to limit solar gains.
There are also passive solar thermal systems for
heating domestic water. An example of one such
system is shown in figure 10.
This system consists of an insulated storage tank
located above a sloped solar collector. The tank may be
located inside or outside. When warmed by incoming
sunlight, water in the solar collector expands. Its
reduced density compared to cooler water in the bottom
of the storage tank creates a gentle circulation effect.
The warmer (lighter) water rises as
the cooler (heavier) water descends.
This is called thermosiphoning, and
it conveys heat from the collector
to the storage tank without need
of a circulator. Thermosiphoning
continues as long as water in the
collector is warmer than water in the
storage tank. As sunlight diminishes,
the collector cools to a temperature
below that of the storage tank, and
the flow stops. As hot water is used
in the building, cool water enters the
storage tank to replace the exiting
hot water. This type of passive water-
heating collector must be drained
if freezing weather is expected. It
is used primarily in climates with
minimal, if any, freezing conditions.
In the system shown, heated water
from the solar storage tank is routed
to the inlet of an electric water heater,
where its temperature is increased
to the desired setpoint (when
necessary). A thermostatic mixing
valve on the outlet of this water
heater prevents high temperature
water from reaching the buildings
fixtures. High water temperatures
are possible in almost any type of
solar water heating system during
prolonged sunny weather, especially
if hot water demand is low.
ACTIVE SOLAR THERMAL SYSTEMS:
Any system that uses a blower or circulator to move air
or a liquid through the solar collector(s) is classified as
an active solar thermal system. As with passive systems,
there are countless variations in design for both space
heating and domestic water heating. These variations all
have strengths and limitations. Several will be discussed
in later sections. However, before discussing systems,
well examine options for one of the most important
components in such systems solar collectors.
Nearly all liquid-based active systems use either a flat
plate collector or evacuated tube collector.
electric DHW tank
cold water
hot water
anti-scald
tempering valve
pressure &
temperature
relief valve
electric
heating
element
s
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t
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insulated
storage
tank

heated space
drain pipe
(min. 1/4"/ft pitch)
cold
water
heated
water
warm water rises
N
.
O
.
N.C.
cool water descends
insulated piping
oat type
air vent
open this
valve to
nanually
drain collector
N
.
O
.
close these
valves before
draining
collector
open to provide
non-solar
water heating
Figure 10
9
FLAT PLATE COLLECTORS:
An example of a flat plate solar collector is shown in
figure 11.
The principal component in this type of collector is the
absorber plate, which is usually an assembly of copper
sheet and copper tubing. The top surface of the absorber
plate is coated with dark colored paint or electroplated
selective surface coating that absorbs the vast majority
of solar radiation striking it. The instant solar radiation
strikes this surface it is converted to thermal energy
(e.g., heat). The copper sheet acts as a wick to conduct
this heat toward the copper tubing that is welded or
otherwise bonded to the sheet. Heat moves across the
copper sheet toward the tubes because the fluid flowing
through the tubes is cooler than the absorber sheet. This
fluid absorbs the heat and carries it out of the collector.
To minimize heat loss, the absorber plate is usually
housed in an enclosure made of aluminum and capable of
withstanding many years of exterior exposure. The sides
and back of this enclosure are insulated with materials
capable of withstanding temperatures in excess of 350F,
which might occur if the collector is exposed to intense
sunlight without fluid flow through its absorber plate.
The upper surface of the enclosure is usually tempered
glass with a low iron oxide content. Tempered glass can
withstand high thermal stress as well as potential impact
from hailstones or other objects. Low iron oxide content
glass minimizes absorption of solar radiation as it passes
through on its way to the absorber plate.
aluminum housing
tempered, low-iron glass
copper sheet absorber plate
(with selective surface coating)
copper tubing welded to copper sheet
high temperature resistant insulation
rear cover sheet
copper "headers"
tempered, low-iron glass
copper "headers"
aluminum housing
selective surface coating
on absorber plate
36" to 48" (typical)
8
4
"

t
o

1
4
4
"

(
t
y
p
i
c
a
l
)
copper header connection
copper tubes
welded to copper sheet
Figure 11
10
EVACUATED TUBE COLLECTORS:
Another type of active solar collector consists of several
glass tubes, each of which has concentric inner and outer
walls. The annular space between these glass tubes has
been evacuated of air and thus acts like a Thermos
bottle. Convective heat transfer between the inner and
outer glass tubes is essentially eliminated. A coated
copper absorber strip with attached tubing is located
within the inner glass tube, as shown in figure 12.
Most current-generation evacuated tubes have a
specialized fluid sealed within the internal copper tubing.
When heated, this fluid changes from liquid to vapor
and rises toward the top of the tube. It then passes into
a small copper capsule that fits tightly into a manifold
assembly at the top of the collector. Heat conducts
though this copper capsule into fluid circulating along
the manifold. The fluid sealed within the evacuated
tubes never contacts the fluid in the manifold. As heat
is released from the fluid within the evacuated tube, it
condenses back to a liquid and flows back to the bottom
of the tube ready to repeat the cycle.
A roof-mounted array of evacuated tube collectors is
shown in figure 13. The manifold can be seen at the top
of the evacuated tubes.
SOLAR COLLECTORS
FOR POOL HEATING:
Pool heating is often one of
the most economically viable
forms of solar energy utiliza-
tion (assuming it displaces
what would otherwise be
conventional fuels used to
heat the pool).
Most solar pool-heating
systems use an unglazed
and uninsulated flat plate
collector. This is acceptable
because the absorber plate
operates very close to if
not lower than ambient
air temperature. Under such
conditions, the absorber plate
loses very little, if any, heat
due to convection, and thus
does not need an enclosure
to prevent heat loss.
The absorber plate is usually
constructed of UV-stabilized
polymers compatible with
pool water chemistry. It
consists of an upper and lower
header with several polymer
insulated copper manifold
evacuated tube envelope
copper absorber strip
concentric copper tubing
selected surface coating
72"-96" (typical)
7
2
"

t
o

8
4
"

(
t
y
p
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c
a
l
)
outer glass tube
inner glass tube
concentric copper heat pipe
copper absorber strip
evacuated annular space
Photo courtesy of Hi Valley Supply
Figure 12
Figure 13
11
tube/plate assemblies thermally fused in between, as
illustrated in figure 14.
Pool-heating collectors have a very high wetted surface
area to compensate for the lower thermal conductivity
of the polymer material versus copper. They are also
designed to accommodate substantially higher flow rates
than would be used with enclosed flat plate or evacuated
tube collectors. These collectors are often mounted on
roofs at relatively low slope angle to optimize summertime
solar gain. Pool-heating collectors are NOT suitable for
domestic water-heating or space-heating applications.
SOLAR COLLECTOR PERFORMANCE:
When designing active solar energy systems, its
important to be able to predict the thermal performance
of solar collectors over a wide range of operating
conditions.
One method of expressing the thermal performance of
a collector is a numerical value for thermal efficiency,
which is the ratio of the instantaneous heat output from
the collector divided by the rate solar radiation strikes
the panel. It is similar to the thermal efficiency of a boiler
in that it states the desired output quantity (collected
heat) as a percentage of the required input quantity
(solar fuel).
The thermal efficiency of a collector changes whenever
the fluid inlet temperature, the ambient air temperature
or the intensity of solar radiation striking it varies. To
account for these factors, the thermal efficiency of a solar
collector is typically expressed graphically, as shown in
figure 15.
Here, the collectors thermal efficiency is plotted on the
vertical axis as a function of a grouping of terms called
the inlet fluid parameter on the horizontal axis.
Where:
Ti= inlet fluid temperature to the collector (F)
Ta = ambient air temperature surrounding the collector (F)
I = solar radiation intensity striking the collector (Btu/hr/ft
2
)
The greater the value of the inlet fluid parameter, the
more severe the conditions under which the collector
operates, and the lower its thermal efficiency.
e
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upper polymer manifold
lower polymer manifold
36" to 48" (typical)
9
6
"

t
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1
4
4
"

(
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p
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Figure 14
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
lnlet uid paraneter (F* hr * sq It/Btu)
C
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(
%
)
p =
T
i
~T
a
( )
I
Figure 15
12
For example, assume water at 160F is supplied to a
flat plate collector having the efficiency line shown in
figure 15. At the same time, the outdoor air temperature
surrounding the collector is 20F, and the solar radiation
striking the collector is 200 Btu/hr/sq. ft. (see figure 4
for examples of solar radiation intensity). The inlet fluid
parameter under these conditions is:
Locating 0.7 on the horizontal axis of figure 15 and
projecting up to the line and over to the vertical axis
indicates the collectors thermal efficiency is 0.16 (e.g.,
16%). Hence, under these operating conditions, only
16% of the solar energy striking the collector is converted
into useful heat output. This is certainly not very high,
especially when compared to the efficiency of hydronic
heat sources such as boilers. The low efficiency is due
to the unfavorable operating conditions (e.g., forcing
the collector to operate with a relatively high inlet fluid
temperature during cold outdoor conditions).
For comparison, assume the same collector operates in
a system where it receives water at 95F under the same
outdoor air temperature and solar radiation conditions.
The inlet fluid parameter is now:
Under these conditions, the collectors
thermal efficiency is 0.43 or 43%.
The significant drop in the inlet fluid
temperature results in much higher
thermal efficiency. This demonstrates
that collector efficiency is extremely
dependent on inlet fluid temperature.
For the best performance, the inlet
fluid temperature to any solar collector
should be kept as low as possible.
The slope and vertical axis intercept of
a solar collectors thermal efficiency line
are established by testing. In the United
States, the standard testing procedure
is ASHRAE Standard 93-77 Methods
of Testing to Determine the Thermal
Performance of Solar Collectors.
The results of such testing are often
published in technical literature for the solar collector.
These performance indices are also used as inputs to
software that simulates the thermal performance of
solar energy systems. Examples of such simulations are
given in later sections.
COMPARING SOLAR COLLECTOR
PERFORMANCE:
Given the different construction of flat plate and evacuated
tube solar collectors, its reasonable to ask which type
is better. There is no simple answer to this question.
The collector with the greatest heat collection potential
depends strongly on the specific application in which the
collector will be used. Beyond thermal performance, the
designer must also weigh factors such as differences in
roof area requirements, maintenance requirements, ability
to shed snow and the type of freeze protection options
available for each type of collector.
From the standpoint of thermal performance only, the
collector with the best performance depends on the
temperature required by the load the system supplies.
This is demonstrated by comparing the three collector
efficiency lines shown in figure 16.
This graph is based on a sampling of performance ratings
for different types of collectors as determined by the SRCC
(Solar Rating and Certification Corporation). It shows that
the collector with the highest thermal efficiency depends
on the value of the inlet fluid parameter, which itself
depends on collector inlet fluid temperature, outdoor air
temperature and solar radiation intensity.
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
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(
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%
)
lnlet uid paraneter
T
i
~T
a
I
J
j
F ft
2
hr
Btu
J
j
unglazed at plate collector
glazed at plate collector
evacuated tube collector
Figure 16
13
If the load is a swimming pool where water temperature
is at or just above ambient air temperature, an unglazed
flat plate collector will provide the highest thermal
efficiency. This is the result of two factors: First, the
incoming solar radiation is not attenuated by passing
through a glazing; secondly, there is very little if any heat
loss from an absorber plate operating close to ambient
air temperature.
However, as the load temperature increases, an unglazed
collector rapidly loses efficiency relative to a glazed/
insulated flat plate collector. At even higher inlet fluid
temperatures, an evacuated tube collector, with its very
low heat loss characteristics, retains higher thermal
efficiency than a glazed flat plate collector.
The only accurate way to compare seasonal performance
of flat plate versus evacuated tube collectors is through
computer simulation based on a specified load in a
specified climate.
Other issues differentiate flat plate and evacuated tube
collectors.
Flat plate collectors typically have a higher ratio of
absorber plate area per square foot of collector enclosure
compared to evacuated tube collectors. This means
evacuated tube collectors usually require more roof area to
accommodate a given amount of absorber plate surface.
Because of their manifold design, most current-
generation evacuated tube collectors must operate with
an antifreeze solution and are not suitable for other types
of systems.
Evacuated tube collectors tend to be more expensive
than flat plate collectors on a dollar per square foot of
absorber plate area basis.
Flat plate collectors cannot produce water temperatures
as high as those possible with evacuated tube collectors.
This may or may not be an issue, depending on intended
application.
Some flat plate collectors can be architecturally
integrated into roofs to minimize their visible profile.
Flat plate collectors sloped at 40 or more shed snow
sooner than evacuated tube collectors mounted at
the same angle. The low heat loss of evacuated tube
collectors increases the time needed to warm snow to
the point where it will slide from the tubes.
STAGNATION CONDITIONS:
There are times when solar collectors will likely be
exposed to bright sun conditions without any fluid flow.
Such a situation could result from a control or circulator
malfunction, the storage tank reaching its high temperature
limit or a power outage. Under such conditions, the
collector is said to be stagnating and can reach internal
temperatures of 350F or more. Such temperatures can
cause failure of PEX or PEX-AL-PEX tubing and thus rule
out its use between the collector array and mechanical
room in most active solar systems. Prolonged stagnation
can also cause a chemical breakdown of glycol-based
antifreeze solutions. Some active solar energy systems
are equipped with heat dump subsystems that limit
temperatures under stagnation conditions.
TYPES OF ACTIVE SOLAR THERMAL SYSTEMS:
There are several ways to combine solar collectors with
other hardware to build active solar energy systems.
Designs differ with the intended use of collected heat
as well as methods of freeze protection. This section
discusses the basic system concepts used for domestic
water heating and space heating. In some cases, both of
these loads can be supplied from a single system.
A simplified schematic for an active solar thermal system
is shown in figure 17.
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)
heating
load
thermal storage tank
collector
circulator
check
valve
load
circulator
differential
temperature
controller
storage
temperature
sensor
collector
temperature
sensor
c
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lle
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t
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R
E
T
U
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N

p
ip
e
collector
SUPPLY
pipe
expansion
tank
pressure
gauge
pressure
relief valve
warnest water "stratiIes"
to top of tank
air vent
air vent
w/ shut off
valve
Figure 17
Flat plate collectors typically have a higher ratio of
absorber plate area per square foot of collector enclosure
compared to evacuated tube collectors. This means
evacuated tube collectors usually require more roof area to
accommodate a given amount of absorber plate surface.
Because of thei r mani fol d desi gn, most current-
generation evacuated tube collectors must operate with
an antifreeze solution and are not suitable for other types
of systems.
Evacuated tube collectors tend to be more expensive
than flat plate collectors on a dollar per square foot of
absorber plate area basis.
Flat plate collectors cannot produce water temperatures
as high as those possible with evacuated tube collectors.
This may or may not be an issue, depending on intended
application.
Some flat plate collectors can be architecturally
integrated into roofs to minimize their visible profile.
Flat plate collectors sloped at 40 or more shed snow
sooner than evacuated tube collectors mounted at the
same angle. The low heat loss of evacuated tube
collectors increases the time needed to warm snow to
the point where it will slide from the tubes.
14
The collector array (one or more collectors) is piped to
a thermal storage tank. The collector circulator moves
water from near the bottom of the storage tank up through
the collector array and back to the tank. This circulator
operates whenever the collector array is warmer than the
storage tank. A check valve in the collector supply piping
prevents reverse flow, which would otherwise occur
when the collector temperature drops below the storage
tank temperature. Another circulator is shown to move
warm water from the top of the storage tank through the
heating load as required.
Although simple in concept, this system as shown
would seldom be suitable for a specific application. It
doesnt contain any method of freeze protection, nor
does it provide a way to supply heat to the load when
the water in the storage tank is too cool to be used
by that load. Both of these issues are critical to proper
system operation and are addressed through the further
refinement and detailing to be discussed.
CONTROLLING THE SOLAR COLLECTION
PROCESS:
Most active solar energy collection systems are controlled
by a differential temperature controller. This device monitors
two temperature sensors. One is located within or very
near the outlet of a solar collector. The other is mounted
in contact with the metal wall of the storage tank, as
shown in figure 17. The differential temperature controller
constantly measures the temperature difference between
these sensors. When the collector sensor temperature
exceeds the storage tank temperature by a specific value
(typically 3 to 10F) the controller turns on the collector
circulator. When the collector temperature is very close
to, equal to, or below the storage tank temperature, the
controller turns off the collector circulator.
This control logic allows collection of solar energy
whenever possible. On a given day, the differential
temperature controller may turn the collector circulator
on and off several times, depending on how the collector
temperature is affected by cloud cover, wind or shading.
Some differential temperature controllers also operate
the circulator at speeds proportional to the differential
temperature between the collectors and storage tank.
As this differential rises, the collector circulator speed
increases, and vice versa. This technique reduces the
electrical consumption of the circulator under partial sun
conditions.
As with any temperature sensor, it is vital that the sensor
housing remain in tight contact with the surface it is
measuring. The portion of the sensor not in contact with
the surface being measured should be protected by
insulation to prevent readings from being affected by
surrounding air.
FREEZE PROTECTION METHODS:
Solar collectors containing water can be severely damage
by a single night of sub-freezing temperatures. This can
occur even in traditionally warm locations like Florida,
Texas and Arizona. All active solar energy systems
installed in the United States and Canada should employ
some method of freeze protection.
Although manually draining the collector and any exposed
piping when freezing conditions are imminent will prevent
damage, this method relies on human intervention and
is only suitable for climates where freezing conditions
are extremely rare. All other locations should use a
system designed for automatic and unattended freeze
protection.
pressure
relief valve
expansion
tank
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heating
load
collector
circulator
internal
heat
exchanger
load
circulator
air
separator
this circuit operates
with antifreeze solution
check
valve
Ill / purge
valves
air vent
w/ shut oII
valve
Figure 18
15
One common method of freeze protection is to design
the collector-to-storage circuit as a closed loop and
operate it with a suitable antifreeze solution. This solution
passes through the collector array and then through a
heat exchanger that transfers the collected heat to water
in the storage tank. The heat exchanger may be located
within the storage tank as shown in figure 18, or outside
the tank as shown in figure 19.
Systems with storage tanks having internal heat
exchangers only require one collector circulator. Those
with external heat exchangers require two circulators, and
thus have slightly higher electrical power consumption.
Both types of heat exchangers should be generously
sized to maximize system efficiency. The larger the heat
exchanger, and the greater its effectiveness, the cooler
the collector array can operate relative to the storage
tank temperature. As previously discussed, the cooler the
collector operates, the higher its efficiency.
CLOSED-LOOP DRAINBACK
SYSTEMS:
An alternative method of freeze
protection is to drain all water from
the collector array and exposed
piping whenever the system is
not collecting solar energy. This is
called a drainback system. It relies
on gravity along with properly
pitched piping and collectors to
quickly drain water whenever the
collector circulator turns off. A
schematic for a typical closed-
loop drainback system is shown
in figure 20.
In a drainback system, the collector
circuit operates with water, and is
initially filled to a predetermined
level. That level is part way up
the height of the drainback tank,
as seen in figure 20. When the
collector circulator is off, all piping
above this water level, as well as the
collector array, is filled with air, and
thus not subject to damage when
temperatures drop below freezing.
All piping and components below
the fill level are filled with water.
When the collector circulator turns
on, water is pushed up the collector
supply piping and into the collector
array. This water pushes air ahead of it. Eventually the
rising water reaches the top of the collector array and
continues flowing down the return piping toward the
drainback tank. Again, air is pushed ahead of the water
or entrained with the flow, and eventually returned to the
drainback tank. This process causes a slight drop in the
water level within the drainback tank as water replaces air
in the collectors and piping.
This operation continues as long as the collector circulator
is running. As soon as this circulator shuts off, air from the
top of the drainback tank rises up the collector return
piping and into the collector array as water returns to the
drainback tank. The majority of the water in the collector
array usually siphons backward and returns downward
into the storage tank. Since the storage tank is filled with
water, the level within the drainback tank rises back to its
original level.
pressure
relief valve
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(w/ check)
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Ill / purge
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heating
load
air
separator
air vent
w/ shut off
valve
Figure 19
16
The collector circuit is a closed loop, as is the remainder
of the hydronic system shown. The initial charge of water
and air are thus sealed within the system and circulated
over and over through the collectors and piping, as well
as other parts of the system. The air within the drainback
tank can be at a slight positive pressure relative to the
atmosphere to ensure the remainder of the system
operates under sufficient pressure. In some systems, the
air space in the drainback tank can be sized to serve as
the expansion volume for the system and thus eliminate
the need for a traditional expansion tank.
No air vents are placed at the top of the collector array
in a drainback system. No automatic make-up water
system or air-separating device can remain active in this
type of system past an initial filling condition. Doing so
would eventually replace the air in the system with make-
up water and thus water log the system. This would
prevent drainage and eventually cause severe damage
due to freezing.
It is critically important that any piping or other
components located outside heated space are
pitched a minimum of 1/4 inch per foot to allow
efficient drainage. The collector array may also
have to be pitched slightly to ensure complete
drainage (verify with collector manufacturer).
The drainback system concept shown in figure
20 eliminates the need for heat exchangers and
antifreeze. This allows the collectors to operate
at the lowest possible temperature and thus
optimizes their efficiency.
However, drainback systems typically require
more electrical energy to maintain flow than do
closed-loop antifreeze-based systems. This is
a result of the lift requirement to push water
up into the collector array and piping each
time the circulator starts. In some systems, two
circulators in series may be needed to provide
the needed lift.
The collector return piping should be sized to
ensure a flow velocity no lower than two feet
per second. This ensures that air bubbles will
be entrained and returned to the drainback tank
when the collector circuit begins operation. It
also allows a siphon effect to be established over
the top of the collector array, which reduces the
lift head present when the collector circulator
first starts. When this is the case, its common
to operate the two series-connected collector
circulators until a siphon is established over the
top of the collector array and the return piping
is completely filled with water. This process,
which may take several minutes, eliminates the initial
lift head and makes the circuit operate as a fluid-filled
closed loop. Once the siphon is established, only one
collector circulator is needed to maintain flow. The other
(downstream) circulator can be turned off to reduce
electrical consumption.
WHICH METHOD OF FREEZE PROTECTION
IS BEST?
Just like the choice between flat plate and evacuated
tube collectors, there is no simple answer to this question.
Listing the strength and limitations of each method can
help steer the designer toward an appropriate choice for
a given application.
Strengths of closed-loop antifreeze systems:
Pitched piping is not required
Low wattage collector circulators can often be used
No drainback tank is required
pressure
relief valve
heating
load
collector
circulator(s)
load
circulator
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lift head
water Ill level
drainback
tank
air space
uid
level
indicator
air vent
w/ service
valve
Figure 20
17
Limitations of closed-loop antifreeze systems:
Requires the added expense of heat exchangers and
antifreeze, as well as additional pressure relief valve,
expansion tank, fill/purge valve
Forces collectors to operate slightly warmer than
storage tank and thus at slightly reduced efficiency
Antifreeze solutions are subject to chemical breakdown
from prolonged stagnation conditions
Chemical Ph of antifreeze solutions should be checked
annually and fluid replacement is necessary when Ph of
solution can no longer be maintained
Strengths of closed-loop drainback systems:
Slightly higher efficiency by operating collectors at
lowest possible temperature
Does not require antifreeze or other components
associated with the use of antifreeze
Drainback tank may serve as expansion tank for
remainder of system
Limitations of closed-loop drainback systems:
Piping or collectors that are not properly pitched
will result in costly hard freeze
Higher pumping power required due to lift head
Must ensure proper f l ui d l evel i n syst em f or
dr ai nback operation
Requires drainback tank placed as high as possible
within the system
As you can see, each approach has its advantages and
disadvantages. The choice between the two tends to
become easier in the context of specific applications.
ACTIVE SOLAR DOMESTIC WATER HEATING:
Some of the most economically viable active solar energy
systems are those used for domestic water heating. They
can be scaled for use in a single-family residence, or
much larger for use in hotels, laundromats, carwashes
or other commercial/industrial buildings with substantial
domestic water-heating requirement. This section exams
many of the options currently available.
SINGLE TANK SYSTEMS:
A schematic for a typical solar domestic water-heating
system based on a single tank with internal heat exchanger
is shown in figure 21.
This arrangement is called a single-tank system. An
internal heat exchanger near the bottom of the tank
provides solar heating (or preheating) of the domestic
water in the tank. The upper portion of the tank is
maintained at a set temperature by a thermostatically
controlled electric heating element.
The warmest water stays near to the top of the tank due
to its lower density. This helps preserve cooler water at
the bottom of the tank to maximize the performance of
the heat exchanger and keep collector temperatures as
low as possible. Cold water entering the tank is directed
near the bottom by the internal dip tube. Temperature
stratification also ensures the hottest water is withdrawn
from the top of the tank.
An anti-scald tempering valve rated to handle incoming
water temperatures of at least 210F ensures that scalding
hot water is not delivered to faucets or other fixtures. This
is a crucially important component in any solar domestic
water-heating system, which can easily produce scalding
hot water during prolonged sunny weather, especially
when demand is low.
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solar storage tank
with internal heat exchanger
and electric heating element
Ill / purge
valves
air
separator
expansion
tank
cold water
hot water
anti-scald
tenpering valve
pressure &
tenperature
relief
valve
electric
heating
element
pressure
relief
valve
air vent
w/ shut oII
valve
Figure 21
18
The solar collector circuit includes circulator, fill/purging
valves, pressure relief valve, pressure gauge, expansion
tank, air separator, check valves, and a high-point float-
type air vent with shutoff valve. Many of these components
provide the same function in the solar collection circuit
as they would in a conventional hydronic system. As
previously mentioned, the check valve prevents reverse
flow when the collectors cool below the temperature of
the storage tank. If such flow were allowed to occur, much
of the heat within the tank would be dissipated through
the collector array at night or under low sun conditions.
The shutoff valve connecting the high-point float vent to
the top of the collector array should be closed as soon
as the collector loop has been deareated. This protects
the vent mechanism against stagnation temperatures.
The shutoff valve can be reopened if the collector loop
is ever drained and refilled.
Another variation of a single-tank system is shown in figure
22. In this case, an external heat exchanger is used along
with an additional circulator between that heat exchanger
and the domestic water tank. This allows a properly sized
existing domestic water storage tank to be retrofitted for
solar heating. The storage tank should provide a minimum
of 1 gallon of storage volume per square foot of collector
area. Tanks that provide 1.5 to 2 gallons of storage per
square foot of collector area will increase the solar energy
collected on an annual basis. Be sure that any existing
hot water tank retrofit in this manner is equipped with
an anti-scald-rated thermostatic mixing valve to protect
against possible high-temperature water produced during
prolonged periods of sunny weather.
Single-tank systems have the advantage of a small
footprint and reduced cost. However, they typically do
not collect as much solar energy on
an annual basis as do systems that
separate the solar storage tank from
the auxiliary heating means (in this
case, the electric heating element).
TWO-TANK SYSTEMS:
Another variation on the closed-loop
antifreeze-based solar water-heating
system is shown in figure 23. This
is called a two-tank system, and its
typical for residential systems where
a conventional water heater is already
installed.
In a two-tank system, cold water first
flows into the solar storage tank. During
sunny weather this tank may provide all
the heating necessary. However, during
less favorable conditions the water may
only be preheated. An example of the
latter is 45F cold water warmed to
85F as it is drawn out of the solar
storage tank. The preheated water then
flows to the inlet port of a conventional
tank-type water heater where heat from
conventional fuel or electricity raises it
to the required delivery temperature.
Its important to remember that, even
when water leaving the solar storage
tank has only been preheated, the
process can represent a substantial
reduction in conventional energy use.
For example, water preheated from
50F to 90F represents about (40/70)
or 57% of the energy input needed to
differential
temperature
controller
existing DHW tank
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pressure
relief
valve
cold water
hot water
anti-scald
tempering valve
pressure &
temperature
relief
valve
electric
heating
element
expansion tank
air vent
w/ shut oII
valve
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Figure 22
19
raise that water to a final temperature of 120F. It takes just
as much heat to raise a gallon of water from 45 to 46F as
it does to raise that water from 119 to 120F. Energy input
at low temperatures is ideally suited to the solar portion of
the system since low operating temperatures significantly
improve collector efficiency.
Two-tank systems typically provide greater solar energy
collection on an annual basis relative to single-tank
systems. This is due to increased storage mass and
the separation of conventional energy input from the
solar storage tank. On the other hand, poorly insulated
storage tanks can all but erase this potential performance
advantage by leaking heat away from the water and
into the surrounding air. In the absence of specific code
requirements, all storage tanks should be insulated to a
minimum of R12 (Fhrft
2
/Btu), and all connecting piping
should be insulated to at least R3 (Fhrft
2
/Btu).
A set of three ball valves is shown on the piping between
the two tanks in figure 23. These allow the solar storage
tank to be completely isolated from the conventional
tank, and the latter to act as the sole water-heating
device should the solar system ever be shut down for
service. Also note that both tanks are equipped with
pressure and temperature relief valves.
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solar storage tank
conventional
tank-type water heater
anti-scald
tempering valve
pressure &
temperature
relief
valve
electric
heating
elements
(shown)
Ill / purge
valves
pressure
relief
valve
N.O.
N.O.
N.C.
expansion
tank
air vent
w/ shut oII
valve
Figure 23
20
BYPASS SYSTEMS:
Still another method of constructing a solar water-heating
system is shown in figure 24. This approach is especially
relevant when modulating tankless water heaters are
used for auxiliary domestic water heating.
In a bypass system, the temperature of the water leaving
the solar storage tank is constantly measured. If the water
is hot enough to go directly to the faucets, the motorized
diverter valve routes it to the anti-scald tempering valve.
If the water requires additional heating, the diverter valve
routes it to the tankless water heater. From there it again
passes to the anti-scald tempering valve before heading
for the faucets.
Isolating ball valves are shown that allow the tankless
water heater to function as the sole domestic water-heating
device if the solar subsystem is turned off for servicing.
This approach has several unique benefits. First, it does
not add heat derived from conventional energy to the solar
storage tank, and thus allows the collectors to operate at the
lowest possible temperature for high efficiency. Secondly, it
does not have the exposed surface area of a second water
storage tank. This, combined with the fact that heated
water does not pass through the tankless heater unless it
is operating, significantly reduces standby heat loss. Finally,
this design significantly reduces the mechanical room
footprint relative to a two-tank system.
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solar storage tank
cold water
hot water
tankless
(modulating)
water heater
motorized
diverting
valve
N.O.
N.O.
N.C.
temperature
setpoint controller
anti-scald
tempering valve
N.O.
pressure
relief valve
expansion
tank
collector
circulator
air
separator
check
valve
Ill / purge
valves
air vent
w/ shut oII
valve
Figure 24
21
SOLAR CIRCULATION STATIONS:
Many solar domestic water-heating systems use the
same or similar components within the solar collection
circuit. To speed installation, some manufacturers offer
preassembled solar circulation stations that combine
the functionality of several independent components into
a single unit. These stations speed installation and ensure
all hardware is correctly sized and located. The concept
of a solar circulation station is shown in figure 25.
ACTIVE SOLAR SPACE HEATING SYSTEMS:
Active solar space heating is possible, both as a singular
application or in combination with other loads such
as domestic water heating and pool heating. Carefully
designed systems can provide years of reliable operation.
Given that solar availability is lowest when space-heating
loads are highest, its unrealistic and uneconomical to
attempt to supply 100% of a space-heating energy
requirement through an active solar energy system.
Active solar space-heating systems are almost always
supplemented with an auxiliary heat source. In many
cases, the transition from solar-derived heat to heat from
conventional fuel is fully automatic and never noticed by
the building occupants. In other systems, the auxiliary
heat source may require manual start-up. An example of
the latter is a wood stove.
There are three principles that need to be observed when
designing solar space-heating systems.
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air vent
w/ shut off
valve
air vent
w/ shut off
valve
Figure 25
22
Principle #1: Space-heating distribution systems that
operate with low-temperature water will result in greater
solar energy utilization.
Principle #2: Conventional energy sources (oil, gas and
electricity) should only be invoked when instantaneously
needed by the load. These fuels should not be converted
to heat prior to being needed and stored in thermal form.
Principle #3: The collector array and all exposed piping
components must be protected against freezing during
non-operational periods.
SYSTEM CONFIGURATIONS:
Hydronic-based solar subsystems can supply heat to either
hydronic or forced-air space heating delivery systems.
Low-temperature hydronic floor heating is an ideal heat
emitter to combine with active solar collectors. Parameters
such as tube spacing, underside insulation and floor
coverings should all be selected to allow the distribution
system to operate at the lowest possible temperature.
An example of an antifreeze-based solar subsystem
supplying a radiant panel distribution system in
combination with a conventional gas-fired boiler is
shown in figure 26.
The solar collection subsystem uses a stainless steel
flat plate heat exchanger between the water in the
storage tank and the antifreeze solution in the collector
circuit. Because the latter is a closed loop, its equipped
with an expansion tank, pressure relief valve and fill/
purging valves. The check valve prevents reverse flow
of collector fluid when the collectors are cooler than
the storage tank. A differential temperature controller
constantly monitors the temperatures of the collectors
and storage tank. Whenever the collector temperature
exceeds the storage temperature by a set amount,
the circulators on both sides of the heat exchanger
are turned on. An optional automatic fluid feeder is
shown. This device constantly monitors pressure in
the collector circuit, and adds premixed glycol solution
when necessary to compensate for minor drops in
pressure. It is usually only needed in larger systems.
VENT
tank circulator (w/ check)
boiler circulator
(w/ check)
closely
spaced
tees
outdoor
temp.
sensor
3-way
motorized
mixing valve
low temperature
radiant panel circuits
outdoor
reset
controller
outdoor
temperature
sensor
differential
temperature
controller
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valves
expansion
tank
pressure
relief
valve
collector
circulator
air vent
w/ shut off
valve
auto uid Ieeder
(optional)
Figure 26
23
An outdoor reset controller monitors the temperature at
the top of the solar storage tank and constantly calculates
the water temperature needed at the supply side of the
distribution system. Upon a call for space heating, this
controller determines if the storage tank temperature is
at or above the currently required supply temperature
for the distribution system. If it is, the tank circulator
is turned on and water from the tank passes through
the air separator and on to the closely spaced tees.
These tees are the interface to a 3-way motorized
mixing valve that supplies the distribution system. This
mixing valve ensures that water from the storage tank,
which may be significantly hotter than required by the
floor circuits, is not sent directly to them without being
blended to the required temperature. The mixing valve
also operates on outdoor reset control.
When there is a call for heat and the storage tank is below
the minimum usable temperature of the distribution
system, the boiler and boiler circulator are turned on.
The storage tank circulator remains off. The 3-way
motorized mixing valve allows the low-temperature
distribution system to operate at the necessary
temperature, while also protecting the conventional
boiler from sustained flue gas condensation.
tank
circulator
(w/ check)
collector
circulator(s)

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lift head
water Ill level
drainback
tank
air space
uid
level
indicator
outdoor
reset
controller
outdoor
temperature
sensor
Collectors and all exposed
piping must pitch minimum
1/4 inch per foot for
proper drainage.
air riser tube
outdoor
temp.
sensor
3-way
motorized
nixing valve
Install drainback tank so static water
level is at least 5 Ieet above other
interior water-Illed systen conponents.
pressure
relief
valve
Figure 27
24
The mixing valve controller must ignore the boiler inlet
temperature sensor when heat is supplied from the solar
storage tank. This sensor is not required if a condensing
boiler is used as the auxiliary heat source. However, the
3-way motorized mixing valve should still be installed to
protect the distribution system against potentially high
storage tank temperatures.
Notice that water heated by the boiler does not circulate
through the storage tank. This allows residual heat
(e.g., heat at temperatures below the minimum usable
temperature of the distribution system) to slowly transfer
from the tank into the surrounding space. The cooler the
storage tank, the sooner the solar collection process can
begin when sunshine returns. When the storage tank
warms back above the minimal usable temperature of
the distribution system, the storage tank automatically
becomes the heat source for the system.
A similar system using drainback freeze protection and a
modulating/condensing boiler is shown in figure 27.
The solar collection subsystem does not use a heat
exchanger or antifreeze. This allows the collectors to
operate at a slightly low water temperature and hence
slightly higher efficiency relative to the antifreeze-
based system.
The drainback tank should be placed as high as
possible within the building to minimize lift head and
minimize drainback volume. The fill level within this tank
should be at least 5 feet higher than other water-filled
components in the system to ensure a minimal static
pressure at these components even with no positive
air pressure in the drainback tank. Pressure within the
system can be further increased by adding air to the
drainback tank using a hand pump or compressor. Be
sure system pressure is high enough to satisfy any
pressure safety switches in the boiler.
The dimensions of the drainback tank must allow it to
accept the drainback volume from the collector array
and exposed piping. In many cases, the dimensions of
this tank can also be selected so it can serve as the
expansion volume for the system. This eliminates the
need for a conventional expansion tank.
As is the case with any hydronic system, there will be
dissolved air in the system water at start-up. As the
waters temperature rises, some of this air will come out of
solution. The goal is to route this air to the upper portion
of the system (collectors and drainback tank) rather than
release it from the system. If the storage tank is capable
of trapping air bubbles above the collector return piping
connection, it should be equipped with a small diameter
air riser line, as shown in figure 27. This allows air at the
top of the tank to rise back to the drainback tank, while
at the same time allowing the majority of water flow from
the collector array to enter the storage tank horizontally
to preserve thermal stratification.
Float-type air vents should be installed at intermediate
high points in the system to allow escape of trapped air. An
example is the vent at the top of the boiler in figure 27.
Drainback systems should NOT have automatic make-
up water assemblies. Installing such an assembly in
combination with an automatic venting device would
eventually replace the air in the system with water.
Although this is desirable in conventional hydronic
systems, in this system it will lead to a waterlogged
drainback tank that prevents the system from draining. A
costly hard freeze is certain to follow.
The water level in the drainback system should be
periodically monitored when the collector circulator is
off. Small quantities of water may have to be added to
the system, especially after initial start-up, to replace the
volume of any air ejected through high point vents.
25
ACTIVE SOLAR SUPPLYING FORCED-AIR
SPACE HEATING:
Although the majority of North American homes are
heated by forced-air furnaces or heat pumps, they can
still be adapted to hydronic-based solar heating. An
example of such a system is shown in figure 28.
This system uses an antifreeze-based solar collection
subsystem to heat the thermal storage tank. Upon
a demand for heat, a setpoint temperature control
determines if the water at the top of the storage tank is
warm enough to supply space heating through the duct
coil. If it is, a circulator moves tank water through the duct
coil and operates the furnace blower. The 3-way mixing
valve protects the coil against excessively hot water from
the solar storage tank. When the water temperature in the
storage tank can no longer provide acceptable comfort,
the setpoint controller allows the furnace burner to
operate, and the storage tank circulator is turned off.
This is a relatively simple system and easily adapted
to most existing furnace or forced-air heat pump
installations. The duct coil should be selected to operate
at the lowest possible water temperature to maximize
solar utilization while also providing acceptable comfort
in the heated space.
VENT
expansion
tank
h
e
a
t

e
x
c
h
a
n
g
e
r
Ill / purge
valves
differential
tenperature
controller
duct coil
(in plenun)
Iurnace
setpoint
controller
pressure
relief
valve
check
valve
air vent
air
separator
air vent
w/ shut oII
valve
3-way mixing valve
s
o
la
r

c
o
lle
c
t
o
r

a
r
r
a
y
Figure 28
26
COMBINED SOLAR SPACE & DOMESTIC
WATER HEATING:
Many buildings with space-heating requirements also
need domestic hot water. This is especially true of
residential buildings. When a solar space-heating
system is planned, it usually makes sense to extend
the capabilities of that system to supply domestic
water heating. In many situations, the auxiliary boiler
that backs up the space-heating requirements can also
supply auxiliary energy to the domestic water-heating
load when necessary.
There are many hardware possibilities for combined
solar space and domestic water heating. They vary on
the solar collection side (i.e., antifreeze-based freeze
protection versus drainback). They also vary based on
available storage tank options, as well as the type of
backup heat source used. This section discusses two
state-of-the-art scenarios.
An example of one modern approach to solar space and
domestic water heating is shown in figure 29a. A unique
feature of this system is its dual coil storage tank, which
contains domestic hot water and can be heated by the
solar collection subsystem as well as the boiler.
Solar heat input is via a standard antifreeze-based
closed-loop collector circuit. The lower coil heat
exchanger is sized proportional to the collector array
area. Since solar space heating typically requires more
collector area than does solar domestic water heating,
this coil may be substantially larger than the coils in
tanks used only for domestic water heating.
The hottest domestic water is drawn from the top of the
tank and passes through a 3-way anti-scald mixing valve
to guard against excessively high water temperature at
the faucets. The temperature at the top of the tank
is constantly monitored. If it falls below a minimum
expansion
tank
Ill / purge
valves
thernal storage tank
(Illed with donestic water)
3-way
anti-scald
nixing valve
tank
circulator
(w/ check)
DHW
VENT
HydroLink
3-way
notorized
nixing valve
outdoor
reset
controller
pressure
relieI
valve
air
separator
check
valve
pressure
regulated
circulator
3-way
notorized
nixing valve
boiler
circulator
(w/ check)
other
load
ON
ON
This node shows heat supplied to upper tank
coil Iron boiler. This node is used to naintain
a suitable DHW delivery tenperature. The two
circuits intersect at the hydraulic separation
chanber in theHydroLink, and thus have
nininal interaction. 5pace heating loads could
be on or oII (shown oII).
air vent
w/ shut oII
valve
s
o
la
r

c
o
lle
c
t
o
r

a
r
r
a
y
Autoow
zone
valve
valve actuators
balancing
valve
zone
valve
Autoow
Figure 29a
27
setpoint, the boiler and its circulator are operated
along with the tank circulator. Hot water from the boiler
mixes with water returning from the upper coil, and the
combined flow enters the hydraulic separation chamber
in the HydroLink. This chamber minimizes interaction
between the two circulators. A portion of the heated
water then passes back to the upper tank coil to boost
DHW temperature. The remaining portion of the heated
water flows back to the boiler. This mode of operation is
shown in figure 29a. Temperature stratification within the
tank minimizes heating of the lower portion of the tank to
ensure solar collection begins at the earliest opportunity.
The upper coil can also extract heat from the tanks
water for use in space heating. With the boiler and its
circulator off, the tank circulator moves hot water from
the upper coil into the HydroLink. It is then distributed
to the active space-heating circuits. Both space-heating
circuits include motorized 3-way mixing valves to
protect against high water temperatures reaching low-
temperature heat emitters. These valves should be
operated by outdoor reset controllers to ensure the
distribution circuits operate at the lowest possible
temperature commensurate with the building heating
load. This mode of operation is shown in figure 29b.
Controls would be configured to stop space heating
from the upper coil in the event the domestic hot
water temperature at the top of the tank dropped to a
minimum acceptable value.
Another possible operating mode is for the boiler to
supply space heating, as shown in figure 29c. In this
mode, the tank circulator is off. The boiler operates on its
own internal reset controller to produce a supply water
temperature equal to or just slightly above the highest
required space-heating supply temperature. The space-
heating subsystems draw from the HydroLink as in a
standard hydronic system.
expansion
tank
Ill / purge
valves
3-way
anti-scald
nixing valve
tank
circulator
(w/ check)
DHW
VENT
HydroLink
3-way
notorized
nixing valve
outdoor
reset
controller
pressure
relieI
valve
air
separator
This node shows heat supplied to HydroLink
Iron the upper tank coil. Boiler and boiler circulator
are oII. 5pace heat loads are supplied Iron HydroLink.
check
valve
pressure
regulated
circulator
3-way
notorized
nixing valve
boiler
circulator
(w/ check)
other
load
OFF
ON
air vent
w/ shut oII
valve
Autoow
zone
valve
valve actuators
balancing
valve
zone
valve
Autoow
s
o
la
r

c
o
lle
c
t
o
r

a
r
r
a
y
Figure 29b
28
expansion
tank
Ill / purge
valves
3-way
anti-scald
nixing valve
tank
circulator
(w/ check)
DHW
VENT
HydroLink
3-way
notorized
nixing valve
outdoor
reset
controller
pressure
relieI
valve
air
separator
This node shows heat supplied to HydroLink
Iron the boiler. Tank circulator is oII. 5pace
heat loads are supplied Iron HydroLink.
check
valve
pressure
regulated
circulator
3-way
notorized
nixing valve
boiler
circulator
(w/ check)
other
load
ON
OFF
air vent
w/ shut oII
valve
Autoow
zone
valve
valve actuators
balancing
valve
zone
valve
Autoow
s
o
la
r

c
o
lle
c
t
o
r

a
r
r
a
y
tank circulator
(w/ check)
VENT
outdoor
reset
controller

b
o
i
l
e
r

c
i
r
c
u
l
a
t
o
r

(
w
/

c
h
e
c
k
)
indirect water heater
3-way
motorized
mixing valve
hydro
separator
differential
temperature
controller
h
e
a
t

e
x
c
h
a
n
g
e
r
Ill / purge
valves
expansion
tank
pressure
relief
valve
collector
circulator
air vent
w/ shut off
valve
s
o
la
r

c
o
lle
c
t
o
r

a
r
r
a
y
Figure 29c
Figure 30
29
Another possible system design is shown in figure 30.
This system uses a standard indirect water heater. A
hydro separator hydraulically isolates the storage tank
and boiler circulators from the circulators used for space
heating and domestic water heating. It also serves as
the central air and dirt separating device in the system.
Transition from solar-supplied heating to boiler-supplied
heating is managed by the outdoor reset controller
monitoring the solar storage tank temperature. This
controller, or another controller, responds upon a call
for domestic water heating to verify if the solar tank is
sufficiently warm to supply the indirect water heater. If
it is not, the boiler is fired to supply the indirect water
heater. Space-heating circuits are temporarily turned off
during this operation.
Again, the 3-way motorized mixing valve on the space-
heating distribution system protects the low-temperature
radiant panel circuits from potentially hot water supplied
from the solar storage tank.
ACTIVE SOLAR SYSTEM INSTALLATION:
The performance and longevity of any active solar energy
system depends greatly on proper siting of the collector
array. Good performance obviously demands absolute
minimal shading of the collectors. A proper assessment
of every potential site is highly recommended, especially
if there are any indications of shading.
Although its possible to calculate the exact solar altitude
and azimuth angles for any location on any day, using
this information to assess the potential shading effects of
nearby buildings, trees, hills or other objects is difficult. A
much simpler approach is the use of a tool called a solar
pathfinder, as shown in figure 31. This simple device is
placed at the location where shading is to be evaluated.
After being leveled and properly oriented using the
internal compass, its clear hemispherical dome projects
the reflections of nearby objects onto a special chart that
indicates the approximate times and months when that
location is shaded.
Because solar intensity varies during the day, morning
and late afternoon shading is not as critical as mid-
day shading. As a rule, no portion of the collector array
should be shaded between 9:00 AM and 3:00 PM
(standard time).
The long-term reliability of an active solar system also
depends on structurally sound collector mounting. Roof-,
wall- and ground-mounted collector arrays are possible.
Examples are shown in figure 32 and 33.
Image courtesy of SolarSkies, Inc.
Photo courtesy of SolarSkies, Inc.
Photo courtesy of Hot Water Products, Inc.
Figure 31
Figure 32
Figure 33
30
Modern solar collectors are tested for survival under
extreme wind conditions as well as the impact of large
hailstones. Most are able to withstand such punishing
weather conditions for decades. However, inadequate
mounting hardware could fail and lead to major structural
damage. All roof-mounted collectors should have bracket
systems that connect directly to structural framing using
stainless steel fasteners and proper sealants for roof
penetrations. Ground-mounted collector supports should
be designed by an engineer in accordance with local
wind loading conditions. Verify that all mounting hardware
complies with local code requirements.
All piping between the collector array and internal
mechanical room should be properly insulated to a
minimum of R3 (Fhrft
2
/Btu), and protected against
the weather where exposed. The piping must also
be properly supported and pitched for drainage. In
drainback systems, all piping exposed to freezing must
be pitched to drain a minimum of 1/4 inch per foot of
horizontal travel.
The equipment in the mechanical room should be neatly
organized to minimize space requirements and provide
easy access for service. When large storage tanks are
planned into a system, provisions must be made for
proper support as well as sufficient openings to get the
tank into or out of the mechanical room. In some cases,
multiple smaller tanks may be required to meet a specific
storage requirement due to limited access.
COLLECTOR MOUNTING ANGLES:
In the Northern Hemisphere, the ideal collector array
azimuth angle is 180 (e.g., the collector array faces directly
polar south). This orientation maximizes total clear day
solar radiation striking the array. However, existing building
surfaces may not provide this orientation. Fortunately, the
annual total solar energy captured by a collector array is
not highly sensitive to the arrays azimuth angle. Variations
of 30 east or west of polar south typically only reduce
annual solar energy collected by about 2.5%. The ideal
slope angle of a solar collector depends on latitude as well
as the intended function of the system.
For solar domestic water heating, the ideal slope angle
is equal to local latitude. However, variations of +/- 10
on this angle will have minimal impact on the annual total
solar energy collected. Thus, it often makes sense to
mount collectors parallel to existing roofs where the slope
of the roof is within +/-10 of local latitude, and forego
the need for bracketing that would only make minor
adjustments to the collector slope. In climates with snow,
a minimum tilt angle of 40 is suggested to encourage
rapid shedding of snow when the sun reappears.
In the case of solar space heating, somewhat steeper
collector angles favor solar collection during late fall,
winter, and early spring. Slope angles equal to local
latitude plus 10 to 20 are appropriate for such systems.
These relatively steep slopes actually reduce summertime
solar collection and help prevent overheating from the
larger collector arrays often used for space-heating
applications. Even with this performance penalty, these
larger arrays often provide a very high percentage of the
domestic water-heating energy needed during warmer
weather.
Figure 34 shows a collector array that supplies both space
and domestic water heating. The collectors are sloped
60 in a location at 44 north latitude. In this project, the
roof trusses were specially constructed to provide this
collector slope while still mounting the collectors parallel
to the roof surface.
ACTIVE SOLAR SYSTEM
PERFORMANCE ESTIMATES:
Given the unlimited combinations of collector area,
mounting angles, storage tank options, water temperature
requirements and many other factors, its essential to
have a tool for evaluating the technical performance of
proposed active solar energy systems. Given the extent
of options and complex nature of solar energy availability,
specialized software that simulates the performance of
user-defined systems in a specific geographic location
is the tool of choice. Several such software tools are
currently available. Three of the most common are:
1. F-Chart: originally developed at the University of
Wisconsin as a manual calculation procedure, the
F-Chart method has been used for technical and economic
analysis of active solar space- and domestic water-heating
systems for over three decades. The current version of
F-Chart software is available from www.fchart.com.
Figure 34
31
2. Tsol: Developed and primarily used in Europe, Tsol is
simulation software for active solar thermal systems. It is
available in both express and professional versions
from http://www.valentin.de/.
3. RET Screen: Developed by Natural Resources Canada,
RETScreen is powerful simulation software that can be
used to study the technical and economic feasibility of
active solar energy systems, as well as several other
types of renewable energy technologies. This software is
available as a free download from www.RETScreen.net.
The performance predictions presented in this section were
derived using the latest version of F-chart software.
SOLAR HEATING FRACTION:
One way of expressing the thermal performance of an
active solar energy system is by stating the percentage
of the load met by solar energy on a month-by-month
basis. These monthly totals can also be combined
to yield the annual solar fraction. The solar heating
fraction is sometimes expressed as a decimal percentage
(e.g., 0.15 = 15%).
SIMULATED PERFORMANCE OF SOLAR
DOMESTIC WATER-HEATING SYSTEMS:
The table in figure 35 lists the annual solar fraction for
various domestic water-heating loads in three different U.S.
cities (Boston, MA; Milwaukee, WI; and Las Vegas, NV).
In all cases, the following system assumptions were made:
Flat plate collector efficiency line intercept (FRta) = 0.76
Flat plate collector efficiency line slope (FRul) = 0.825
Storage tank volume = collector area (ft
2
) x 1.5 (gallon/ft
2
)
Closed-loop antifreeze system with heat exchanger
effectiveness = 0.50
Collector azimuth = 0 (e.g., collectors face directly south)
Collector slope = approximately equal to local latitude
Collector flow rate = 11 lb/hr/ft
2
(or 0.02 gpm/ft
2
) of
collector area
Setpoint temperature for domestic hot water = 120F
Cold water temperature = typical of location
Annual solar fractions are given for four daily hot water
loads (left column) and three solar collector area/storage
tank volume scenarios (top row).
[As would be expected, the larger collector arrays and
correspondingly larger storage tanks yield higher solar
heating fractions in all locations. In looking at these
results, one might assume the best system is the one
supplying the highest percentage of the load. From
a pure energy conservation standpoint, this may be
true. However, the economic viability of the system is
a different matter. Systems that supply very high solar
heating fractions may not provide returns on investment
as high as systems supplying lesser amounts of the
load. The only way to know for sure is through detailed
economic analysis of competing system options. Most
solar system simulation software can also perform an
economic analysis of the system.
BOSTON 40 ft
2
/60 gal. 80 ft
2
/120 gal. 120 ft
2
/180 gal.
40 gal/day 72% 91% 96%
60 gal/day 57% 85% 92%
80 gal/day 48% 77% 89%
100 gal/day 41% 69% 84%
MILWAUKEE 40 ft
2
/60 gal. 80 ft
2
/120 gal. 120 ft
2
/180 gal.
40 gal/day 67% 88% 94%
60 gal/day 54% 82% 90%
80 gal/day 45% 74% 86%
100 gal/day 38% 65% 81%
LAS VEGAS 40 ft
2
/60 gal. 80 ft
2
/120 gal. 120 ft
2
/180 gal.
40 gal/day 94% 99% 100%
60 gal/day 88% 98% 100%
80 gal/day 77% 96% 99%
100 gal/day 69% 94% 98%
Figure 35
32
SIMULATED PERFORMANCE OF COMBINED SOLAR
SPACE AND DOMESTIC WATER-HEATING SYSTEMS:
Figure 36 shows the monthly solar heating fraction for the
energy required to heat a house with a design heat loss of
50,000 Btu/hr located in either Syracuse, NY, or Colorado
Springs, CO. In each case, the system also supplies heat
to a 60 gallons per day domestic hot water load having a
setpoint temperature of 120F.
The collector array for the system is that shown in figure
34. The six flat plate collectors have a total gross area
of 112 square feet and face directly south at a slope
of 60. The storage tank has a volume of 300 gallons
and is equipped with an upper coil heat exchanger
for domestic water heating. Space heating is supplied
through low-temperature heated floors.
Not surprisingly, the monthly solar heating fractions are
rather low in winter given the relatively cold climates.
However, its clear the system in Colorado Springs does
significantly better at supplying winter heat compared to the
same system in the much cloudier Syracuse, NY, location.
In both locations, solar fractions rise significantly during
spring and fall. This results from increased solar energy
availability as well as reduced heating load. As the space-
heating load goes away during summer, both systems
are able to supply very high percentages of the domestic
water-heating load. During July and August, each system
is estimated to supply 99-100% of the domestic water-
heating load. Keep in mind that the collector slope of 60
favors winter sun angles. However, the relatively large
collector area more than compensates for the losses due
to the steep collector slope.
SOLAR PRODUCT CERTIFICATIONS:
Maintaining the quality of solar energy products and
system installations is vital to the long-term success of
the solar energy industry. To this end, the Solar Rating
and Certification Corporation (SRCC) was formed in
1980 as a non-profit organization to provide independent
testing, rating and certification of active solar collectors
and solar domestic water-heating systems.
The SRCC has developed and maintains two standards
for testing and rating of solar hardware:
Standard OG-100 Operating Guidelines for Certifying
Solar Collectors
Standard OG 300 Operating Guidelines and Minimum
Standards for Certifying Solar Water Heating Systems
These guidelines are widely accepted across the United
States as the basis for qualifying collectors and domestic
water-heating systems for state and national tax credits,
as well as for other organizations offering financial
incentives for solar system installation.
Standard OG-100 requires that collectors undergo
stringent testing for both thermal performance and
durability. Collectors are tested for thermal output under
a range of solar intensity and ambient temperature
conditions. Their ability to withstand stagnation, severe
weather and thermal stock are also tested.
Standard OG-300 combines the physical testing of
collectors with a quality assurance review of all major
components in a solar water-heating system proposed
for sale by a manufacturer. The standard also provides
simulated performance estimates for that system in
specific geographic locations.
Additional information on the SRCC can be obtained from
their Web site, www.solar-rating.org.
SUMMARY:
Weve discussed the fundamentals of active solar energy
systems. As with hydronic heating, there are many specialized
sub-topics within this area of technology. Future releases of
idronics will address these subjects in more detail.
The use of solar energy in North America will increase with
each passing year. Rapid increases in the cost of conventional
fuel will accelerate the pace of this expansion. Knowing how
to size and configure active solar heating systems is an
important skill for hydronic heating professionals that expect
to serve the growing demand for active solar space-heating
and domestic water-heating systems.
1 2 3 4 5 6 7 8 9 10 11 12
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
P
r
e
d
i
c
t
e
d

s
o
l
a
r

f
r
a
c
t
i
o
n

o
f

t
o
t
a
l

s
p
a
c
e

h
e
a
t
i
n
g

a
n
d

D
H
W

l
o
a
d

(
d
e
c
i
m
a
l

%
)

(
b
a
s
e
d

o
n

F
-
c
h
a
r
t

s
i
m
u
l
a
t
i
o
n

s
o
f
t
w
a
r
e
)
Month
Colorado Springs, CO ( ) annual solar fraction = 32.1%
Syracuse, NY ( ) annual solar fraction = 23%
Figure 36
33
APPENDIX 1:
Volume and surface area reference information:
This appendix provides formulas and data for calculating
the volume and surface areas of cylindrical tanks as
well as the volume of tubing used in solar / hydronic
systems.
Tank volume formula:
Formula 1 can be used to calculate the volume of a
cylindrical storage tank of known diameter and height:
Formula 1:
Where:
Vtank = volume of tank (gallons)
D = diameter of tank (inches)
H = height of tank (inches)
Formula 2 can be used to calculate the volume of liquid
of known height (h) with a vertically-oriented cylindrical
storage tank of known diameter and height:
Formula 2:
Where:
Vfluid = volume of fluid in tank (gallons)
h = height of fluid in tank (inches)
Tank surface area formula:
Formula 3 can be used to calculate the total surface area
of a cylindrical tank of known diameter and height:
Formula 3:
Where:
A
surface
= total surface area of tank (square feet)
H = height of tank (inches)
Pipe volume data:
The data in table 1 can be used to calculate the volume
of tubing in solar energy systems as well as other types
of hydronic systems.
Tube type/size Gallons/foot
3/8 type M copper: 0.008272
1 type M copper: 0.0454
1.25 type M copper: 0.068
3/8 PEX 0.005294
1/2 PEX 0.009609
5/8 PEX 0.01393
3/4 PEX 0.01894
1 PEX 0.03128
1.25 PEX 0.04668
1.5 PEX 0.06516
2 PEX 0.1116
3/8 PEX-AL-PEX 0.00489
1/2 PEX-AL-PEX 0.01038
5/8 PEX-AL-PEX 0.01658
3/4 PEX-AL-PEX 0.02654
1 PEX-AL-PEX 0.04351
Table 1
APPENDIX
H
h
h
e
i
g
h
t

o
f

t
a
n
k
diameter of tank
h
e
i
g
h
t

o
I

u
i
d
D
V
tank
=
D
2
( )
H
924
V
fluid
=
D
2
( )
h
924
A
surface
=

144
D
2
2
+ DH
34
APPENDIX 2:
Expansion Tank Sizing for Solar Collection Circuits:
During its service life, almost every closed-loop solar
collection system will experience stagnation conditions,
where bright sunshine strikes the collectors without flow
through the absorber plates. Under such conditions, the
fluid within the collectors can change to vapor. In addition,
the fluid within the piping to and from the collector array
could be filled with very hot fluid.
To prevent the relief valve from opening under these
conditions, the expansion tank must absorb the liquid
volume expansion plus the fluid displacement volume
caused by vapor formation in the collector array. The
following procedure determines the minimum volume of a
diaphragm-type expansion tank volume to accommodate
this situation.
Step 1: Calculate the potential expansion volume of the
entire collector circuit using formula 5a.
Formula 5a
Where:
V
a
= expansion volume to be accommodated (gallons).
V
c
= total volume of collector array (gallons)
V
p
= total volume of collector circuit other than collector
array (gallons)
e = coefficient of expansion of collector circuit fluid
(e = 0.045 for water, or e=0.07 for glycol)
1.1 = safety factor of 10% to allow for system volume
estimates
The volume of the collectors is usually listed in the
manufacturers specifications, as is the volume of the
heat exchanger. The volume of the piping can be
estimated using data from table 1 in appendix 1.
Step 2: Calculate the static pressure at the location
of the pressure relief valve. This is the pressure caused
by the weight of fluid in the collector circuit above the
pressure relief valve location. It can be calculated using
formula 5b.
Formula 5b:
Where:
P
i
= initial pressure at the relief valve location (psi)
H = height of collector circuit above location of
pressure relief valve (feet)
0.454 = constant based on the density of 50% propylene
glycol
5 = allowance for 5 psi gauge pressure at top of
collector circuit
Note: The air chamber in the expansion tank must be
pressurized to the pressure calculated using Formula 5b
before fluid is added to the collector circuit.
Step 3: Calculate the minimum required expansion tank
volume using formula 5c.
Formula 5c
Where:
V
T
= minimum required expansion tank volume (gallons)
V
a
= expansion volume to be accommodated (from step 1)
(gallons)
P
i
= initial pressure at the relief valve location (from step 2)
(psig)
P
f
= maximum allowed pressure at the relief valve location (psig).
Recommended value is pressure relief valve rating
minus 5 psi
Example: Determine the minimum expansion tank volume
for the following system:
4 collectors, each having a volume of 1.5 gallons
Total of 120 feet of 1-inch copper tubing between heat
exchanger and collector array
Heat exchanger volume = 2.5 gallons
Height of top of collector array above relief valve
location = 25 feet
Pressure relief valve rating = 60 psi
Collector circuit fluid = 50% solution of propylene glycol
Solution:
Total collector array volume:
4 x 1.5 = 6 gallons
Total piping + heat exchanger volume:
120 ft x (0.0454 gallon/ft) + 2.5 = 7.95 gallons
V
T
=V
a
P
f
+14.7
P
f
~ P
i
|
|
J
j
j
35
Step 1:
Step 2:
Pressure at relief valve under stagnation (relief valve
rating 5 psi):
Pf = 60 5 = 55 psi
Step 3:
This procedure is conservative in several ways:
It assumes that all collector circuit piping contains fluid
at the maximum system temperature.
It allows a 5 psi margin between the rated opening
pressure of the relief valve and the pressure allowed to
occur at the relief valve during stagnation.
It assumes that all the fluid in the collector array has
changed to vapor under stagnation conditions.
It adds 10% to the estimated system piping volume.
A conservatively sized expansion tank is good insurance
against the system requiring servicing following a
stagnation condition.
In cases where the minimum required expansion tank
volume exceeds the volume of available tanks, it is
acceptable to use multiple tanks connected in parallel.
Be sure the air side pressure in each tank is set to the
calculated pressure (Pi) prior to filling the collector circuit.
APPENDIX 3:
Domestic water-heating load estimating:
Formula 5 can be used to estimate the energy required for
heating domestic water. A typical North American family
uses about 20 gallons of hot water per day per person.
Formula 5:
Where:
E
DHW
= Daily energy required for domestic hot water (Btu)
g = day requirement of domestic hot water required
(gallons)
T
h
= setpoint temperature of hot water heater (F)
T
c
= entering cold water temperature (F)
APPENDIX 4:
Unit Conversion Factors:
Temperature
Temperature difference (AT):
Heat:
Power:
Pressure:
Volume:
Flow rate:
Solar heat intensity:
Inlet fluid parameter:
1 Ra = 0.555555 K
1 F = .0555555 C
F = C (1.8) =32
0.555555
36
circulator
circulator w/
isolation fanges
circulator w/
internal check valve
& isolation fanges
gate valve
globe valves
ball valve
thermostatic
radiator valve
thermostatic
radiator valve
strainer
primary/secondary
Itting
cap
hose bib
drain valve
diverter tee
union
pressure gauge
diaphragm-type
expansion tank
3-way motorized
mixing valve
4-way motorized
mixing valve
swing check valve
spring loaded
check valve
purging valve
metered
balancing
valve
pressure
relief
valve
brazed
plate
heat
exchanger
Modulating / condensing boiler
conventional boiler
indirect water heater (with trim)
GENERIC COMPONENTS
pressure &
temperature
relief valve
CALEFFI COMPONENTS
Modulating tankless water heater
solar collector array
DISCAL central
air separators
backow preventer
pressure
reducing
valve
zone valve
(2 way)
zone valve
(3 way)
foat -type
air vent
3-way
thermostatic mixing
valve
ow-check valve
differential
pressure
bypass valve
VENT
Hydro
Separator
Hydrolink
(3 conIgurations)
manifold station with
balancing valves
pressure
relief valve
air & dirt
separator
DIRTCAL
dirt separator
high temperature
solar DISCAL
air separators
high temperature
solar pressure
relief valve
high temperature
solar air vent
high temperature
solar 3-way thernostatic
mixing valve
high
temperature
solar
expansion
tank
isolar
differential
temperature
controller
Autoow
balancing
valve
high temperature
shut-oII valve Ior
solar air vent
solar
circulation
station
37
The Calef Solar series of products are specically designed for use in circuits of
solar systems. In these systems the heating uid may contain glycol as additive
and may operate at high temperatures.
The materials and components used in its manufacture and the performance of
these must be suitable for these operating conditions.
Components for primary circuit - Solutions with glycol
+
+
SET
38
Automatic air vent and shut-off valve
for solar systems
250 series
Function
Automatic air vents are used in the closed circuits of solar heating systems to allow air contained in
the fluid to be released automatically during the filling process, by means of a valve operated by a
float in contact with fluid in the system.
The shut-off valves are used in combination with the automatic air vent vents to be able to isolate
them after filling the circuit of solar heating systems.
These series of products have been specially made to work at high temperature with a glycol medium.
.
Product range
Code 250041A Automatic air vent for solar systems size 1/2" M NPT
Code NA29284 Shut-off valve for automatic air vent size 1/2" M NPT x 1/2" F NPT
Technical specifications of 250 series valve
Materials: - body: brass chrome plated
- cover: brass chrome plated
- control spindle: stainless steel
- float: high resistance polymer
- seals: EPDM
s n o i t u l o s l o c y l g , r e t a w : m u i d e M
% 0 5 : l o c y l g f o e g a t n e c r e p . x a M
Working temperature range: -20 to 360F (-30 to 180C)
Max. working pressure: 150 psi (10 bar)
Max. discharge pressure: 75 psi (5 bar)
Connection: 1/2" M NPT
Technical specifications of valve NA29284
- ball: brass chrome plated
- seals: P.T.F.E.
Connection: 1/2" F x 1/2" M NPT
Dimensions Dimensions
A
1/2
B
4
C
2 1/8
D
1/2
C
B
D
A
Code
250041A
Weight (lb)
0.7
A
1/2
B
2 7/8
C
1/2
D
1 1/2
Code
NA29284
Weight (lb)
0.5
A
A
B
D
C
Tmax = 180C / 360F
Pmax = 10 bar / 150 psi
CALEFFI
39
250 series
Automatic air vent for solar heating systems. 1/2" Male NPT connections. Brass body and cover. Chrome plated. Float
in high resistance polymer. Seals in high resistance elastomer. Medium: water and glycol solutions. Maximum percentage
of glycol: 50%. Working temperature range: -20 to 360F. Maximum working pressure: 150 psi. Maximum discharge
pressure: 75 psi.
Code NA29284
Shut-off valve for automatic air vent for solar heating systems. 1/2" F NPT x 1/2" M NPT connections. Chrome plated brass
body and ball. Seals in high resistance elastomer. Medium: water and glycol solutions. Maximum percentage of glycol:
50%. Working temperature range: -20 to 360F. Maximum working pressure: 150 psi.
SPECIFICATION SUMMARIES
Operating principle
The accumulation of air bubbles in
the valve body causes the float to
drop so the air vent valve opens.
This phenomenon occurs, and
consequently, the valve functions
correctly, as long as the water
pressure remains below the
maximum discharge pressure.
Installation
250 series automatic air
vents must be installed in
a vertical position, typically
on the top of the solar
heating system panels and at points in the circuit where air bubbles
gather that need to be discharged.
They must always be installed in combination with a shut-off valve.
This is necessary since the vent valves must be shut off after use to
remove the air during the filling and starting up phase of the system.
Hydraulic characteristics
Discharge capacitywhen the system is being filled
Construction details
Resistance to temperature
The high performance level of this series of automatic air vent
valves, required in solar heating systems, is ensured by using materials
that are highly resistant to temperature. The materials allow the vent
function with glycol water temperatures up to 360F (180C).
Application diagram
Tmax = 180 C / 360 F Pmax =10bar / 150psi
Tmax = 180 C / 360 F
T m a x = 1 8 0 C / 3 6 0 FP m a x = 1 0 b a r / 1 5 0 p s i
Tmax = 180C / 360 F
P max = 10 bar / 150 psi
Maintenance
The 250 series automatic air vent is made to
allow checking of the internal mechanism.
Access to the moving parts that govern the air
vent is attained by simply removing the top
cover.
A shut-off valve must be installed before the
250 series device to allow shut off to simplify
any maintenance work and for shutting off after
the filling phase.
Tmax = 180C / 360F
Tmax = 180 C / 360 F
Pmax =10bar / 150psi
3
.
5
4
.
5
4
.
5
3
.
5
2
.
5
2
.
5
1
.
5
1
.
5
0
.
5
0
7
0
6
0
5
0
4
0
3
0
2
0
1
0
0
(
b
a
r
)

(
p
s
i
)
) s / l N ( ) M F C S (
1
0.1
0
0.5
0.9
0.8
0.7
0.6
0.4
0.3
0.2
1.2
1.1
0
2.5
0.25
0.5
0.75
1
1.25
1.5
1.75
2
2.25
40
Air separators for solar heating systems
DISCAL SOLAR
251 series
Product range
Code 251003A Air separator for solar heating systems with drain size 3/4" F NPT
Technical specifications
- cover: brass chrome plated
r e m y l o p e c n a t s i s e r h g i h : t a o l f -
l e e t s s s e l n i a t s : t n e m e l e l a n r e t n i -
- float guide: brass
- valve stem: dezincification resistant brass
l e e t s s s e l n i a t s : r e v e l t a o l f -
l e e t s s s e l n i a t s : g n i r p s -
- seals: high resistance elastomer
F NPT " 4 / 3 Connections: - Main
Dimensions
Function
Air separators are used to continuously eliminate air from the primary circuits of
solar heating systems. The air vent capacity of these devices is extremely high.
They are able to automatically remove all the air from the solar circuits, including
microbubbles. The circulation of fully separated fluid allows the system to work under
optimal conditions without any trouble with noise, corrosion, local overheating and
mechanical damage.
This particular series of air separaots has been specifically designed to work at high
temperature with a glycol medium, which is typical of solar heating systems.
A
3/4"
B
3
C
2 1/8
D
5 5/8
F
6 7/8
Code
251003A
Weight (lb)
2.0
CALEFFI
General
The removal of dissolved gases from a solar primary circuit is an essential process in
a solar heating system. The presence of dissolved oxygen in a solar circuit causes rapid
localized corrosion in collectors and heat exchangers. Carbon dioxide will dissolve in
water, resulting in low pH levels and the production of corrosive carbonic acid. Low pH
levels in a solar circuit causes severe acid attack throughout the solar heating system.
While dissolved gases and low pH levels in the solar circuit can be controlled by the
addition of chemicals, it is more economical and thermally efficient to remove these
gases mechanically. This mechanical process is known as air separation and will
increase the life of a solar heating system dramatically.
- Drain: 1/2" F NPT
C
A
D
B
E
A
Tmax = 160C / 320F
F
E
1/2
41
Operating principle
The air separator is composed
of a set of metal screen surfaces
arranged like spokes (A). This
screen creates a swirling motion
to assist the release of micro-
bubbles and their adhesion to the
metal screen. The bubbles join
and increase in size until the
hydrostatic force increases to
overcome the force of adhesion
to the screen.
Next, they rise to the top of the
chamber where they are released
by the float-operated automatic
air vent valve (B).
B
A
The process of air formation
The quantity of air that can remain dissolved in solution in the water
depends on the pressure and temperature.
This is known as Henry`s law. It may be noted that there is a greater
release of air from the solution as the temperature increases and
the pressure decreases. This air is in the form of microbubbles with
diameters of approximately tenths of a millimeter.
The microbubbles form continuously in the water of the solar
heating systems on the top of the panels, because that is the point
in the circuit where the highest temperatures are reached.
A portion of the air is re-absorbed as the medium reaches the parts
of the circuit at a lower temperature. Because air remain the medium
it must be extracted.
System operation
In solar panel heating systems with forced circulation, it is
necessary to expel all the air in the medium during the phases of
start up and operation.
The air separator permits separating and expelling this air from
the fluid continuously and automatically. Any decrease in pressure
due to the release of air is compensated by the expansion tank or
automatic filling unit.
Automatic
filling
Tmax = 160C / 320F Pmax = 10 bar / 150 psi
T max= 160C / 320F
Pmax= 10 bar / 150 psi
Installation
The air separator must always be installed vertically and preferably:
- before the pump to ensure a drop in pressure so microbubbles of
air can develop.
- on the return and in the bottom portion of the solar circuit where
there is no potential for formation of steam.
0
.
2
4
3
3.5
Ap (ft of water) (kPa)
1
0
.
5
0
.
2
5
0
.
3
0
0
.
3
5
0
.
4
0
0
.
4
5
0
.
6
0
.
7
0
.
8
0
.
9
1
.
2
1
.
4
1
.
6
1
.
8
2
.
5
4
.
0
4
.
5
23
.
0
3
.
5
5
Recommended max. flow
2
1
0 5
2
0
6789
1
2
1
4
1
6
1
8 3
3
.
54
4
.
5
2
.
5
1
.
7
5
1
.
5
1
.
2
5
1
.
0
0
.
7
F

(
m
3
/
h
)

(
g
p
m
)
0.1
0.05
0.09
0.08
0.07
0.06
0.035
0.04
0.045
0.12
0.14
0.16
0.18
0.25
0.3
0.35
0.2
1
0.1
0.2
0.5
0.9
0.8
0.7
0.6
0.12
0.14
0.16
0.18
0.25
0.3
0.35
0.4
0.45
1.2
1.4
1.6
1.8
2.5
2
1
0.5
0.9
0.8
0.7
0.6
0.45
0.4
1.4
1.6
The maximum recommended speed of the fluid in the piping is 4.2 ft/sec,
which is equivalent to a flow rate of 6.5 gallons per minute.
Tmax = 160C / 320F
Discal air separator is built to permit
maintenance and cleaning operations
without having to remove the valve
body from the pipe.
Access to the moving parts that
control the air vent is attained by
simply removing the top cover.
Resistance to heat and high discharge pressure, allows the maintenance
of the functional features of the air separator with glycol water temperatures
up to 320F. The internal geometry of
the air separator has been designed
to discharge the air up to a pressure
of 150 psi.
42
High-performance automatic air vent
DISCAL SOLAR
251 series
Product range
F NPT " 2 / 1 e z i s s m e t s y s g n i t a e h r a l o s r o f e v l a v t n e v r i a c i t a m o t u a e c n a m r o f r e p - h g i H 4A 0 0 1 5 2 e d o C
Materials: - body: brass, chrome plated
- cover: brass, chrome plated
r e m y l o p e c n a t s i s e r h- g i h : t a o l f -
- float guide: brass
- valve stem: dezincification-resistant alloy
l e e t s s s e l n i a t s : r e v e l t a o l f -
l e e t s s s e l n i a t s : g n i r p s -
- hydraulic seals: high resistance elastomer
% 0 5 : l o c y l g f o e g a t n e c r e p x. a M
Dimensions
Function
DISCALAIR solar devices are used in hydronic systems or in the filling and start-up
phase of solar heating systems to discharge even large quantities of air that have
formed in the circuits. This function is performed even when there is considerable
pressure thanks, to the special geometry of the discharge mechanism, which is
identical to the mechanism on DISCAL Solar 251 series air separators.
This particular series of automatic air vent valves has been specifically designed to
work at high temperatures with a glycol medium, typical of solar heating systems.
A
1/2"
B
4 1/2
C
1 3/8
D
21/8
Weight (lb)
1.3
Code
251004A
D
B
A
C
Tmax = 160C / 320F
CALEFFI
1/2" F NPT Connections:
43
Operating principle
The accumulation of air bubbles in
the valve body causes the float to
drop so that the valve opens.
This action, and correct air valve
valve operation, is ensured as
long as the water pressure
remains under the maximum
discharge pressure.
Installation
DISCALAIR series 251
automatic air vent valves
must be installed
vertically, typically on the
top of solar heating system panels and at points in the circuit where
bubbles of air gather that must be discharged.
They must always be installed in combination with a shut-off valve.
This is necessary since the vent valves must be shut off after use to
remove the air as the system is filling and starting up.
Discharge capacity in the phase of filling the system
Resistance to heat and high discharge pressure
The high performance of this series of automatic air vent valves,
required in solar heating systems, is ensured by the use of heat
resistant materials.
The materials allow the vent function with glycol water temperatures
up to 320F. The internal geometry of the valve has been designed
to discharge air up to a pressure of 150 psi.
Application diagram
T
T max= 160C / 320F
T max= 160C / 320 F
Maintenance
The DISCALAIR automatic air vent valve is
bui l t to permi t i nspecti on of the i nternal
mechanism.
Access to the moving parts that govern the air
vent is attained by simply removing the top
cover. In addition, the body can be separated
from the bottom portion connected to the pipe.
A shut-off valve must be installed before the
DISCALAIR device to allow for shut off after
the filling phase and to simplify any maintenance
work.
Tmax = 160C / 320F
DISCAL SOLAR 251 series
High-performance automatic air vent valve for solar heating systems. Connections 1/2" F. Brass body, chrome plated. High
resistance polymer float. Stainless steel float lever and spring. Brass float guide. Dezincification-resistant alloy release stem. High
resistance elastomer hydraulic seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Temperature range
-20 to 320F. Maximum working pressure 150 psi. Maximum discharge pressure 150 psi.
1
0.1
0
0.5
0.9
0.8
0.7
0.6
0.4
0.3
0.2
1.2
1.1
0
2.5
0.25
0.5
0.75
1.0
1.25
1.5
1.75
2.0
2.25
3.25
2.75
3.0
1.3
1.5
1.4
3
.5
4
.0 .5
4
.5
5
.0 .5
5
.5
6
.0 .5
3
.0.5
2
.5
2
.0.5
1
.5
1
.0.5
0
.5
0
9
0
8
0
7
0
6
0
5
0
4
0
3
0
2
0
1
0
0
(b
a
r
)

(p
s
i)
7
.5
8
.0 .5
8
.5
9
.0 .5
9
.5
1
0
.5
7
.0.5
6
.5 .5
1
5
0
1
4
0
1
3
0
1
2
0
1
1
0
1
0
0
) s / l N ( ) M F C S (
44
Adjustable thermostatic mixing valve
for solar systems
Function
The thermostatic mixing valve is used in systems for scald protection in
the production of domestic hot water.
It is designed to maintain the set temperature of the mixed water supplied
to the user when there are variations in the temperature and pressure
conditions of the incoming hot and cold water or in the water`s flow rate.
This particular series of mixing valves can function continuously at the high
temperatures of the incoming hot water from the solar storage tank.
Product range
sizes 1/2", 3/4", 1" sweat Code 2521 series Adjustable thermostatic mixing valve for solar systems
sizes 3/4", 1" sweat Code 2523 series Adjustable high flow thermostatic mixing valve for solar systems
Materials: - body: dezincification resistant alloy brass
U S P : r e t t u h s -
l e e t s s s e l n i a t s : s g n i r p s -
M D P E : s t n e n o p m o c l a e s -
Setting range: 80-150F (27-65C)
Accuracy: 3F (2C)
Max. working pressure (static): 150 psi (10 bar)
Max. working pressure (dynamic): 75 psi (5 bar)
Min. working pressure (dynamic): 30 psi (2 bar)
Max. inlet temperature: 210F (100C)
Min. temperature difference between hot water at inlet
and mixed water at outlet for optimum performance: 30F (15C)
Min. flow rate to ensure stable temperature:
Connections: - 2521 version: 1/2", 3/4", 1" with sweat union
- 2523 version: 3/4" and 1" with sweat union
Dimensions
A
1/2
3/4
B
2 1/4
2 1/2
D
5 5/8
5 7/8
E
3 1/8
3 1/4
F
2 5/8
2 5/8
C
4 1/2
5
Code
252149A
252159A
Weight (lb)
2.2
2.4
A
F
E
D
B B
C
A
A
H
O
T
C
O
L
D
MIX
MIN MAX 7 1 2
A
F
E
D
B B
C
A
A
E
3 1/4
3 3/4
D
6 3/4
7 1/4
C
6 1/4
7 1/4
F
3 1/2
3 1/2
B
3 1/8
3 5/8
Weight (lb)
5.3
5.6
A
3/4
1
Code
252359A
252369A
CALEFFI
MIN MAX 7 1 2
CALEFFI
1 3 1/8 6 3/8 3 7/8 2 5/8 6 1/4 252169A 2.6
NSF.
ASSE 1017
- 2521 version: 1.3 gpm (5 lpm)
- 2523 version: 2.3 gpm (8.5 lpm)
Max. inlet pressures ratio (H/C or C/H): 2:1
General
In solar systems, the temperature in the storage tank can vary considerably,
depending on the solar radiation, and can reach very high temperatures
over long periods. In summer, and if there is little water usage, the hot water
at the storage tank outlet can actually reach temperatures around 200 F.
At these temperatures, the hot water cannot be used directly because of
the danger of scalding.
252 series
45
Temperature adjustment
The temperature is set at the desired value by the knob with the
graduated scale, located on the top of the valve.
Temperature adjustment table
Position Min. 1 2 3 4 5 6 7 Max.
T (F) 80 90 100 110 120 130 135 145 150
Reference values: T
hot
= 155F; T
cold
= 55F; Hot and cold water inlet pressures = 45 psi
Locking the setting
After selecting the temperature, the
setting can be locked at the desired
value using the control knob.
To do this, unscrew the lock screw
on the upper part of the control knob,
remove the knob and put it back on
so that the internal reference couples
with the protrusion on the knob carrier
ring nut.
Use
Thermostatic mixing valves are typically installed at the outlet of hot
water storage tanks in solar systems to ensure constant temperature
of the mixed water supplied to the end user. Because of their flow
characteristics, the valves can be installed to control the temperature
for both single point of use and for point of distribution. In order to
guarantee the delivery of mixed water at the set temperature, the
thermostatic mixing valves must have a minimum flow rate of:
2521 series min. flow of 1.3 gpm
2523 series min. flow of 2.3 gpm
M
IN
M
A
X
7
1
2
3
Shut-off valve
Pressure reducing valve
Air gap
Check valve
T/P safety valve
Temperature gauge
Expansion vessel
Automatic
diverting valve
Thermostat
Pump
Safety valve
HOT
C O L D
CALEFFI
MIN
MAX7
1
2
T
Normally closed
valve
T
T
Application diagrams - System with thermal integration
The controlling element of the solar thermostatic mixing valve is a
temperature sensor that is fully immersed in the mixed water outlet
passage. As it expands or contracts, the sensor continuously establishes
the correct proportion of hot and cold water entering the valve. The flow
is regulated by a piston sliding in a cylinder between the hot and cold
water passages.
Even when there are pressure drops due to the drawing off of hot or
cold water for other uses or variations in the incoming temperature,
the mixer automatically regulates the water flow to obtain the required
temperature.
Operating principle
Installation
Before installing the mixing valve, the pipework must be flushed out
to ensure that there are no circulating impurities to harm the system.
We recommend always installing filters of sufficient capacity at the
inlet of the water system.
Thermostatic mixing valves can be installed horizontally or vertically.
The following are indicated on the body of the mixing valve:
hot water inlet, indicated with the color red and the word "HOT"
cold water inlet, indicated with the color blue and the word "COLD"
mixed water outlet with the word "MIX".
Ap (psi) (bar)
1.00
1
0
2
0
5
0
2
.
0
4
.
0
8
.
0
2
0
F
l
o
w

r
a
t
e
(
l
/
m
i
n
)

(
g
p
m
)
0.70
0.35
0.20
0.14
0.07
0.03
15
10
5
3
2
1
0.5
2523 2521
2521 series Cv 3.0 (gpm) (Kv 2.6 (l/min))
2523 series Cv 5.5 (gpm) (Kv 4.6 (l/min))
46
Differential temperature controllers
iSolar
257 series
Function
A multi-functional temperature differential controller with add-on system functions, the iSolar series
can be used for a wide variety of applications and has inputs for four PT1000 sensors. Preset factory
defaults are defined for control of a standard solar water heating system with a second relay (some
models) to divert any surplus heat. The auxiliary relay can be used to maintain the tank temperature,
protect the system from overheating, or use another source to heat the storage tank.
This controller features a large Liquid Crystal Display (LCD) user interface with three function keys.
The easy-to-use icons assist to operate and customize a solar heating system.
Product range
Code 257210A iSolar1 controller with 1 standard output relay for pump control, includes 3 temperature sensors
Code 257220A iSolar2 controller with 1 electronic output relay for pump speed control, includes 3 temperature sensors
Dimensions
CALEFFI
Housing plastic: PC-ABS
Protection type: Indoor only
Mounting: wall or in 255 series pump station
Display: LCD with symbols and text
Interface: three soft push buttons
Inputs: 4 temperature sensors
Outputs: 1 or 2 electronic or standard relays
Switching relay capacities: 2 (1) A 115V
Power supply: 115 V - 60 Hz
Bus interface: V-Bus
Performance
LT adjustment range: 240 Ra (120K)
Min. temperature differential 2 Ra (1K)
Hysteresis: 2 Ra, 1 Ra (1K, .5K)
Max. tank temperature range: 35205F (295C)
Max. collector temperature range: 210375F (100190C)
Emergency shut down of the collector: 230395F (110200C)
Min. collector temperature range: 50195F (1090C)
Antifreeze temperature option: 1550F (-1010C)
kWh (BTU) flow input: 05 gpm (020 lpm)
Agency approvals cTVus
Temperature sensors
Platinum RTD type: 1,000 ohm
Collector sensor working range: -58355F (-50180C)
Tank sensor working range: 15175F (-1080C)
Length of collector cable: 60 in. (1.5 m)
Length of tank sensor cable: 95 in. (2.5 m)
F 14 23 32 41 50 59 68 77 86
O 961 980 1000 1019 1039 1058 1078 1097 1117
F 95 104 113 122 131 140 149 158 167
O 1136 1155 1175 1194 1213 1232 1252 1271 1290
F 176 185 194 203 212 221 230 239 248
O 1309 1328 1347 1366 1385 1404 1423 1442 1461
Resistance values for sensors subject to the temperature
Code 257230A iSolar3 controller with 2 standard output relays for pump control, plus valve or second pump control, includes 3 temp. sensors
Code 257260A iSolarPlus controller with 2 electronic output relays for pump speed control, plus valve or second pump control, includes 3 sensors
US US CC
Tested and Approved by TV Rheinland as an approved U.S. Nationally Recognized
Testing Laboratory (NRTL) Exceeds or is equivalent to:
UL 60730-1A
CAN/CSA E60730-1
A
4 3/8
B
6 3/4
C
6
D
2
A
B
D
Code
250041A
Weight (lb)
0.9
C
47
Selectable systems Characteristics
+
+
SET
!
F
R
System screen LCD display
with 16-segment display and
8 symbols for system status
Operating LED control lamp
3 push-button controls
Attractive design and compact
dimensions
Easy to install
User-friendly operation
S1
S2 S4 / TRL
R1
S3
S1
S3
S4
R1
R2
S2
Tank 1
Tank 2
R2
S1
S2
R1
S3
S4 / TRL
R2
S4 / TRL
S1
R1
S2 S3
Tank 1 Tank 2
S1
S2 S3
R1 R2
Tank 1 Tank 2
S4 / TRL
R1
R2
S1
S2
S3
S1
S4
S2
S3
R1
R2
S1
S3
S2
S4
R2
R1
Standard system with 1 tank, 1 pump and 3
sensors. S4 / TRF can be used as BTU meter
System and heat exchange with an existing
tank with 1 tank, 4 sensors and 2 pumps
Solar system and backup heating with 1 tank, 3
2-tank-solar system with valve logic, 3
sensors, 1 solar pump and 3-way valve.
Sensor S4 / TRF can used as BTU meter
2-tank solar system with pump logic, 3
sensors and 2 solar pumps
Solar system with east-west collectors,
1 tank, 3 sensors and 2 solar pumps.
System with backup heating by wood boiler
with 1 tank, 4 sensors, 1 solar pump and
1 pump for backup heating.
System and heating circuit pre-heat with
1 tank, 4 sensors, 1 solar pump and 3-way
valve for heating circuit.
S2
R1
S3
R2
S1
S4 / TRL
System and tank charge in layers with 1 tank,
3 sensors, 1 solar pump and 3-way valve.
Sensor S4 / TRF can be used as BTU meter
R2
S1
S2
R1
S3
S4 / TRL
Solar system and heat dumping with 1 tank, 3
iSolar 1 iSolar 2 iSolar 3 iSolar Plus
Electronic relayy 0 1 0 2
Standard relay 1 0 2 0
Pump speed control no yes no yes
Operating hours counter yes yes yes yes
kWh (BTU) measurement yes yes yes yes
V-bus for data recorder yes yes yes yes
PC-interface RS232 yes yes yes yes
Heat dumping function no no yes yes
Backup heat function no no yes yes
Additional T control no no no yes
Two-tank priority no no no yes
Clock with scheduling no no no yes
A 0 6 2 7 5 2 A 0 1 3 7 5 2 A 0 2 2 7 5 2 A 0 1 2 7 5 2 e d o C
Selectable programs 1 1 2 9
Standard operation functions
T controI - When the switch-on difference is reached, the pump is
activated until the differential temperature drops below.
Maximum tank temperature - When the adjusted maximum tank
temperature is exceeded, the pump switches off.
Collector emergency shutdown - If adjusted collector temperature
is exceeded, the solar pump is switched off.
System cooling - If the temperature rises to the maximum collector
temperature the solar pump remains on until the temperature drops.
Minimum collector temperature - a minimum set temperature
which must be exceeded before the solar pump is switched-on.
Antifreeze function - If the adjusted temperature drops, the solar
pump is switched on to protect the fluid from freezing.
Tank cooIing function - In the evening, the solar pump continues
running until the storage tank is cooled down.
Tube coIIector function - The controller measures an increase of heat
rise in the collector and adjusts operation for maximum efficiency.
Heat generation measurement kWh (BTU) - The heat generated is
measured by the flow and the temperature of feed and return sensors.
Operating hours counter - Operating hours counter stores the
solar operating hours of the respective relay.
Manual operating mode - For control and servicing, the operating
mode of the controller can be switched manually.
Heat dumping function - Heat dumping works independently from
the solar operation and activates the second relay.
Backup heating function - Backup heating works independently
from the solar operation and activates the second relay.
Second independent T controI - The differential temperatures
can be adjusted separately.
Priority tank / tank rotation - The controller checks the temperatures
and rotates or gives priority to charging two tanks.
East / West collectors - Two separate LT controls activate each
solar pump based on collectors and the one-tank temperature.
Advanced operation functions (some two-relay models)
Pump speed control functions (some models)
Pump speed control can improve system efficiency by reducing the flow to
the collectors on cloudy days to improve solar thermal transfer and reduce
electrical consumption. This is achieved by the differential temperature
value between the collectors and storage tank.
If the value for the LT switch-on is reached (e.g. LT on = 9 ), the pump
will start with 100% pump speed for 10 seconds, then reduce the speed to
the adjusted minimum pump speed (min. pump speed = 30 %, adjustable).
If the temperature difference reaches the set value (e.g. LT Set = 18 ),
pump speed will increase by 10 %. At any further rise of 3 LT the pump
speed will increase by 10% until the maximum of 100% is reached.
Model selection
48
Solar pump stations
for solar heating systems
255 - 256 series
Product range
Code 255056A Dual pump station, flow and return connection, flow meter scale: 1/2-5 gpm size 3/4" M NPT unions
Code 255059A Dual pump station, flow and return connection, flow meter scale: 1/2-5 gpm size 3/4" sweat unions
Code 255060A Dual pump station, flow and return connection, flow meter scale: 1/2-5 gpm size 1" male half unions
Code 256059A Single pump station, return connection, flow meter scale: 1/2-5 gpm size 3/4" sweat unions
Function
Solar pump stations are used on the primary circuit of solar heating
systems to control the temperature of the hot water storage. The
pump inside the units is activated by the signal from the differential
temperature controller. The units contain the functional and safety
devices for an optimal circuit control, and ar available with flow and
return connection and with return connection only.
Wilo Star S-16 U15 hydraulic characteristics
CALEFFI
Body: brass
Temperature gauge: steel / aluminium
Seals: PTFE / EPDM
O-Rings: EPDM / Viton
Union gaskets: AFM 34, asbestos free
Insulating shell: EPP, thermal conductivity value = R4
Medium: water, glycol solutions
Max. percentage of glycol: 50%
Max. working temperature: 360F (180C)
Safety relief valve temperature range: -20 to 360F (-30 to 180C)
Safety relief valve factory setting: 90 psi (6 bar)
Min. opening pressure for check valve: Lp: 1/4 psi (2 kPa)
Adjustment range of flow meter: 1/4 to 5 gpm (1 to 20 l/min)
Max return flow meter temperature: 265F (130C)
Pressure gauge scale: 0-90 psi (0-6 bar)
Temperature gauge scale: 32-320F (0-160C)
Connections: 1" male half union
Filling/drain hose connections: 3/4"
Wilo solar model: Star S-16 U15
Body: cast iron
Power supply: 115 V - 60 Hz
Max. pressure: 150 psi (10 bar)
Max. temperature: 230F (110C)
Agency approval: cULus
16
14
12
10
8
6
4
2
4.9
4.3
3.6
3.0
2.4
1.8
1.2
0.6
Head (mm) Head (ft.)
0 2 4 6 8 10 12 14 16 18
Flow (m
3
/h) 0 0.45 0.9 1.36 1.81 2.27 2.72 3.18 3.63 4.08
Flow (gpm)
1
2
3
Wilo pump
Performance
General
The solar pump station is a pre-installed and leak-tested unit with fittings
for transferring heat from the collector to the storage tank. It contains
important fittings and safety devices for the operation of the solar
thermal system:
Ball valves in flow and return in combination with check valves to
prevent gravity and thermo circulation.
Unit for flushing, filling and emptying the system.
Air vent for manual bleeding of the solar thermal system.
Flow meter for displaying and setting the flow rate.
Thermometer in flow and return for displaying both temperatures.
Pressure gauge for displaying the system pressure.
Safety relief valve to prevent overpressure.
Three-speed solar pump for wide range of flow rates.
(Daul station with cover and controller)
49
Characteristic components
The shut-off and check valves are built into the ball valves of the temperature gauge
connectors.
To allow the fluid to flow in both directions, it is necessary to open the respective ball
valve (A) to 45 with a 14mm wrench. The check valve is opened by the ball (B).
In normal system operation, the ball valves must be fully open.
1
4
A
1 Wilo-Solar circulation pump
2 Safety relief valve 253 series
3 Filling/drain valve
4 Pressure gauge
5 Flow meter
6 Air trap and vent
7 Flow temperature gauge
8 Return temperature gauge
9 Pre-formed insulation shell
10 Shut-off and check valve
11 Expansion Tank connection kit
12 3/4" plug (used if no expansion
tank is installed)
Dimensions
A
3/4
3/4
1
B
4
4
4
C
4 7/8
4 7/8
4 7/8
D
15
15
13
E
8
8
8
F
16
16
16
Code
255056A
255059A
255060A
Weight (lb)
15
15
15
A A
B C
A A
E
D
F
A
3/4
B
7
C
16 1/4
D
17
E
5
Code
256059A
Weight (lb)
10
A
B
A
E
C
D
2
5
1
12
6
3
9
8
7
10
4
11
Air trap
The solar pump unit version with flow and return connection is equipped with an air trap
on the flow line. The gases, separated from the fluid, are collected at the top of the trap.
The collected gases must be released from time to time - every day after the initial
installation; however, it can eventually be done weekly or monthly, depending on the
quantity of the air. The collected gases are released using the manual air vent with a
screwdriver. To maintain optimal efficiency of the solar heating system, it is necessary
to vent the system every six months by using the manual air vent.
B
50
Safety relief valve for solar systems
253 series
General
The safety relief valves manufactured by Caleffi are produced in
compliance with the essential safety requirements of the Directive
97/23/EC of the European Parliament and the Council of the European
Union for the Harmonization of Member States with regard to pressurized
equipment.
Function
These safety relief valves are used to control pressure in the primary
circuits of solar heating systems.
When the calibrated pressure is reached, the valve opens to release
the fluid into the atmosphere and prevents the pressure in the system
from reaching levels that might damage the solar collectors and
equipment.
These particular series of products have been specially made and certified
to work at high temperature with a glycol medium.
Product range
253 series Safety relief valve for solar systems size 1/2" F x 3/4" F
1
1
1
5
- control spindle: brass
- relief seal: high resistance elastomer
stainless steel : g n i r p s -
0 3 G 6 A P : b o n k l o r t n o c -
Normal pressure: 150 psi (10 bar)
V I PED section:
according to TV SV 07 2009 : l a v o r p p A
TV SOL 50 p
F " 4 / 3 x F " 2 / 1 : s n o i t c e n n o C
Performance
% 0 1 : e r u s s e r p r e v o g n i n e p O
% 0 2 : l a i t n e r e f f i d g n i s o l C
: y: 171,000 BTU (50 kW) t i c a p a c e g r a h c s i D
Code 253043 253044 253046 253048 253040
Preset psi (bar) 45 (3) 60 (4) 90 (6) 120 (8) 150 (10)
Dimensions
A
1/2"
B
3/4"
C
1
D
2 3/4
E
1 3/8
A
E
D
C
B
Code
25304_
Weight (lb)
0.3
CALEFFI
TV Rheinland is an approved U.S. Nationally
Recognized Testing Laboratory (NRTL)
Certification Body for Pressure Equipment
CALEFFI
51
253 series
Safety relief valve for solar heating systems. CE mark as per Directive 97/23/EC. TV certified for solar systems. 1/2" F x 3/4" F
threaded connections. Brass body. Chrome plated. Diaphragm and disk seal in high resistance elastomer. Spring of stainless steel
Control knob of PA6G30. Temperature range: -20 to 360F (-30 to 180C). Nominal pressure: 150 psi (10 bar). Calibration setting:
45, 60, 90, 120, 150 psi (3, 4, 6, 8, 10 bar). Medium: water and glycol solutions. Maximum percentage of glycol: 50%.
Operating principle
The valve disk (1), pressed by a
preset spring (2), raises off the seat
when reaching the preset pressure
and fully opens the outlet vent.
The preset pressure is chosen
according to the maximum
permissible pressure in the solar
heating system.
The di amet er of t he out l et
connection (3) is greater than the
inlet in order to help discharge
the required volume.
As the pressure decrease, the
opposite action, occurs with the
valve subsequently closing within
the preset tolerances.
Discharge pipe
Temperature and glycol
In solar systems, heating fluid of the primary circuit contains glycol
as an additive and operates at high temperatures. Because of these
particular operating conditions, the valve disk seal of the safety
valve is made of high resistance elastomer.
The knob is made of plastic material especially resistant to increases
in temperature and to UV rays, in the case of outdoor installations.
Chrome plating
The valve body is chrome plated to protect it from dirt and moisture,
in the case of outdoor installations of solar heating systems.
Certification
253 series safety relief valves are certified for specific use in solar
heating systems by the certifying body TV, in accordance with
standard SV 100 Ed. 10.01 par. 7.7. TV Rheinland is an approved
U.S. Nationally Recognized Testing Laboratory (NRTL)
Installation
The safety relief valves for solar systems must be installed near the
point in the circuit where the system is filled - before the expansion
tank.
Make sure there are no shut-off devices between the valve and the
rest of the system.
The safety relief valves can be fitted vertically or horizontally but
not upside down. This prevents deposits of impurities from affecting
correct functioning.
The safety relief valves must be installed in line with the flow direction
indicated by the arrow on the valve body.
1
2
3
Application diagram
This valve should only be used and properly installed so that spillage
of glycol could not cause damage. To avoid damage due to valve
operation, a discharge pipe must be installed. It should terminate
approximately 12" (305mm) above an appropriate container or through
an air gap, as shown in the diagram,
piped into a suitable container or other
suitable place of disposal. Under no
circumstances should the vent opening
or drain line be plugged.
52
Expansion tanks for pressurized systems
SolarPlus
259 series
General
Product range
Code 259 series SolarPlus expansion tanks for pressurized solar heating systems sizes 3, 5, 7, 9, 13 gallons
Materials: - body: welded steel
- coating: epoxy paint
- diaphragm: EPDM
System temperature range: 15...250F (-10...120C)
Max. diaphragm temperature: 210F (100C)
Pre-charged pressure: 35 psi (2.5 bar)
Connection: 3/4" M
Dimensions Dimensions
A
3/4
B
11 7/8
C
15 1/2
D
3/4
A
Code
250025
Size (gal)
7
A B C D Code Size (gal)
B
C
CALEFFI
Modern solar heating systems can reach temperatures of up to 385F during inactivity. The rsult is the
vaporization of the solar liquid and extreme temperatures in the solar circuit, up to the solar station.
This damages parts of the system, including pumps, connection joints and the diaphragm in the
expansion tank. Furthermore, in the event of prolonged heat absorption, for example in the summer,
when on vacation or if the electricity is out, the pressure of the solar system can increase to the point
of activating the safety relief valve. In order to support the highest possible inactivity temperatures, the
special heat-resistant diaphragm in the SolarPlus expansion tank can withstand temperatures up to 210F.
A
D
C
D
B
3/4 10 5/8 13 3/4 3/4 250018 5
3/4 10 5/8 10 5/8 3/4 250012 3 3/4 15 3/4 16 1 259035 9
3/4 21 1/8 16 1 259050 13
The diaphragm pressure expansion tank ensures that the system pressure does not exceed or drop
below the limits established in the system design. The diaphragm divides the space inside the tank
occupied by the pre-charged gas and the solar fluid. When the volume of the solar fluid expands because
of the heat, the diaphragm stretches into the gas chamber. As a result, the space available for the solar
fluid increases and the pressure inside the system remains constant at the designed value. When the
volume of the solar fluid decreases because of cooling, the diaphragm returns to the correct initial
pre-charged pressure.
Function
Mounting feet for wall installation.
CALEFFI
53
0
1
2
3
4
5
0
20
40
60 80 100
120
140
160 0
20
40
60 80 100
120
140
160
0
1
2 3 4
5
6
Shut-off valve
Pump
Air vent
Expansion vessel
Safety relief valve
Installation
The expansion tank can be installed after the flow check valve on the outlet side of the circulation
pump, between the solar collector (exit pressure), or it can be on the inlet side of the circulation pump
(entrance pressure). Since there can be no check valve between the collector and the expansion
tank, the expansion tank should be installed on the outlet side of the pump (exit pressure).
+
+
SET
A expansion tank connection kit, consisting of a flexible stainless steel hose,
a double automatic shut-off valve, wall bracket and mounting hardware, helps
reduce installation time and provides suitable mounting.
Code: 255001
Max. working pressure: 150 psi (10 bar).
Max. check valve working temperature: 250 F (120C).
Hose length: 20 in. (500 mm).
Connections: 3/4" straight.
Bracket for expansion tank with a maximum capacity of 7 gallons.
0
20
40
60
80
100
120
140
160
0
1
2 3
4
5
6
Accessories
54
Flexible stainless steel insulated piping
SolarFlex
NA3540-15
Function
Product range
Code NA3540-15 SolarFlex 50 foot coil with four 1" union nuts, four segment rings. four flat-sealing washers and two 1" double nipples
Code NA637304 SolarFlex pipe hangers includes four hanger and mounting hardware
Materials:
- pipe: two corrugated stainless steel 316L
insulation: two closed cell elastomer UV resistance EPDM -
outer cover: UV resistant polyolefin copolymer foil
-
Thermal conductivity at 105F (40C): R-3.6 (.04W/mK) Min. bending radius: 5 inch (130mm)
Dimensions
CALEFFI
SolarFlex is a system solution with pre-insulated flow and return pipes for solar hot water heating systems
used to connect the solar collector with the storage tank in an easy, quick and professional way. It optimizes
thermal efficiency of the entire system. The pre-insulation solution of two flexible stainless steel pipes inside
two EPDM closed cell insulation and the integrated sensor cable, saves time and reduces cost of installation.
SolarFlex is packaged in a 50-foot continuous coil with a complete range of accessories to ensure a smooth
and secure installation.
General
- Easy to separate, without damaging the tubes.
- External copolymer foil protects against UV radiation and mechanical strain.
- Identification mark for flow and return.
- Meets highest requirements for modern solar heating systems.
- Pre-insulated feed and return pipes can be joined easily without special tools.
A
3/4
B
15/16
C
4
D
2 1/8
Code
NA3540-15
Weight (lb/f)
0.5
Example: pressure drop at a flow of 3.0 gpm = 0.08 psi x 50 feet of pipe = 4 psi
Length per coil: 50 feet (15m)
Fluid capacity per foot: 0.0346 gallons (0.13 liters) Insulation thickness: 5/8 inch (16mm)
Max. fluid temperature: 350F (175C)
Min. surface temperature: -60F (-50C)
Code NA1210-3 SolarFlex connection kit includes four 1" union nuts, four segment rings and four flat-sealing washers
A B
C
D
Pressure drop per foot (psi) (kPa)
F
lo
w

(
lp
m
)

(
g
p
m
)
0
.
0
0
.
5
1
.
0
1
.
5
2
.
0
2
.
5
3
.
0
3
.
5
4
.
0
4
.
5
5
.
0
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
0.18
0.20
0.22
0.00
0.14
0.28
0.41
0.55
0.69
0.83
0.96
1.10
1.24
1.38
1.52
0
.
0
1
.
9
3
.
8
5
.
7
7
.
6
9
.
5
1
1
.
3
1
3
.
2
1
5
.
1
1
7
.
0
1
8
.
9
55
Flexible stainless steel pipe
UV resistant protection film
Closed cell elastomeric
EPDM foam insulation
Integrated two-wire
sensor cable
Installation of union nuts
Flow and return pipes are easy to separate without damaging the
insulation or sensor cable.
SolarFlex pipe is a flexible, quick installation system to connect solar
collectors to the pump station and to the storage tank. The pipe system
is easy to install, enabling pipes to be run without using a torch in
confined spaces or on the roof. Two closed cell elastomeric foam
extrusions of high temperature resistant EPDM are protected against
damages by a common outer cover. Flow and return pipes can be
easily separated without damaging the insulation.
SolarFlex is the way to reduce installation time while ensuring a leak-
free installation. SolarFlex`s union nut assembly method does not
require special tools or time.
General
SolarFlex is packaged in a 50` coil with four 1" union nuts, four flat
sealing washers, four segment rings and two each 1" male nipples.
Optional pipe hangers keep pipe secure and reduce installation time.
Cut pipe with tubing cutter. Do not
use a hack saw.
Connect 1" nipple with 1" union nut
without flat-sealing washer.
Remove union nipple to inspect
flat-sealing surface.
Slide on 1" union nut and close
segment ring around pipe groove.
Tighten 1" nipple to 1" union nut.
Forming a flat-sealing surface.
Insert flat-sealing washer and
connect to other fittings.
Cut the length of pipe required to connect solar collector to the solar
pumping stations and attach 1" union nut fittings on each end.
Any remaining short sections of pipe can be used for tank connection
or other connections.
Use connection kit NA1210-3,
which includes four each 1" union
nuts, segments rings and sealing
washers.
Model Description
NA637204 1" union male to 1" union male nipple
NA10060 1" union male to 3/4" NPT female adaptor
NA10061 1" union male to 3/4" sweat adaptor
NA10062 1" union male to 1" sweat adaptor
NA10064 1" union male to 1" NPT male nipple
254462 1" union male to 22 mm compression
255862 1" union male to 22 mm compression elbow
Fitting for connecting to collectors and tanks
Using cut sections of pipe
2 Panel/80 Gallon Tank System
3-5 People, 60 gallons use per day
Using Viessmann Flatplate Collector
2 7248-395 VITOSOL 100-F, FLAT PLATE COLLECTOR
1 7248-240 GENRAL CONNECTION SET
1 SSU-80SB SUPERSTOR STAINLESS SOLAR TANK
1 255059A SOLAR CIRCULATION UNIT
1 253046 3/4" FPT 90 PSI SAFETY VALVE
1 257230A I SOLAR 3 DIF TEMP CONTROLLER
1 259025 7 GAL HIGH TEMP EXPANSION TANK
1 255001 3/4" STRAIGHT EXPANSION TANK CONNECTION KIT
4 NA10061 3/4" SOLFLEX TO 3/4" COPPER SWEAT FTG
1 251003A 3/4" SOLAR IN-LINE AIR SEPERATOR
50gal/Day
121.5F
2xVitosol 200F
Total Gross SurfaceArea: 53.99sq.ft
Azimuth: 0
Incl:30
Vitocell-H 100(130Liter) Vitocell-H 300(350Liter) Vitola10022kW
Results of Annual Simulation
Page 1
Line 1: Please enter under Options
2.80 Flat Plate System
Variant1
T*SOL Pro 4.4 7/3/2008
Installed Collector Power: 11.98 kBtu/hr
Collector Surface Area Irradiation: 25.79 MBtu 514.75 kBtu/sq.ft
Energy Produced by Collectors: 11.34 MBtu 226.44 kBtu/sq.ft
Energy Produced by Collector Loop: 9.89 MBtu 197.49 kBtu/sq.ft
DHW Heating Energy Supply: 10.98 MBtu
Solar Contribution to DHW: 9.09 MBtu
Energy from Auxiliary Heating: 3.39 MBtu
fuss
kopf
Fuel Oil Savings: 102.1 gal
CO2 Emissions Avoided: 2,267.93 lbs
DHW Solar Fraction: 72.9 %
Fractional Energy Savings (prEN
12976):
73.3 %
System Efficiency: 35.2 %
fuss
Basic Data
Page 2
Variant1
T*SOL Pro 4.4 7/3/2008
Climate File
Location: Boston MA
Weather Data Record: "Boston MA"
Global Radiation Annual Total: 4.86 MBtu
Latitude: 42.37
Longitude: 71.05
Domestic Hot Water
Average Daily Consumption: 50 gal
Desired Temperature: 121.5 F
Load Profile: Detached House (evening max)
Cold Water Temperature: February:45.48 F / August:52.72
F
Fuss
System Components
Collector Loop
Manufacturer: Viessmann Werke GmbH & Co
Type: Vitosol 200 F
Number: 2.00
Total Gross Surface Area: 53.992 sq.ft
Total Active Solar Surface Area: 50.095 sq.ft
Inclination (Tilt Angle): 30
Azimuth: 0
DHW Standby Tank
Manufacturer: Viessmann
Type: Vitocell-H 100 (130 Liter)
Volume: 34.34 gal
Solar Preheating Tank (S)
Volume: 92.46 gal
Auxiliary Heating
Fuss
Original T*SOL Database
With Test Report
Solar Keymark
System Components
Page 3
Variant1
T*SOL Pro 4.4 7/3/2008
Type: Vitola 100 22 kW
Nominal Output: 75.06 kBtu/hr
Fuss
With Test Report
Solar Keymark
Page 4
Variant1
T*SOL Pro 4.4 7/3/2008
Solar Energy Consumpt ion as Percent age of Tot al Cosumpt ion
Solar System 9,122,921 Btu Total EnergyConsumption 12,521,862 Btu
Dec Nov Oct Sep Aug J ul J un May Apr Mar Feb
[

B
t
u

]
300,000
280,000
260,000
240,000
220,000
200,000
180,000
160,000
140,000
120,000
100,000
80,000
60,000
40,000
20,000
0
Daily Maximum Collect or Temperat ure
Dec Nov Oct Sep Aug J ul J un May Apr Mar Feb J an
[

F

]
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
These calculations were carried out by T*SOL Pro 4.4 - the Simulation Programme for Solar Thermal Heating
Systems. The results are determined by a mathematical model calculation with variable time steps of up to 6
minutes. Actual yields can deviate from these values due to fluctuations in the weather, consumption and other
factors.The Schematic System Diagram above does not represent and cannot replace a full technical drawing of the
solar system.
Report-/Druckmodul List & Label Version 11.0: Copyright combit GmbH 1991-2005
0
10
20
30
40
50
l
0
20
40
60
80
100
120
140
kg
0
20
40
60
80
100
%
0
200,000
400,000
600,000
800,000
1,000,000
Btu
Variant1
J an Feb Mar Apr May J un J ul Aug Sep Oct Nov Dec
Time Period 1/ 1/ - 12/31/
Saving Fuel Oil 387 l CO2 Emissions Avoided 1,029 kg
DHW Solar Fraction 73 % Efficiency 35 %
E Solar - DHW 9,122,921 Btu
3 Panel/119 Gallon Tank System
5-7 People, 75 gallons use per day
Using Viessmann Flatplate Collector
3 7248-395 VITOSOL 100-F, FLAT PLATE COLLECTOR
1 7248-240 GENERAL CONNECTION SET
1 SSU-119SB SUPERSTOR STAINLESS SOLAR TANK
1 255059A SOLAR CIRCULATION UNIT
1 253046 3/4" FPT 90 PSI SAFETY VALVE
1 257230A I SOLAR 3 DIF TEMP CONTROLLER
1 259025 7 GAL HIGH TEMP EXPANSION TANK
1 255001 3/4" STRAIGHT EXPANSION TANK CONNECTION KIT
4 NA10061 3/4" SOLFLEX TO 3/4" COPPER SWEAT FTG
1 251003A 3/4" SOLAR IN-LINE AIR SEPARATOR
75gal/Day
121.5F
3xVitosol 200F
Total Gross SurfaceArea: 80.99sq.ft
Azimuth: 0
Incl:30
Vitocell-H 100(130Liter) Vitocell-H 300(500Liter) Vitola10022kW
Results of Annual Simulation
Page 1
3.120
T*SOL Pro 4.4 7/3/2008
Installed Collector Power: 17.97 kBtu/hr
Collector Surface Area Irradiation: 38.68 MBtu 514.75 kBtu/sq.ft
Energy Produced by Collectors: 16.48 MBtu 219.27 kBtu/sq.ft
Energy Produced by Collector Loop: 14.93 MBtu 198.72 kBtu/sq.ft
DHW Heating Energy Supply: 16.47 MBtu
Solar Contribution to DHW: 13.83 MBtu
Energy from Auxiliary Heating: 4.24 MBtu
fuss
kopf
Fuel Oil Savings: 154.7 gal
CO2 Emissions Avoided: 3,434.59 lbs
DHW Solar Fraction: 76.5 %
Fractional Energy Savings (prEN
12976):
77.1 %
System Efficiency: 35.8 %
fuss
Basic Data
Page 2
3.120
T*SOL Pro 4.4 7/3/2008
Climate File
Location: Boston MA
Weather Data Record: "Boston MA"
Global Radiation Annual Total: 4.86 MBtu
Latitude: 42.37
Longitude: 71.05
Domestic Hot Water
Average Daily Consumption: 75 gal
Desired Temperature: 121.5 F
Load Profile: Detached House (evening max)
Cold Water Temperature: February:45.48 F / August:52.72
F
Fuss
System Components
Collector Loop
Manufacturer: Viessmann Werke GmbH & Co
Type: Vitosol 200 F
Number: 3.00
Total Gross Surface Area: 80.988 sq.ft
Total Active Solar Surface Area: 75.143 sq.ft
Inclination (Tilt Angle): 30
Azimuth: 0
DHW Standby Tank
Volume: 34.34 gal
Solar Preheating Tank (S)
Volume: 132.09 gal
Auxiliary Heating
Fuss
With Test Report
Solar Keymark
System Components
Page 3
3.120
T*SOL Pro 4.4 7/3/2008
Type: Vitola 100 22 kW
Nominal Output: 75.06 kBtu/hr
Fuss
With Test Report
Solar Keymark
Page 4
3.120
T*SOL Pro 4.4 7/3/2008
Solar Energy Consumpt ion as Percent age of Tot al Cosumpt ion
Solar System 13,880,614 Btu Total EnergyConsumption 18,138,892 Btu
Dec Nov Oct Sep Aug J ul J un May Apr Mar Feb
[

B
t
u

]
440,000
420,000
400,000
380,000
360,000
340,000
320,000
300,000
280,000
260,000
240,000
220,000
200,000
180,000
160,000
140,000
120,000
100,000
80,000
60,000
40,000
20,000
0
Daily Maximum Collect or Temperat ure
Dec Nov Oct Sep Aug J ul J un May Apr Mar Feb J an
[

F

]
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
These calculations were carried out by T*SOL Pro 4.4 - the Simulation Programme for Solar Thermal Heating
Systems. The results are determined by a mathematical model calculation with variable time steps of up to 6
minutes. Actual yields can deviate from these values due to fluctuations in the weather, consumption and other
factors.The Schematic System Diagram above does not represent and cannot replace a full technical drawing of the
solar system.
Report-/Druckmodul List & Label Version 11.0: Copyright combit GmbH 1991-2005
0
10
20
30
40
50
60
70
80
l
0
50
100
150
200
kg
0
20
40
60
80
100
%
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
Btu
3.120
J an Feb Mar Apr May J un J ul Aug Sep Oct Nov Dec
Time Period 1/ 1/ - 12/31/
Saving Fuel Oil 585 l CO2 Emissions Avoided 1,558 kg
DHW Solar Fraction 77 % Efficiency 36 %
E Solar - DHW 13,880,614 Btu
Project Information
Heating Contractor Project Information
Company Name: Customer Name:
Contact Name: Street:
Phone: City:
Fax: State, Zip:
Cell:
Installation Area 3. Roof Construction:
(Check One) (Check One)
Slope Roof Asphalt Shingle
Flat Roof Tar & Gravel
Other Roof Tile
Other
Is there any shading? Yes No
Collector Alignment Collector Inclination_______________ Available Roof Surface Area
Deviation from South Legnth:______________________
Width: ______________________
Solar Project Check List
Solar Project Check List
Building Data
New Construction Retrofit
Pipe length from collector to solar storage tank (one way): feet. #of floors:
Mechanical room location: Basement Roof Other:
Solar System Use
DHW Heating Swimming Pool Heating Space Heating Support
DHW Heating Load
Residential Home How many people in home? DHW usage: USG/day
#of bathrooms: Whirlpool tub size: USG
Multi-family/Apartment #of units: Average #of people per uit:
DHW usage: USG/day Recirc loop Yes No
Other DHW Application Building type: DHW usage: USG/day
DHW Temperature Desired f DHW use pattern: Is it the same all year? Yes No
Swimming Pool Heating
Open Air Pool Location: Wind exsposed Wind protected
Indoor Pool Period of use: J une - August May - September
Swimming Pool Size (L/W/D): / / ft. Pool Volume:(LxWxDx7.5) USG
Desired Pool Temperature: f Pool cover used: Yes, hrs/day used: No
Backup reheating available Yes No If Yes, what type:
Space Heating Support
Size of heated area: s.f. Building heat load: MBH
High temp heating (radiator/fan coil) System temp: f % of building heated:
Low temp heating (radiant floor) System temp: f % of building heated:
Installed boiler output: MBH Fuel type:
Example: Family of 5
1 What is the hot water demand per day?
Most common multiplier is 20 gals pp/pd
5 * 20 = 100 gals/day
2 What is the BTUH requirement to heat the water?
Multiply gals by BTU/lb multiplier by delta T of water
100 * 8.3 * 65 = 53,950 BTU/day
3 What type of collector do you want to use?
4 How many BTU/day are the collectors capable of?
Use row D of SRCC Rating for safety (Water Heating Cool Climate)
(Ti-Ta = Fluid Temp at collector Versus Ambient Air Temp at Collector)
s.f. BTU/s.f/d BTU/s.f/d Collectors
D rating C rating Needed
Viessmann 100 Series Flat Plate 27.16 22k 30k 3
Buderus SKS 4.0 25.95 19k 28k 3
5 Once you have determined the number of collectors, determine
the flow requirements.
Collector Collector Example
p.d. flow flow rate
Viessmann 100 Series Flat Plate .25 iwc .79 gpm 2.4 gpm
6 Select piping size between collector like any other hydronic system.
Rule of Thumb: (50' or less)
1/2" piping will support 2-4 collectors
3/4" piping will support 4-8 collectors.
1" piping will support 8-12 collectors.
Collector Type
Collector Type
SIZING A SOLAR DHW SYSTEM
7 Storage Tank Sizing.
In general, the storage tank should be sized to handle to Gals/day required.
In this example, we calculated a 100 Gal/day need so a 119 gallon tank would
be used. If you install a recirc pump between tanks, you can use the combined
volume of the two tanks.
A second school of thought is to have a 1:1 - 2:1 ratio between tank volume in
gallons and collector area in s.f.
In our example, the tank volume is 119 gallons, the collector area is 109 s.f.
This works out to a 1.1 - 1.0 ratio.
If you added a recirc pump to an existing 60 gallon tank, the ratio
would be 1.6 - 1.0.
8 How do you size the Solar Pump?
The same rules apply for the Solar Pump as they do in any other hydronic
application.
What are my BTU needs?
What are my flow requirements?
What is my pressure Drop?
Now size my pump.
EXAMPLES OF SOLAR SYSTEM COSTS WITH INCENTIVES
SYSTEM #1
$6,700.00 INSTALLED COST (Minimum required to maximize Federal & State incentives)
Federal Tax Credit = 30% of Installed Cost up to $2,000.00
$2,000.00 / .30 =$6,666.66
or $6,667.00 * .30 =$2,000.00
MA Tax Credit = 15% of Installed Cost up to $1,000.00
$1,000.00 / .15 =$6,666.66
or $6,667.00 * .15 =$1,000.00
Keyspan Rebate = 15% of Installed Cost up to $1,500.00
6,700.00 * .15 =$1,005.00
This does not maximize Keyspan incentive!
The Federal and State incentive come in the form of TAX CREDITS.
These you take off of your Taxes Owed when filling out your tax returns.
The Keyespan incentive comes in the form of a direct cash REBATE. Remember,
this is for Keyspan Customers only installing Solar for DHW!
A homeowner who installed a system for $6,700.00 would be able to reduce
their taxes owed by $3,000.00 in this example. This would result in a net
installed cost of $3,700.00. If they are also a Keyspan Customer, the net installed
cost drops to $2,695.00.
SYSTEM #2
$10,000.00 INSTALLED COST
A homeowner who installed a system for $10,000.00 would also be able to reduce
their taxes owed by $3,000.00. This would result in a net installed cost of $7,000.00.
If they are also a Keyspan Customer, they would be able to maximize the Keyspan Rebate.
The net installed cost in this example would drops to $5,500.00.
Solar Cost Analysis
20 * 8.34 * 60 = 10,008
gals/pp/pd lbs. per gal temp. rise BTU/pp/pd
of water
5 * 10,008 = 50,040
family size BTU/pp/pd BTU/day
3 * 22,000 = 66,000
flat plate panel output system output
collectors sunny day sunny day
Versus Oil
1 gal/oil = 4.5 = 138,000
$ per gal BTU/hour
138,000 * 0.75 = 103,500
BTU/hour efficiency BTU/gal
w/ standby oil
50,040 / 103,500 = 0.48
BTU/day BTU/gal gals/pd
DHW need oil oil
0.48 * 4.5 * 365 = 794.11 $
gals/pd $ per gal days gross savings
oil per year
794.11 $ * 0.65 = 516.17 $
gross savings Solar net savings
per year Fraction per year
Massachusetts
Residential Renewable Energy Income Tax Credit
Incentive Type: Personal Tax Credit
Eligible Renewable/Other
Technologies:
Solar Water Heat, Solar Space Heat, Photovoltaics, Wind
Applicable Sectors: Residential
Amount: 15%
Maximum Incentive: $1,000
Carryover Provisions: Excess credit may be carried forward three years
Eligible System Size: Not specified
Equipment/Installation
Requirements:
System must be new and in compliance with all applicable performance and
safety standards and must be reasonably expected to remain in operation for
at least five years.
Authority 1: M.G.L. Ch. 62, 6(d)
Date Enacted: 1979
Website: http://www.state.ma.us/
doer/programs/renew/renew.htm#taxcred
Summary:
Massachusetts allows a 15% credit -- up to $1,000 -- against the state income tax for the cost of a renewable-energy
system (including installation costs) installed on an individuals primary residence. If the credit amount is greater than
a resident's income tax liability, the excess credit amount may be carried forward to the next succeeding year for up
to three years. Eligible technologies include solar water and space heating, photovoltaics (PV), and wind-energy
systems.
The credit is available to any owner or tenant of residential property. For a newly constructed home, the credit is
available to the original owner/occupant.
Contact:
Legal Department
Massachusetts Division of Energy Resources (DOER)
100 Cambridge St.
Suite 1020
Boston, MA 02114
Phone: (617) 727-4732
Fax: (617) 727-0030
E-Mail: doer.energy@mass.gov
Web site: http://www.mass.gov/doer/home.htm
Tax Information
Massachusetts Department of Revenue
P.O. Box 701
Boston, MA 02204
Phone: (800) 392-6089
Web site: http://www.dor.state.ma.us

Federal Incentives for Renewables and Efficiency

Printable Version

Residential Solar and Fuel Cell Tax Credit
Last DSIRE Review: 01/08/2008

Incentive Type: Personal Tax Credit
Technologies:
Solar Water Heat, Photovoltaics, Fuel Cells, Other Solar Electric
Technologies
Applicable Sectors: Residential
Amount: 30%
Maximum Incentive: $2,000 for solar-electric systems and solar water-heating systems; $500
per 0.5 kW for fuel cells
Carryover Provisions: Excess credit may be carried forward to succeeding tax year
Eligible System Size: Not specified
Equipment/Installation
Requirements:
Solar water heating property must be certified by SRCC or by comparable
entity endorsed by the state in which the system is installed. At least half
the energy used to heat the dwelling's water must be from solar in order for
the solar water-heating property expenditures to be eligible.
Authority 1: 26 USC 25D
Date Enacted: 8/8/2005
Effective Date: 1/1/2006
Expiration Date: 12/31/2008

Summary:

Note: IRS Form 5695 & Instructions: Residential Energy Credits for Tax Year 2007 are now
available. Also note that the federal tax credits for home energy-efficiency improvements under
26 USC 25C expired on 12/31/07, but the solar and fuel cell tax credits are available through
12/31/08.

The Energy Policy Act of 2005 (H.R. 6, Sec. 1335) established a 30% tax credit up to $2,000 for the
purchase and installation of residential solar electric and solar water heating property. An individual can
take both a 30% credit up to the $2,000 cap for a photovoltaics system and a 30% credit up to a separate
$2,000 cap for a solar water heating system. A 30% tax credit up to $500 per 0.5 kilowatt (kW) is also
available for fuels cells. Initially scheduled to expire at the end of 2007, the tax credits were extended
through December 31, 2008, by Section 206 of the Tax Relief and Health Care Act of 2006 (H.R. 6111).

Solar water heating property must be certified for performance by the Solar Rating Certification
Corporation (SRCC) or a comparable entity endorsed by the government of the state in which the
property is installed. Note that the tax credit does not apply to solar water heating property for swimming
pools or hot tubs.

The credit is calculated based on the individuals expenditures excluding subsidized energy financing,
which is defined as "financing provided under a Federal, State, or local program a principal purpose of
which is to provide subsidized financing for projects designed to conserve or produce energy."
Consumers who receive other incentives are advised to consult with a tax professional regarding how to
calculate this federal tax credit.

If the federal tax credit exceeds tax liability, the excess amount may be carried forward to the succeeding
taxable year. Expenditures include labor costs for the onsite preparation, assembly, or original installation
of the system and for piping or wiring to interconnect the system to the dwelling.

To be eligible for the credit, a system must be "placed in service" or activated on or after J anuary 1, 2006,
and on or before December 31, 2008. Expenditures with respect to the equipment are treated as made
when the installation is completed. If the installation is on a new home, the "placed in service" date is the
date of occupancy by the homeowner.

Contact:
Public Information - IRS

Federal Incentives for Renewables and Efficiency
Printable Version
Business Energy Tax Credit
Last DSIRE Review: 07/25/2007
Incentive Type: Corporate Tax Credit
Technologies:
Solar Water Heat, Solar Space Heat, Solar Thermal Electric, Solar Thermal
Process Heat, Photovoltaics, Geothermal Electric, Fuel Cells, Solar Hybrid
Lighting, Direct Use Geothermal, Microturbines
Applicable Sectors: Commercial, Industrial
Amount: For equipment placed in service from January 1, 2006 until December 31,
2008, the credit is 30% for solar, solar hybrid lighting, and fuel cells, and
10% for microturbines. The geothermal credit remains at 10%.
Maximum Incentive: $500 per 0.5 kW for fuel cells; $200 per kW for microturbines; no maximum
specified for other technologies
Eligible System Size: Microturbines less than 2 MW; fuel cells at least 0.5 kW
Authority 1: 26 USC 48
Authority 2: IRS Form 3468 (Tax Year 2006)
Summary:
The federal Energy Policy Act of 2005 (H.R. 6) expanded the federal business energy tax credit for solar
and geothermal energy property to include fuel cells and microturbines installed in 2006 and 2007, and to
hybrid solar lighting systems installed on or after January 1, 2006. These provisions of the tax credit were
later extended through December 31, 2008, by Section 207 of the Tax Relief and Health Care Act of
2006 (H.R. 6111). (A 10% federal energy tax credit was available to businesses that invested in or
purchased solar or geothermal energy property in the United States prior to January 1, 2006.)
For eligible equipment installed from January 1, 2006, through December 31, 2008, the credit is set at
30% of expenditures for solar technologies, fuel cells and solar hybrid lighting; microturbines are eligible
for a 10% credit during this two-year period. For equipment installed on or after January 1, 2009, the tax
credit for solar energy property and solar hybrid lighting reverts to 10% and expires for fuel cells and
microturbines. The geothermal credit remains unchanged at 10%.
The credit for fuel cells is capped at $500 per 0.5 kilowatt (kW) of capacity. The maximum microturbine
credit is $200 per kW of capacity. No maximum is specified for the other technologies.
Solar energy property includes equipment that uses solar energy to generate electricity, to heat or cool
(or provide hot water for use in) a structure, or to provide solar process heat. Hybrid solar lighting
systems are those that use solar energy to illuminate the inside of a structure using fiber-optic distributed
sunlight. Geothermal energy property includes equipment used to produce, distribute, or use energy
derived from a geothermal deposit. It does not include geothermal heat pumps. For electricity produced
by geothermal power, equipment qualifies only up to, but not including, the electrical transmission stage.
Energy property does not include public utility property, passive solar systems, or pool heating
equipment.
To qualify, the original use of the equipment must begin with the taxpayer or it must be constructed by the
taxpayer. The equipment must also meet any performance and quality standards in effect at the time the
equipment is acquired. The energy property must be operational in the year in which the credit is first
taken.
If the project is financed in whole or in part by subsidized energy financing or by tax-exempt private
activity bonds, the basis on which the credit is calculated must be reduced. (The formula is described in
the tax credit instructions.) Subsidized energy financing means "financing provided under a federal, state,
or local program, a principal purpose of which is to provide subsidized financing for projects designed to
conserve or produce energy." Therefore, a business must reduce the basis for calculating the credit by
the amount of any such incentives received.
Contact:
Public Information - IRS
.
Massachusetts
KeySpan Energy Delivery - Solar Thermal Rebate Program
Incentive Type: Utility Rebate Program
Technologies:
Solar Water Heat and Solar Pool Heating for residential customers;
Also, Solar Space Heat and Solar Thermal Process Heat for
commercial/industrial customers
Applicable Sectors: Commercial, Industrial, Residential, Multi-Family Residential (KeySpan
Customers Only)
Incentive Amount: Residential: $1,500;
Commercial/Multi-family: $3/therm based on estimated first-year savings
Maximum Incentive: Residential: $1,500;
Commercial/Multi-family: $100,000 per project, up to 50% of project costs
Summary:
KeySpan provides funding support to residential, commercial, industrial, and multifamily customers that install solar
thermal technologies between 5/1/07 and 4/28/08. Recommended solar thermal applications include solar hot water
heating, solar pool heating, and in some cases solar space heating or high temperature process applications. Eligibility
requirements are in place to ensure quality installation of solar thermal systems.
Residential customers: KeySpan customers with eligible SHW systems can apply for a rebate of 15% off project costs
up to a maximum of rebate of $1,500 for solar water heating systems . This rebate requires that participating
customers share their water heating usage data for a period of 12 months in order to receive funding. KeySpan works
directly with residential solar installers, who submit rebate application on behalf of the KeySpan customer.
Commercial & Industrial, and Multi-family customers: KeySpan requires a free energy audit to interested participants
to identify appropriate solar thermal technologies as well as estimated natural gas savings. Commercial, industrial,
and multifamily customers receive a one-time rebate of $3 per therm of estimated first-year savings, up to 50% of
the project costs or $100,000 per project. Visit www.keyspansaves.com to get started.
Funding is limited. For further information please use the website above or contact Keyspan by e-mail.
Contact:
General Information
Solar Thermal/Energy Efficiency
KeySpan Energy Delivery
52 Second Ave
Waltham, MA 02451
E-Mail: solar@keyspanenergy.com
S

o

l

a

r

C

o

l

l

e

c

t

o

r
SX40V
SYSTEM FILL
To heat zones
Existing DHW
Tank
Solar Storage
Tank
EXISTING HYDRONIC
SYSTEM
Cold In Hot Out
S1
S2
Fill & Purge
Valve
781-721-0303 FAX 781-721-9119 WWW.CAPCOSUPPLY.COM
THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE
FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR
10INDUSTRIAL PARKWAY
WOBURN MA 01801
ENERGY SUPPLY, INC.
C A P C O
Thermal Solar
Retrofit
2.21.08
NLC
S1
S2
This example shows a hydronic system heating
the existing domestic hot water. The retrofit
application would work with any type of DHW
heater. It could be electric, oil-fired or gas-fired.
The Solar portion of work would remain the same.
The Hot Out of the Solar Tank would be the Cold
In on the existing tank.
Defrost Air
From Inside
Stale air to
outside
Fresh Air In
From
Outside
Stale air
from
inside
Warmed Air
To Inside
Solar Pumping Station
SX40V
SYSTEM FILL
781-721-0303 FAX 781-721-9119 WWW.CAPCOSUPPLY.COM
THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD
VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR
10INDUSTRIAL PARKWAY
WOBURN MA 01801
C A P C
ENERGY SUPPLY, INC.
O
Conceptual Solar with DHW and
reheat to HRV
7.02.08
NLC
Condensing
Wall Hung
Boiler
GAS
SUPPLY
Collectors
DHW Tank
Solar Tank
HRV
S1
S2
S1
S2

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