Al!2.

endixes

APPENDIXES

A LIST OF DESIGN AND INSTALLATION DRAWINGS

B DRAWING REVIEW CHECKLISTS

C COMPONENT SPECIFICATION CHECKLISTS

D SITE SURVEY CHECKLIST

E PRE-OPERATIONAL CHECKOUT

F SYSTEM EFFICIENCY TEST

G ONE-DAY ENERGY COLLECTION TEST

H . CALCULATION OF SOLAR NOON

Installation Manual
Desi1(n and Installation Drawin1(s Appendix A -Page I
APPENDIX A

liST OF DESIGN AND INSTAllATION DRAWINGS

Drawing Provided?
Yes No N/A
General

Legend of symbols and abbreviations - -

Site plan and locations

Architectural/Civil

Grading and site preparation - --

Plot plan and floor plan(s)
Roof plan - -
Elevations and sections - -
Mechanical equipment location plan
Rock bed construction details - -

Structural

Collector support structure and details --

Collector structure-to-building attachment details
Structural framing plan of building --
Tank/rock bed support details

Mechanical

System schematic (e.g., P&ID)

Collector piping/ducting schematics and details - -
Storage tank piping and rock bed ducting schematics and details
Piping routing and support details - -
Installation of all mechanical components
Conventional SHW/HVAC system mechanical drawing(s) and interface
requirements with solar heating system
Equipment schedule - -

Electrical

Control, instrumentation, and electrical schematics - -

Wiring diagrams and wire routing drawings
Control mode matrix
Interface requirements with conventional SWH/HVAC systems --

All necessary drawings present?

Installation Manual
DrawinlI.Review Checklists Appendix B - Page 1

APPENDIX B

DRAWING REVIEW CHECKLIST NO.1

System Schematic (liquid).

See ExampleSystem P&IDat end ofchecklist(fromthe Design Manual).

SolarSystem
Yes No
D* G* R*
Circlesolar system type beinginstalled . . . --
Collectorloopshown?
. . --
Heat exchanger to storage loop shown?
Interface with load and auxiliary shown?
. . . 0
--

ARE THE FOllOWING SYSTEM COMPONENTSINDICATED?

. . . - -
Collectors
Storage tank
.. . . --
--
Drainback tank
.. 0
.. 0
0 --
..
Collector loop heat exchanger
--
Delivery loop heat exchanger (if SH)
Collector loop pump
.. .. --
Storage loop pump
Delivery loop pump (if SH)
.. . .
0 --
--
Vent pipe
Expansiontank 0 ..
0 0
0
--
--
0 0 --
Airseparator . . .
. - -
Isolation valves on each pump
. . --
Isolationvalves on collectors
. . .. - -
Isolationvalves on heat exchanger
Isolation valves on storage tank
.. .. 0
--

.. ...
--
Bypasswithpressuregaugeat eachpump
Airvent at collectorloophighpoint 0 . --
0 --
Airvent at storage loophighpoint .
Air vent at delivery loop high point (if SH)
Isolationvalveon collectorloopairvent 0 .. 0
.
--
--
0 --
Reliefvalveon collectorloop
. . .
.. ...
Collector loop flowsetting valve --
CollectQrloop fillprovision 0 0 --
0 --
Storage loop drain provision
. - -
.
. ..
Deliveryloop drain provision
Collectorloopcheck valve 0 --
--
Storage loopcheck valve
Collectorflushvalve 0
." 0. ..
0
--
Storage tank drain provision --
'
Thermometer or PIT plug in collector supply and return
Thermometer or PIT plug in storage supply and return .. .. ..
0
--
--
Thermometeror PITplugin deliveryline
Thermometer or PIT plug in cold water supply line . . --
--

Installation Manual
DrawinG..Review Checklists Appendix B - Page 2

System Schematic (liquid - continued)

Solar System

Collector temperature sensor

D G
.. R

...
Yes
--
No

Storage temperature sensor

Freeze temperature switches . . --
--

Storage overtemperature sensor .. . --

Storage overtemperature switch
Flow switch in loop with each pump .
.
.. --
--
Btu meter flowmeter(s)
"Hot" and "cold" temperature sensors for each Btu meter . .. .. --
--
Delivery loop components
Equipment schedule* . --
--

Notes:

* A table listing the major components (collectors, storage tank, drainback tank, expansion tank, heat
exchangers, pumps, motorized valves, controls, and Btu metering systems) and their design parameters.

Installation Manual
 ~
~
~
~.
Collector Array Data: C1 CollectorTemperatureSensor ~
42 collector panels C2, C3, FreezeTemperatureSwitch(NC) ~
40 tt2 lpanel (3.7 of /panel) FS1,FS2 RowSwitch(NO) ~.
~
FM1,FM2,FM3 Btu MeterFlowmeter ~
42° slope
TH1,TC1 Btu Meter1 TemperatureSensor
TH2,TC2
TH3,TC3
Btu Meter2 TemperatureSensor
Btu Meter3 TemperatureSensor
g
From S1, S2 StorageTemperatureSensor
~
Other S3 OvertemperatureSwitch(NC) ~
N.
Collector 56,S7 RecirculationWater~T TemperatureSensors
f.'.I
~
Banks

NOTE: Use of Btu meters is optional; when used, the flowmeters

,'- - -1=-,-
- fl'§Elle and temperature sensors must be installed as shown.
, " Line-

, ,,
" Fill

To , ,, , Lme
,
,,
Other

,,
CoDector
Banks ,
',

COLD WATER

~
-
~
S-
S-
=-.
P2
~
~
~
;:
~
~
c::>
;= ~
I
"'0
~ ExampleSystem P&ID for Drainback Solar System for Service Water Heating

-
;= ~
~
;::: t.w
~
~
C'.I
~
~
is' ~
N.
::s
s= Collector Array Data: C1 Collector Temperature Sensor
~. 42 collector panels C2,C3, Freeze Temperature Switch (NC)
;:s 40 ft2/panel (3.7 r3- /panel) FS1,FS2 Row Sw~ch (NO)
42° slope FM1,FM2,FM3 Btu Meter Flowmeter
TH1,TC1
~
;:s
TH2,TC2
Btu Meter 1 Temperature
Btu Meter 2 Temperature
Sensor
Sensor
TH3,TC3

-
Btu Meter 3 Temperature Sensor
;:: 51,52
~ 53
Storage Temperature Sensor
Overtemperature Switch (NC)
86,57 Recirculation Watlr T Temperature Sensol

From
Other NOTE: Use of Btu meters is optional; when used, the llowmeters
Collector and temperature sensors must be installed as shown.
Banks
Flow
C1 C2 C3 Setting
Valve TH1

To
Other
Collector
Banks

COLD WATER

~
Fill & Drain
Lines
~
~
::s
~
b:I
ExampleSystemP&IDfor Anti-freezeSolarSystemfor ServiceWaterHeating I
~
~~
~
 t;:,
~
C1 Collector Temperature Sensor
~
"'.
Collector Array Data:
42 collector panels
C2,C3,
C4,C5
First Stage Freeze Temperature Switch (NO)
Sec:ond Stage Freeze Temperature Switch
~
40 tt2/panel (3.7 ri- /panel) FS1,F82 Flow Switch (NO)
~
~
42°slope FM1,FM2 Blu Meter Rowmeter :1.
TH1,TC1 Blu Meter 1 Temperature Sensor ~
TH2,TC2 Blu Meter 2 Temperature Sensor ~
51,82
53
Storage Temperature Sensor
Overtemperature Switch (NC) g
86,57 Recirculation Water ~T Temperature Sensors ~
V1 Collector Flush Valve (FO)
~
tt
NOTE: Use of Blu meters is optional; when used, the fIowmeters
From and temperature sensors must be installed as shown.
Other
Collector
Banks

/
/ / 1H1
/
/
/
/
/
/

To 1;.\ /
Other
-1-- - - .freeze / /
Colledor Line-- J
Banks
82

COlD WATER

~ ~
i FI Une
=
~
:I
~
t:a
ExampleSystem P&IDfor Direct Recirculation Solar System for Service Water Heating
I
~
:I ~
a:::: ~
Q CollI
....
 - --- - --- n -- -- - un - n - -. __n----

Drawing Review Checklists Appendix B - Page 6

APPENDIX B

DRAWING REVIEW CHECKLIST NO.2

System Schematic (air)

Note: See example P&IDat the end of checklist for air collector solar space heating system with
service water heating option (fromthe Design Manual).

~ ~
Collector loop shown?
Pebble bed storage bypass shown?
Interface with space heating load and auxiliaryshown?
Service water heating loop shown?

ARE THE FOLLOWING SYSTEM COMPONENTS INDICATED?

Collectors
Pebble bed storage
Fan in collector loop (F1)
Fan in space heating loop (F2)
Remotely operated control damper in collector loop
Remotely operated control damper in heating loop
Manuallyoperated control damper in collector loop between storage bypass
and storage
Manuallyoperated damper in storage bypass
Backdraft damper in heating loop return
Backdraft damper in collector loop supply
Filter in collector loop before fan F1
Filter in heating loop return
Thermometers in collector supply at storage and at collector side
of bypass
Thermometers in collector return at Fan F1 and at storage
Thermometers at top and at bottom of storage
Collector temperature sensor (S1)
Storage temperature sensor (S2)
Collector return air temperature switch (S6)
Auxiliaryspace heating equipment
Btu meter flowmeters
"Hot"and "cold"temperature sensors for each Btu meter
ARE THE FOLLOWING SERVICE WATER HEATING LOOP COMPONENTS INDICATED?

Auxiliarywater heatingequipment
Hotwater storage tank
Heat exchanger
Pump
Bypasswithisolationvalvesand pressure gauge at pump
Airvent at highpoint
Reliefvalveon storage tank

Installation Manual
Drawing Review Checklists Appendix B - Page 7

System Schematic (air - continued)

~ ~
Check valve
Thermometer or PfT plug at heat exchanger inlet and outlet
Thermometer or PfT plug at top of storage tank
Collector temperature sensor (53)
Storage temperature sensor (54)
Storage overtemperature sensor (57)
Storage overtemperature switch (55)
Flow switch
Btu meter flowmeters
"Hot"and "cold"temperature sensors for each Btu meter
Equipment schedule.

Notes:

. A table listingthe major components (collectors, pebble bed storage, heat exchanger, fans, dampers,
and Btu metering systems) and their design parameters.

Installation Manual
DrawinG. Review Checklists Appendix B - Page 8

Collector Array Data: S1, S2, S3 Temperature Sensor

Type Flat Plate S4,56,S7 Temperature Sensor
Area 100<fft (92.a m S5 Temperature Switch
Slope 50° FS Flow Switch
Fluid Air TL1, TH1 Btu Meter-1 Temperature
Sensors
TL2, TH2 Btu Meter-2 Temperature
Sensors
TL3, TH3 Btu Meter-3 Temperature
Sensors
TL4, TH4 Btu Meter-4 Temperature
Sensors
FM1, FM2 Btu Meter Flowmeters
FM3, FM4 Btu Meter Flowmeters

NOTE: Use of Btu meters is optional; when

used, the flowmeters and temperature
sensors must be installed as shown.'

HOT
WATER

S5

SPACE
HEATING
SUppy
~
TH2

SPACE
HEATING
FILTER T RETURN
.....
S2

Example P&ID for Air Collector Solar System for Space H.eating
with Service Water H~ating Option

Installation Manual
DrawinG.. Review Checklists Appendix B - Page 9

APPENDIX B

DRAWING REVIEW CHECKLIST NO.3

Collector Layout and Installation

COLLECTORLAYOUT: ARE THE FOLLOWING ITEMS SHOWN ON THE DRAWINGS?

~ ~
Collector orientation
Collector tilt
Number of collector rows and overall layout of collector rows on roof, with dimensions
of each row and spacing between rows
Setbacks from edges and identifiable building features
Number and arrangement of collectors in each row --
Collectors subject to shading --
Direction in which collectors must slope to drain (if required) --
Is there adequate room to work while installing and maintaining collectors? --
Is there access to fire escapes? --
Is there access to other mechanical equipment, TV antennae, etc., on roof? --
Is there access for roof maintenance? --
COLLECTOR SUPPORT STRUCTURE: ARE THE FOLLOWINGITEMS SHOWN ON THE DRAWINGS?

Specificationsand dimensions of all rack materials and connectors --

Front, side, and rear views of rack configuration --
Material finish, painting, or other surface treatment for weatherproofing --
Layout of support structure for each collector row, with overall dimensions and
location of each roof connection --
Details of connections between support structure and building, including
specifications and dimensions of all connectors and method of sealing roof
penetrations --
Details of any curbs, piers, runners, etc., on which support structure will be mounted,
including specifications and dimensions of all materials and connectors and
method of flashing --
Any modifications required of existing framing members and/or connections? --
Are racks made from standard, off-the-shelf components? --
Will custom fabrication be required? --
Have all the drawings been stamped by an engineer? --
Have supporting calculations been provided? --
COLLECTOR INSTALLATION: ARE THE FOLLOWING ITEMS SHOWN ON THE DRAWINGS?

Whether collectors are vertically or horizontally mounted --

Whether collectors are internally or externally manifolded --
Location of the collectors on each support structure, including spacing
between collectors --
Collector-to-rack connection details, including specifications and locations
of all connectors . --

Installation Manual
Drawing Review Checklists Appendix B - Page 10

Collector Layout and Installation (continued)

~~
Dielectric separation of collector frame from rack --
Provision for thermal expansion within row of collectors --
Provision of collector grounding for lightning protection --
Construction details of any collector enclosures required, including
all dimensions, materials and connectors, surface treatment, and
method of securing to collectors ancIJorroof --
Are any materials, components, or assemblies too heavy to carry by hand? --

Notes:

Installation Manual
DrawinK.Review Checklists Appendix B - Page 11
APPENDIX B

DRAWING REVIEW CHECKLIST NO.4

Collector Piping (liquid)

PIPING LAYOUT
~~
Plan(s) and elevation(s) (ifrequired) showing pipe routingthroughout the
collector array (to/fromlwithineach bank, each row, and the overall array) --
Dimensions of pipes and locations of size changes --
Locations and details of piping branches --
Locations of vents, relief valves, and other piping components to be
installed at the collectors (see Checklist No.1) I --
Locations of control and instrumentation sensors to be installed at the
collectors (see Checklist No.1) --
Flow path within the array, each row, and each bank --
Flow rate required for the array, each row, and each bank --
Flowcontrol and balancing method for each row and each bank --
Provision for piping thermal expansion --
Location of piping supports and hangers --
Required piping slope and direction --
(Ground-mounted collectors) depth of trench and trench layout details --
PIPING MATERIALS AND CONSTRUCTION

Pipe materialand types/schedules --

Fittingmaterialsand types/schedules --
Joiningmethods,includingmaterialsand specifications --
Pipingsupportsand hangers, includingmethod(s)of attachment --
Connectiondetailsto pipingcomponentsand sensors --
Detailsof rooflbuildingpenetrations,includingpipingsupportsand methods
and materialsfor sealing --
Identificationof pipe and pipingcomponentsto be insulated,withmaterials,
thicknesses, and installation/application
methods --
Jacketing materialsand installation/application
methods --
Materialsand methodsforweatherproofingoutdoorinsulation --
PIPING AND COMPONENT IDENTIFICATION

Notice of pipes and componentsto be identified --

Identificationsto be used for each pipe/component --
Methods of identification --

Notes:

Installation Manual
Drawin/I.Review Checklists Appendix B -Page 12

APPENDIX B
DRAWINGREVIEW CHECKLIST NO.5

Collector Ducting (air)

DUCTING LAYOUT
::w ~
Plan(s) and elevation(s) (if required) showing duct routing throughout
the collector array (to/from/within each bank, each row, and the
overall array) --
Dimensions of ducts and locations of size changes --
Locations and details of ducting branches --
Location of control and instrumentation sensors to be installed at the
collectors (see Checklist No.2) --
Flow path within the array, each row, and each bank --
Flow rate required for the array, each row, and each bank --
Flow control and balancing method for each row and each bank --
Location of ducting supports and hangers --
DUCTING MATERIALS AND CONSTRUCTION

Duct materials and types --

Joining methods, including materials and specifications --
Ducting supports and hangers, including method(s) of attachment --
Connection details to sensors --
Details of rooflbuilding penetrations, including ducting supports
and methods and materials for sealing --
Identification of ducting to be insulated, with materials, thicknesses,
and installation/application methods --
Jacketing materials and installation/application methods --
Materials and methods for weatherproofing outdoor insulation --

DUCTING IDENTIFICATION

Notice of ducting to be identified --

Identifications to be used for each duct --
Methods of identification --

Notes:

Installation Manual
Drawing Review Checklists ApPl!"l!~ll=~age 13

APPENDIX B
DRAWING REVIEW CHECKLIST NO.6

Mechanical Layout and Piping (liquid)

~~
Location of each component is shown (storage tank, pumps, valves, etc.;
see Checklist No.1) --
Relative location of each component is consistent with system schematic --
Adequate space is available around each component for operation,
maintenance, inspection, and servicing --
Each component can be isolated for servicing and repair --
PIPING AND PIPING COMPONENTS

Plan(s) and elevation(s) (if required) showing pipe routing from (1) collector
array to the drainback tank, heat exchanger, or storage tank and back
to the collectors; (2) from drainback tank or heat exchanger to storage
tank and back to drainback tank or heat exchanger; and (3) from storage
tank to load (and back; if space heating) --
Dimensions of pipes and locations of size changes --
Locations and details of piping branches --
Location of valves, air eliminator, and any other piping components to be
installed (see Checklist No.1) --
Locations of any control and instrumentation sensors and flowmeters
to be installed (see Checklist No.1) --
Required piping slope and direction --
Provision for thermal expansion of piping --
Location of piping supports and hangers --
All high points indicated and vented --
All low points indicated and drained --
Provision for filling and draining the system --
Provision for loop pressurization --
Required loop pressure --
Type and location of required dielectric fittings --
Valve settings --
Relief valve settings --
Relief lines from relief valves safely routed --
Flow direction within each loop --
Flowrate required within each loop --
Provision for determining and setting flowrates --
PIPING MATERIALS AND CONSTRUCTION

Piping materials and types/schedules --

Fitting materials and types/schedules --
Joining methods, including materials and specifications --
Connection details to piping components and sensors --

Installation Manual
DrawinK.Review Checklists
~-- n~ --~~ ~~~
~~-
Mechanical Layout and Piping (liquid continued) -
Appendix B -Page 14

~ No.

Pipingsupports and hangers, includingmethodsof attachment --

Detailsof buildingpenetrations,includingpipingsupportsand methods
and materialsforsealing --
Identificationof pipe and pipingcomponentsto be insulated,withmaterials,
thicknesses, and installation/application
methods --
Jacketing materialsand installation/application
methods --
Materialsand methodsforweatherproofingoutdoorinsulation --
TANKS, HEAT EXCHANGER, AND PUMPS

Locations relative to identifiablebuildingfeatures --

Dimensions and weight --
Support details --
Installation details --
Piping connection details --
STORAGE TANK

Details of tank ports --

Inspection manholes --
Tank materials and lining --
Maximumand operating temperature and pressure --
Pad details and concrete specifications --
Method of securing against seismic forces (ifrequired) --
Adequate room between bottom of tank and footing/pad to work --
Sensor installation details --
Insulation requirements, including materials, thicknesses, and
installation/application methods for insulation and jacketing --
Ifthe tank is to be foamed in place, provision of adequate room
around all sides of the tank for the foamer --
Are all inlet and outlet pipe nozzles long enough to clear the specified
insulation thickness? --
Tank enclosure details --
Provision of adequate room to remove anode rod --
HEAT EXCHANGER

Type of heat exchanger --

Iftube-and-shell, provision of adequate room to remove tube bundle --
Details of heat exchanger ports --
Insulation requirements --
PUMPS

Requiredshaftorientation --
Pad details,concretespecifications --

Installation Manual
DrawinG.Review Checklists' Appendix B - Page 15

Mechanical Layout and Piping (liquid - continued)

~~
DRAINBACK TANK

Sight glass details --

Fill/operating levels --
Provision of sufficient clearance between top of tank and ceiling to install piping
to collectors with required minimumslope --
Insulation requirements --
INTERCONNECTION WITH AUXILIARY SYSTEM

Auxiliarysystem components and layout --

Location, type, and size of interconnection --
Interconnection details, including materials and methods of installation --
Interface with tempering, alarm, or other safety systems --
Interface with controls and control mechanisms --
Provisions for bypassing solar system when shut down for servicing/repair --
Provision for operating auxiliarysystem while solar system is being
serviced/repaired --

PIPING AND COMPONENT IDENTIFICATION

Notice of pipes and componentsto be identified --

Identificationsto be used for each pipe/component --
Methods of identification --
Notes:

I nstallation Manual
Drmvinf Review Checklists Appendix B - Page 16

APPENDIX B

DRAWING REVIEW CHECKLIST NO.7

Mechanical Layout and Ductlng (air)

~~
Location of each component is shown (storage box, fans, dampers, etc.;
see Checklist No.2) --
Relative location of each component is consistent with system schematic --
Adequate space is available around each component for operation,
maintenance, inspection and servicing --
DUCTING

Plan(s) and elevation(s) (if required) showing duct routing from

(1) collector array to pebble bed storage and HVACinterface,
(2) HVAC interface back to pebble bed storage and to collectors,and
(3) from pebble bed storage back to collectors, includingpebble bed bypass. --
Dimensions of air ducts and locations of size/configuration changes --
Locations and details of duct branches --
Location of filters and backdraft dampers --
Location of any control and instrumentation sensors and flowmeters to be installed
(see Checklist No.2) --
location of duct supports and hangers --
Damper settings --
Flowdirection within each loop --
Flowrate required within each loop --
Provision for determining and setting flowrates --
DUCT MATERIALS AND CONSTRUCTION

Constructiondetails,includingmaterials,thicknesses,dimensions,and seaming
methodsof allnoncommercialductingsections,and materialsand thicknesses
of commerciallyavailableductingand fittingswhere use is specified --
Methodofjoiningand sealingduct sectionsand attachingfittings
(elbows,branches, etc.) --
Installationdetailsforsensors and other instrumentsrequiredforcontrolsand
instrumentation --
Ductsupportsand hangers, includingmethodsofattachment --
Provisionsfor expansion --
Detailsofbuildingpenetrations,includingductsupportsand methods
and materialsfor sealing --
Identificationof ductingto be insulated,withmaterials,thicknesses,
and installation/applicationmethods --
Jacketing materialsand installation/application
methods --
Materialsand methodsforweatherproofingoutdoorinsulation --

Installation Manual
Drawing Review Checklists AppendixB -Page 17

Mechanical Layout and Ducting (air - continued)

~ t:l2
PEBBLE BED STORAGE BOX

Dimensionsand weight --
Locationsrelativeto identifiablebuildingfeatures --
Connectingduct details --
Insulationrequirement,includingmaterials,thicknesses,and
installation/application
methodsforinsulatingand jacketing --
PEBBLE BED STORAGE BOX INSTAllATION

Materials, sizes, and shapes of various component members, including

grating to support the pebbles --
Method for assembly of components into the integrated box assembly --
Sealing, finishing, and lining (ifrequired) of interiors and exterior --
Pad details and concrete specifications --
Locations and preparation of support base for storage box --
Installation and securing of storage box to support base --
Pebble sorting, washing, and loading procedure --
Provision for inspection of pebble bed --
Procedure for closing and sealing the storage box --
Sensor installation details --
Duct connection details --
AIR HANDLER UNIT(S)

Overall configurations with dimensions and weight --

. Materialthicknesses and detailshapes ofvariousmembers --
Methods for attachment and fastening of various members to complete assemblies --
Finishing of complete assemblies --
Methods for installation of various components that are integrated with unit --
Location relative to identifiablebuildingfeatures --
Installation details --
Ducting connection details --
Insulation requirements, including materials, thicknesses, and
installation/application methods for insulation and jacketing --
INTERCONNECTION WITH AUXILIARY HEATING SYSTEM

Auxiliaryheatingsystem componentsand layout --

Locationand size of interconnections --
Interconnectiondetails,includingmaterialsand methodsof installation --
Interfacewithsafetysystems --
Interfacewithcontrolsand controlmechanisms --
Provisionfor bypassingsolar systemwhenshut downforservicing/repair --
Provisionfor operatingauxiliarysystemwhilesolarsystem shut down --

Installation Manual
DrawinK.Review Checklists Appendix B - Page 18

Mechanical Layout and Ducting (air - continued)

~~
SERVICE WATER HEATING see Checklist No.2 and Checklist No.6, as applicable

DUCTING AND COMPONENT IDENTIFICATION

Notice of ducts and components to be identified --

Identifications to be used for each duct/component --
Methods of identification --

Notes:

Installation Manual
DrawinG.. Review Checklists Appendix B - Page 19
APPENDIX B

DRAWING REVIEW CHECKLIST NO.8

Controls, Instrumentation, and Electrical

~ ~
Solar system control mode matrix and interface control mode matrix provided
Control schematic is consistent with control matrices
All items listed in Checklist NO.1 or NO.2 are shown on control schematic:
Control components (temperature sensors and switches, flow switches,
DTC)
Operation monitoring components (thermometers, PIT plugs, pressure
gauges, provision for determining and setting flowrates)
Performance monitoring components (Btu meter flowmeters and
temperature sensors, Btu meter)
Relative locations of all components are consistent with collector and
mechanical piping/ducting drawings (see Checklist Nos. 4-7)
Provision for freeze protection and overtemperature protection
Location of each item (including DTC and Btu meter) indicated
Installation details and method for each item
Any required calibrations and set points indicated
All components are accessible for testing and replacement
Table with sensor number, type, location, DTC connection is provided

WIRING

Sizes, types, code numbers, and terminals for each wire

Requirements for conduits and cable trays
Wire routing drawings show physical routing of power wiring and
control wiring from power source to DTC and Btu meter, from
all temperature sensors and switches to DTC, from temperature
sensors and flowmeters to Btu meter, and from DTC to pumps, fans,
and other controlled components
End points of each wire identified by termination identification on
the component or termination designation on an intermediate
terminal board
Power source indicated, described and located
Power wiring separate from instrumentation/sensor wiring
Connection details between all wires and between wiring and
each component
Weatherproofing details for all outdoor wiring and connections

WIRING AND COMPONENT IDENTIFICATION

Notice of wires and components to be identified

Identifications to be used for each wire and component
Identifications correspond to designations in matrices and control schematics
Methods of identification: Identifications attached to each end of wires

Notes:

Installation Manual
Component Specification Checklists Appendix C - Page 1
APPENDIX C
COMPONENT SPECIFICATION CHECKLIST NO.1

Liquid System

Are specifications provided for:

~ NQ ~
Flat-plate liquid collectors ---
Evacuated tube collectors ---
Storage tank ---
Drainback tank ---
Sight glass ---
Expansion tank ---
Heat exchangers ---
Pumps ---
Isolation valves ---
Motorized valves ---
Pressure relief valves ---
Pressure temperature relief valves ---
Pressure-reducing valve ---
Backflow preventers ---
Check valves ---
Automatic flow control valves ---
Flow-balancing valves ---
Tempering valves ---
Strainer ---
Air separator ---
Air vents ---
Drain cocks ---
Thermometers ---
Pressure gauges ---
Pressureltemperature ports ---
Piping ---
Fittings ---
Flex couplings ---
Expansion compensators ---
Solder ' ---
Pipe hangers and supports ---
Insulation ---
Insulation jacketing ---
Flowmeters ---
Visual flow indicators ---
Differential temperature controller ---
DTC temperature sensors ---
Temperature switches ---
Btu meters (including flowmeters and sensors) ---
Pump motor starter boxes ---
Flow switches ---
Time delay relays ---
Transformers ---
Power wiring ---
Sensor wiring ---
Heat transfer fluid (including water) ---
Dielectric union ---
Installation Manual
Component Specification Checklists Appendix C - Page 2
COMPONENT SPECIFICATION CHECKLIST NO.2

Air System

Are specifications provided for:

~ t:lQ NLA
Flat-plate air collectors ---
Pebble bed construction materials ---
Pebbles ---
Heat exchangers ---
Fans or air handlers ---
Filters ---
Motorized dampers ---
Manual dampers ---
Backdraft dampers ---
Ducting ---
Flexible connectors ---
Duct hangers and supports ---
Insulation ---
Thermometers ---
Manometers (pressure gauges) ---
Anemometers (flowmeters) ---
Differential temperature controller ---
DTC temperature sensors ---
Temperature switches ---
Btu meters (including flowmeters and sensors) ---
Two-stage thermostats ---
Pump/fan starter boxes ---
Time delay relays ---
Transformers ---
Power wiring ---
Sensor wiring ---
Service water heating system components
(see Drawing Review Checklist No.2) ---

Installation Manual
Component Specification Checklists Appendix C - Page 3

TYPICAL COMPONENT SPECIFICATION SHEET

Flat Plate Liquid Collectors

Certain collector parameters are relevant to their installation:

Parameter Relevant to:

Quantity required Pricing

Dimensions Layout, handling
Empty weight Handling
Manifold
internal or external Piping
size Piping
distance manifold projects beyond frame Layout, piping
connection type Piping
inleVoutlet connection locations Piping
Glazing
material Handling
number of covers Handling
Weep hole locations Mounting
Absorber plate expansion capability
(fixed or floating within frame) Piping
Absorber plate coating type High-temperature service

Installation Manual
Site Surve~ Checklist Appendix D -Page 1

APPENDIX D

SITE SURVEY CHECKLIST

Job Designation:
BuildingAddress:
Owner's address and phone:
Contact person at site: Phone:
Plans available for existing building:
BuildingUse:
Occupancy Schedule:

Note each of the followingitems, as applicable.

Collectors

Roof mounted:
Type of roof:
Ifwood, access to framing:
orientation of framing:
member size, spacing, span, and connection details:
type of sheathing:
Ifconcrete, type of insulation:
Ifprestressed concrete, location of cables (see plans):
Condition:
Warranty in effect:
Name of roofer:
Shading, existing and possible, from buildings, equipment, landscaping, etc.:
Self-shading,existingand possible: .
Location of flues and vent pipes:
Access required to other roof equipment, billboards, etc.:
Locations of fire escapes:
Other obstructions to collector layout:
Dimensions of usable area:
Room for staging:
Slope at collector locations:
Walkway required:
Height of building:
Height of parapet:
Crane access:
Helicopter access:
Dimensions of freight elevator:
Personnel access:
Vandalism potential from ground or higher roof:

Ground mounted:

Soil conditions:
Slope:
Grading required:
Concreted areas:
Underground utilities:

Installation Manual
Site Survez Checklist Appendix D - Page 2
Groundmounted: (continued)

Access for concrete truck and collector delivery:

Personnel and vehicle access:
Vandalism potential from ground or higher elevation:
Shading, existing and possible:
Adjacent activityarea (e.g., sports) that could be hazardous to collectors:

Storaoe Tank/Pebble Bed and Drainback Tank

Location, with dimensions:

Constraints affecting tank dimensions or verticaVhorizontalinstallation:
Type of floor at tank location:
Drainage:
Preparatory work required:
Access for concrete truck:
Access route for tank, dimensions of smallest openings, ceiling heights, stairs, etc.:

-
Ifground-mounted outside the mechanical room, see "Collectors Ground Mounted."
Note if shed is required.

Piping and Mechanical

Location of pumpslfans, heat exchangers, valves/dampers, etc.:

Access route for each, noting stairs:

Pipe/duct routing from collectors to storage and from storage to load, noting:
Distances:
Penetrations required and types of materials:
Access for securing (especially vertical runs):
Types of materials to which piping/ducting is to be secured:
Ifin chase, access to chase:
Lightingat work locations:
Room to apply insulation:
Electrical

Type of power source:

Location of power source:
Access to power source:
Distance from power source to controls and pumpslfans power supply:
Adequate circuitcapacity:
Spare circuit breakers:
Interconnection

Type of system:
Water treatment:
Cold water supply size and type of piping:
Shutoff valve in cold water supply:
Hot water supply size and type of piping:
Shutoff valve in hot water supply:
Tempering valve model and size:
Recirculation hot water loop size, type of piping, and insulation:
Installation Manual
Site SurveJ'..Checklist Appendix D - Page 3

Interconnection (continued)

Shutoff valves in recirculation loop:

Check valve in recirculation loop:
Type of boiler/heat exchanger:
Name of boiler service company:
Boiler set temperature and reset controls:
Type of existing insulation:

Components that may not work after existing system has been shut down to make the
interconnection (e.g., tempering valve):

,
Existing conditions or problems (e.g., insufficient capacity for peak loads, crossover
between hot and cold water supply lines, fluctuating temperatures with fluctuating
flowrates, excessively hard or active water, insufficient or fluctuating water pressure -
if found, notify the designer):

Personnel access to interconnection location:

Major existing equipment or systems scheduled for replacement or modification in the
near future:

Miscellaneous

Take photographs of locations of all major components and of pipe/duct routing.

If you have building plans or design and installation drawings from a construction pack-
age, simply verify each item and note any deviations or additional information on the
plans/drawings.

Note any existing hazardous working conditions, e.g., asbestos-containing material that
must be disturbed or removed.

If the system is for an existing building and no building plans exist:

Draw roof plan, showing all relevant dimensions, slope, shading, obstructions, access,
relative location of storage, pipe routing, etc.

Draw mechanical room plan, showing dimensions, storage/pump/fan/heat exchanger

locations, access, etc.

Draw roof framing, showing structural member dimensions, spacing, spans, support at
load points, and all connection details.

Site Survey Tool List:

Camera
Paper pad and pencil
Mini tape recorder
Solar site selector or equivalent
Compass

Installation Manual
Site SurveJ? Checklist Appendix D - Page 4

Site Survey Tool List: (continued)

Slope indicator
Level
Multimeter
Digitaltemperature sensor
Pressure gauge with adapters
Pocket calculator
Flashlight
Ladder
1OO-ft tape
25-ft tape
Screwdrivers
Pliers.
Penknife and small rollof duct tape (it is sometimes necessary to cut through existing insula-
tion to inspect pipe or component)
Knee pads
Hard hat
Inspection mirror

Installation Manual
Pre-°1!.erationalCheckout Appendix E -Page 1

APPENDIX E

PRE-OPERATIONAL CHECKOUT

E -1. After FIlling the System (before turning it "ON,"verifythe following)

~ MQ

1. The system is isolatedfromlinewaterpressure and willnotdeliverheat to the

loadduringthe checkout:
Procedure:
Close the isolationvalve inany makeupwater line.

For service water heating systems:

Closethe bypass valves. (Ifthe system was installedin an occupied
building,be sure to open the isolationvalveinthe linecarryingcold
makeupwaterdirectlyto the water heater.)
For space heating systems:
Turnoffthe building'sheatingsystem.

2. The collectorloophas been filledwiththe specifiedheat transferfluid,the

pressure in any closed-looppart(s)ofthe system is as specified.
3. Drainbacktankwater levelis as specified.
4. The pH of the collector loop water or water/glycol mixture is withinthe
range recommended by the collector manufacturer; if a glycol solution
has been used, its concentration meets the specifications.

5. Allvalves/dampers,manualand automatic,are inthe properposition

(open or closed) as necessary forsystemoperation.
6. Specified relief valves have been installed.

7. Thermometersare registering.

8. Collectorglazingshave been washed clean of any dirtor debris.

CAUTION

Do not turn the system ON ifthe collectors are stagnating.

E . 2. Turn "ON"the system.

Set the differential temperature controller (DTC) to "ON."

Verify the following:

1. Pumpimpellersor fan rotorsare rotatinginthe correctdirection.

Installation Manual
Pre-°1!..erational Checkout Appendix E - Page 2

Procedure:
Visually check shaft rotation of the motor. Use the pressure gauge(s)
at each pump/fan to verify that the pressure increase across the pump
meets the design criteria and is in the specified flow direction.

~ ~

2. All air has been vented from the liquid system.

Procedure:
Check all manual and automatic air vents.

3. Ducts, dampers, and other air system components are free from leaks.

4. Both the flowmeters and electronic registers of any Btu metering systems
are functioning.

5. Record the following flow rates

. Collector loop

For drainback and closed loop systems:

Storage tank to collector heat exchanger loop

For space heating systems:

Storage tank to delivery heat exchanger loop.

E -3. Set Collector Loop Flow Rate as Specified

With all collector bank balancing devices wide open, adjust any valves/dampers
or other components used to set loop flow to the specified rate. Mark the settings
and set any memory stops.

E -4 Balance the Flowthrough Collector Banks

Using flow setters, set the flow through each bank at the specified rate using the
manufacturer's recommended procedure. This method of balancing can be done
day or night.

Using temperature ports and balancing valves, balance flow through all collector
banks by adjusting the balancing valves until the outlettemperature from each
bank is the same. Closing the valve increases the outlet temperature, while
opening the valve decreases it. Allow adequate time for the outlet temperature
to reach equilibrium.

Start with all balancing valves wide open. Measure and record all bank outlet'
temperatures. Begin balancing by closing the valve in the coldest bank until its
outlet is approximately 5°F (3°C) below that of the warmest bank. Repeat with
the next coldest bank and continue until one half of the banks in that array
have been adjusted. Measure and record all bank outlet temperatures again,
then continue balancing until all bank outlet temperatures are within a
5°F (3°C) spread.

Installation Manual
Pre-01!..erational Checkout Appendix E - Page 3
E -4 Balance the Flow through Collector Banks (continued)
~ f:Q

This method of balancing flow can only be done when the sun is out and there
is a temperature rise of at least 10°F (6°C) through the collectors.

Mark any adjustable components to show the setpoint. Set any

memory stops on balancing valves or remove handles from
conventional valves.
If required, adjust the overall collector loop flow rate during/after
balancing the flow through the collector banks.

E -S. Verify the following (after setting and balancing flow rates)

1. The current drawn by pumps/fans does not exceed the normal operating
range specified by the manufacturer for the voltage used.

Procedure:
Use an ammeter to measure the amperage at each pump/fan motor.

2. There is no sign of pump cavitation or other improper operation.

3. Fan operation is quiet and smooth.

4. If an air handler unit is used, its operation meets the manufacturer's

performance specifications.

5. For a drainback system, the collectors and collector loop piping

drain completely back to the drainback tank.

Procedure:
Note the water level in the drainback tank with the system on. Mark
it on the sightglass. Turn the DTCto "OFF." Verifythat draining
the collectorsand pipingfills the drainbacktank to its originallevel.
Notethe amountof time it takesfor the collectorloopto draincompletely.
CAUTION

If system drainback does not fill the drainback tank to its original
"PUMP OFF" level, water is trapped somewhere and there is danger
of freeze damage. Find and correct the piping that is not draining.

If hose bibs have been installed on the collectors or in the collector supply
line on the roof, open them to verify that the collectors have drained.

Turn the DTC to "ON." (Watch collector stagnation. If the system has
only been shut off for a short time, it may be possible to refill the
collectors even when the sun is out. Otherwise, keep the system
shut off until the collectors are no longer stagnating.)

6. Flow switches are functioning.

Installation Manual
Pre-op"erational Checkout Appendix E - Page 4
E-5. Verifythefollowing(Continued)
Procedure:
For each flow switch, disconnect one lead from the flow switch and verify
that the pump(s) shut off. Reconnect the lead and verify that the pump(s)
turn on. Note: Each step of the flow switch checkout must be done after
the time delay relay has opened. Shut the DTC off momentarily to
restart the system after each step.
~ ~
Turn the DTC to "OFF." Verify that there is an open circuit between the
lea.dsof each flowmeter. Turn the DTC to "ON."

7. All temperature sensors and switches are functioning properly.

Procedure:
Ifthe DTC has a digital sensor readout, use the readout to verify that
there is no short or break in any sensor/switch circuit, and that the
sensor readings are appropriate for the ambient and system operating
conditions.

If the DTC is not digital, use an ohmmeter to determine that there is

continuity in the circuits and appropriate resistance readings. Disconnect
each sensor from its control terminals. Attach the meter leads to the
sensor wire. Measure the resistance through the sensor circuit. Use a
temperature vs. resistance chart (See Table 1. This chart should
be provided by the DTC manufacturer for each specific system) to
convert the resistance to temperature. Note any apparent problems.

If possible, measure the temperature at the point of sensor mounting

with a digital thermometer or probe thermometer and PIT port and
compare that temperature with the digital readout and the sensor
resistance check. Do this for each sensor immediately after
measuring its circuit resistance with the meter.

When using a digital thermometer, coat the probe with heat-

conducting grease and insert it under the insulation.
(Note: This may be difficult to do if the insulation and
jacketing have been correctly applied. Be prepared to remove
and replace insulation and jacketing as required.) Be sure the
probe is in good physical contact with the surface of the pipe,
tank, etc., and is covered with insulation.

When using a probe thermometer and PIT port, use caution

during removal of the safety cap and insertion of the probe to
protect hands and eyes. Coat the probe with a silicone grease
before insertion. Do not leave a probe in a PIT port for long
periods of time. When the temperature has been read,
remove the probe and replace the safety cap.

8. All adjustable setpoints on each control have been set to specifications.

9. The "On-Auto-Off" switch on the DTC functions correctly. Leave the

switch on "AUTO."

The system is now operating normally.

Installation Manual
Pre-°1!..erational Checkout Appendix E - Page 5
E -6. Record Baseline Operating Data (aftercompletionof alltests)
For dralnback and recirculating systems: The system willtolerate a delay of a few days before proceeding
to the operational testing and subsequent interconnecting of the solar system withthe building load.
(Note: Iffreezing is even a remote possibility,either drain the collector loop or proceed directly to the opera-
tional testing to verifyoperation of the system freeze protection.)

For closed-loop systems: The system rnustnotbe operateddisconnectedfromthe buildingloadforany

lengthoftime due to the effectsof stagnationon the glycolsolution. Proceed immediatelywiththe opera-
tionaltestingand subsequent interconnectingofthe solarsystemwiththe buildingload.

Record the followinginformationon a separate page:

. Pressure at each pressure gauge or PIT port.

Inletand outletpressures for each heat exchanger.

. Temperature at each thermometer or PIT port.
. Inletand outlettemperaturesforeach heat exchanger.
. Flow rate at each flow setting/measuring device.
. Suction and discharge pressure for each pump.
. Voltageand amperage at each pump
. For a drainback system: Water levels in the drainback tank withthe collector loop pump off and on;
time to drain.

AllDTC adjustable set point settings and sensor readouts.

Take the measurements in as short a time as possible. Notethe date and timethe measurementswere
taken and the name ofthe personwhotookthem. Put this record with the system Operation and
Maintenance Manual.

E -7. Tools

The followingtools are needed to perform the preoperational checkout:

. pH test kit
Glycoltest kit
Pressure gauge or differentialpressure gauge with adapter(s) forPIT ports
Ifcircuit setters are used to set/measure flowrates, the manufacturer's readout device and
. conversion scale
If PIT ports are used, a probe thermometer (digitalor bi-metal)
Digitalthermometer with probes for flat and curved surfaces
Digitalm,ultimeter(or separate voltmeter and ammeter)
. Ohmmeter
Continuitytester
Screwdriver
.. Heat-conducting grease
Silicone grease
Hardhat.

Installation Manual
System Efficiency Test Appendix F -POKe 1

APPENDIX F

SYSTEM EFFICIENCY TEST

This appendix provides guidelines for evaluating the thermal performance of a solar energy system by a
one-day efficiency test. The efficiency determined in this test can be compared with the collector operating
curve supplied by the manufacturer. This test can be run at any time of the year when insolation is above
200 Btu/ft21h.

This test requires measuring flow rates, temperatures, and insolation over one day's operation. Procedures
for measuring and recording the data are given.

1.0 INSTRUMENTATION

The following instrumentation must be installed in the system:

. Some form of flow-measuring device in the collector loop and in the storage loop.
. Some form of temperature measurement in the supply and retum lines of the collector loop
and storage loop.

Additional instrumentation kept on hand at the site will be used:

If PIT ports are used, a pressure gauge or differential pressure gauge with adapters to fit
the ports and a probe thermometer with digital readout with probes to fit the ports.
. A digital multimeter, or an ammeter and a voltmeter.
. A pyranometer with an integrator for determining insolation (if no pyranometer is available,
see Section 5.0).

If available, a clamp-on ultrasonic flowmeter.

2.0 DETERMINING FLOW RATES

If possible, determine flow rates using two diferent methods, then compare the results. Record the flow rate
at the start and end of the test and once in between.

2.1 Visual Flowmeter

Read the flow rate directly from the visual flowmeter if one is installed.

2.2 Flow-setting Devices

Ifsome form of flow-setting device was used to set the flow through each collector bank, the sum of the flow
rates will equal the total collector loop flow rate. Measure the differential pressure across each circuit setter,
noting the valve setting and using the conversion chart for the circuit setter supplied by the manufacturer to
calculate the flow.

Note: DO NOTDISTURBTHEVALVE SETTING.

Installation Manual
System Efficiency Test Appendix F - Page 2

2.3 Pressure Drop

Use permanentpressure gauges on the inlet/outletofpumpsand heat exchangerwhere installed,or use a

pressure probe in PITports inthose locations. Measurethe pressure on the inletand outletof the pump,
subtractthe inletpressure fromthe outletpressure to determinethe pressure increase across the pump,then
use the graph of pumphead vs. flowrate suppliedbythe manufacturerto estimatethe flowrate. Thismethod
shouldalwaysbe used as a check on any otherflowrate estimate.
Alternatively,measure the pressure on the inletand outletsides ofthe heat exchanger,determinethe pres-
sure drop,then use the heat exchangerflowrate/pressuredropcharacteristicssuppliedbythe manufacturer
to estimatethe flowrate. Thisestimate is less accuratethan using pump~P but is usefulifreadingsare
repeated regularlyto detect heat exchangerfouling.
2.4 Btu Meter

Ifa Btumeteringsystem has been installed,flowrate can be determinedby measuringhowlongittakes for

the flowmeteror the electronicregister(or both)to indicatethe passage of a givenamountoffluid.
2.5 Clamp-on Ultrasonic Flowmeter

Measurethe flowrate withan ultrasonicflowmeterwithclamp-onexternalsensors. (Usethis methodas a

last resort, as these flowmetersare difficultto calibrateand use, and are extremelyexpensive.)
3.0 DETERMINING TEMPERATURES

3.1 Installed Thermowells

Read the temperature directly from an installed thermometer. Use bi-metal thermometers, not mercury type,
in the thermowell.

3.2 DTC Readout

Read tank temperatures directlyfrom the DTCdigital readout, ifavailable.

3.3 PITPorts

Wherea PITportwas installed,use a probethermometerto measure temperature. Cautionshouldbe used

duringremovalofthe safetycap and insertionofthe probeto protecthands and eyes. Coat the probe with
siliconegrease before insertion. Donot leavethe probe inthe portfor longperiodsoftime. Whenthe
temperaturehas been read, removethe probeand replacethe safetycap.
3.4 Surface Probe

Where there are no thermometers or PIT ports, use a digitalthermometer. Coat the probe with heat-conduct-
ing grease and insert it under the insulation. (Note: Ifthe piping has been insulated and jacketed correctly,
this may be difficultto do. Be prepared to remove and replace insulation and jacketing as required.) Be sure
the probe is in good physical contact withthe surface of the pipe, tank, etc., and is insulated from drafts.

3.5 Ambient

Read ambient temperature on a thermometer or probe used withdigitalthermometer, installed in the shade,
out of the wind, and away from heat sources like kitchen vents.

Installation Manual
System Efficiencv Test Appendix F-Page 3

4.0 DETERMINING PUMP POWER

Usea digital multimeter or separate voltmeter and ammete.rto measure voltage to, and current draw of, each
pump. Record these data at the start and end of the test, and once in between.

5.0 DETERMINING INSOLATION

When a pyranometer is available, mount it on the collectors to measure total solar insolation falling on the
collector plane. Run wires to a convenient operation location where PIT readings are being taken. Connect
the integrator here also.

When no pyranometer is available, estimate total daylong solar insolation from Table F-1 using the latitude of
the site and the tilt of the collectors, and interpolating for the day of the month. This is not as accurate as
using a pyranometer; note the restrictions on test procedures in Section 6.0 that must be followed if you use
this method. In addition, the collector operating curve cannot be plotted without pyranometer readings.

6.0 TEST PROCEDURES

6.1 Test Conditions

Make the performance test on a clear day with moderate wind conditions, ambient temperature normal for
this time of year, and insolation averaging about 250 BtuIft2/h. Do not take data when insolation is below
200 Btu/ft2/h. Isolate the solar energy system from the load before starting the test.

6.2 Data Recording

Record data at 15-minute or 30-minute intervals over a 4-hour period, with at least two hours on either side of
solar (not "clock") noon. (See Appendix H for calculation of solar noon.) Use the sample Performance Data
Sheets or equivalent to record the data. Note the time each data point was measured. (Make all measure-
ments for one data-taking period in as short a time as possible to improve the validity of "instantaneous"
energy flow calculations.) Record the following for each data-taking period. (Item numbers refer to the data
sheets.)

1. Instantaneous and integrated insolation (Items 1 and 2).

2. Collector array inlet and outlet temperatures (Items 4 and 5).

3. Storage tank inlet and outlet temperatures (Items 12 and 13).

4. Ambient temperature (Item 3).

Record the following at the start of the test, at solar noon, and at the end of the test:

1. Collector loop flow rate (Item 6).

2. Storage loop flow rate (Item 14).

3. Collector loop pump current and voltage (Items 9 and 10).

4. Storage loop pump current and voltage (Items 16 and 17).

Note where each temperature and flow rate measurement was made and how the flow rate was determined,
50the test can be duplicatedsix monthsor a year later. Whereno pyranometeris available,estimatetotal
daylong insolation from Table F-1 and enter the total as'ltem 2 of the last data-taking period.

Installation Manual
System Efficiency Test Appendix F - PaB..e4

Table F-1 Estimating Solar Insolation

Total DaylongSolar Insolation on South-Facing TiltedSurfaces Btu/ft2 -

TILT
DATE DEG. LATJI LAT.-10 I
II TILT
LAT. I LAT.+10 DATE IDEG. LATJ LAT.-10 I LAT. I LAT.+10

24 1984 2174 2300 24 2412 2250 2036

48 1955 2090 2215 48 2427 2250 2033
32 1893 2008 2118 32 2442 2250 2030
21-Jan 36 1800 1910 2020 21-Jul 36 2425 2240 2018
40 1660 1810 1906 40 2409 2230 2006
44 1525 1660 1750 44 2398 2215 1990
48 1360 1478 1550 48 2386 2200 1974

24 2276 2396 2446 24 2402 2316 2168

48 2240 2350 2390 48 2395 2306 2156
32 2188 2300 2345 32 2388 2296 2144
21-Feb 36 2130 2245 2280 21-Aug 36 2370 2278 2124
40 2060 2162 2202 40 2354 2258 2104
44 1970 2080 2120 44 2328 2230 2076
48 1880 1972 2024 48 2300 2200 2046

24 2428 2456 2412 24 2332 2366 2322

48 2405 2430 2385 48 2315 2335 2296
32 2378 2403 2358 32 2288 2308 2264
21-Mar 36 2340 2363 2320 21-Sep 36 2250 2275 2220
40 2308 2330 2284 40 2210 2228 2182
44 2260 2280 2235 44 2155 2185 2130
48 2208 2228 2182 48 2102 2118 2070

24 2458 2374 2228 24 2198 2314 2364

48 2451 2365 2217 48 2150 2265 2315
32 2444 2356 2206 32 2100 2208 2252
21-Apr 36 2430 2340 2188 21-Oct 36 2035 2140 2185
40 2412 2320 2158 40 1962 2060 2098
44 2390 2395 2142 44 1880 1975 2010
48 2358 2266 2114 48 1774 1860 1890

24 2447 2286 2076 24 1962 2146 2268

48 2450 2285 2068 48 1895 2065 2180
32 2454 2284 2064 32 1816 1980 2084
21-May 36 2448 2274 2052 21-Nov 36 1730 1885 1980
40 2442 2264 2040 40 1636 1778 1870
44 2430 2250 2025 44 1500 1645 1710
48 2418 2234 2010 48 1336 1448 1518

24 2422 2230 1992 24 1852 2058 2204

48 2430 2232 1991 48 1780 1980 2120
32 2436 2234 1990 32 1704 1888 2016
21-Jun 36 2433 2230 1982 21-Dec 36 1610 1800 1890
40 2434 2224 1974 40 1480 1634 1740
44 2427 2214 1962 44 1320 1450 1560
48 2420 2204 1950 48 1136 1250 1326

Table F-1 derived from: ASH RAE Handbook - 1987 HVAC, SYSTEMS AND APPLICA TlONS, Ch. 17, Table 3.

Installation Manual
 ~
Sunrise:
PerformanceData Sheet
Solar Noon:
(Sheet 1 of 2)
Sunset: (Initials/Date)

Parameter Time of Data Reading

Measured/ I-P Expected

Calculated Units Range ~
t..}
-
1. Instantaneous Btut
solar insolation ft2. h
2. Integratedsolar Btut
insolation tf!
3. Ambient of
temperature
4. Collectorarray of
inlet temperature
5. Collectorarray OF
outlet temperature
6. Collectorloop gpm
flow rate
7. Rate of solar Btuth
energy collection
8. Instantaneouscol- %
lector array efficiency
9. Collectorloop pump amps
current*
~
- 10. Collectorloop pump volts
I;ooJ

S' voltage* ~
I~
~
is" 11. Collectorloop pump :::
s. Btuth ~
power ~
;=
~I
12. Storageinlet OF
~ temperature ~

-
:=
;:::
~ * For 3-phase motors,use the averageof the 3 legs.
~
~
VI
 ~
~
-
I;J

S'
5"
:::to
Sunrise:
Solar Noon:
Sunset:
PerformanceData Sheet
(Sheet 2 of 2)
(Initials/Date)
~
;:
Parameter Time of Data Reading
~
-
;:
;::
~
Measured/
Calculated

13. Storageoutlet
I-P
Units

OJ:
Expected
Range
~
f'J
-

temperature
14. Storageloop gpm
flow rate
15. Rateof energy Btu/h
storage
16. Storageloop amps
pumpcurrent*
17. Storageloop volts
pump voltaae*
18. Storageloop Btu/h
pump power
19. Instantaneous %
systemefficiency
20. Averagestorage OJ:
temperature
21. Integratedenergy Btu
input to storage
22. Collectorlooppump Btu ~
energy input -g
;::
23. Storage looppump Btu eo
~.
energy input
~
24. Integratedsystem I
% ~
efficiency
~
~
* For 3-phase motors,use the averageof the three legs. Q\
u

System Efficiency Test Appendix F-pac..e 7

Performance Data Sheet Notes (I-P Units)

Calculate for each data reading:

Item 1 - As measured in the plane of the collectors

Item 2 - As measured in the plane of the collectors

Item 7 - As determined by the following equation:

8.021 x Pc x cpc x Item 6 x (Item 5 - Item 4)

where: pc = collector loop fluid density, Ib/ft3*

cpc = collector loop fluid specific heat, Btu/lb-OF*
8.021 = conversion factor.

Item 8 - As determined from the following equation:

100 x Item 7 + (Item 1 x Ac)

where: = gross collector area, ft2

Ac
100 = conversion factor.

Item 11 - As determined from the following equation:

For single phase: 3.413 x Item 9 x Item 10 x PF

For three phase: 5.905 x Item 9 x Item 10 x PF

where: PF = collector loop pump power factort

3.413, 5.905 = conversion factors.

Item 15- As determined from the following equation:

8.021 x Ps x cps x Item 14 x (Item 12 - Item 13)

where: Ps = storage loop fluid density, Ib/ft3*

cps = storage loop fluid specific heat, Btu/lb-OF*
8.021 = conversion factor

*Evaluated at average temperature of fluid; see Figures F-1, F-2.

tWill generally range from 0.8 to 0.9 for motor under load.

Installation Manual
System Efficiency Test Appendix F - PaG..e 8
1.1 4.61

u.
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ca
CG
CD
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-caCD
0

%
.7 2.9

-1l!
0
37.8
-'-
100
-
°C
of
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Figure F-1. Heat Capacity of Heat Transfer Fluids vs. Temperature

70 1120
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Figure F-2. Densityof. HeatTransfer Fluids
.
vs. Temperature

Installation Manual
 -- - u_-

System Efficiency Test Appendix F-Pa!I.e 9

Performance Data Sheet Notes- I-P Units(Continued)

Item 18 As determined from the following equation:

For single phase: 3.413 x Item 16 x Item 17 x PF

For three phase: 5.905 x Item 16 x Item 17 x PF

where: PF = storage loop pump power factort

3.413, 5.905 = conversion factors.

Item 19- As determined from the following equation:

100 x (Item 15 - Item 18 - Item 11) + (Item 1 x A c)

where: 100 = conversion factor.

Item 20 - As determined from the following equation:

(Item 12 + Item 13) + 2.

Item 21 - As determined from the following equation:

ps x cps x Vs x [(Item 20)at t2 - (Item 20)at t1] + 7.48

where: Vs = storage tank liquid volume, gal

t1 = beginning of test period
t2 = end of test period
7.48 = conversion factor.

Add to integrated energy from previous data reading to get

integrated energy up to that time.

Item 22 - As determined from the following equation:

For single phase: 0.0167 x Item 11 x At

For three phase: 0.0289 x Item 11 x At

where: At = duration of test period, min

0.0167,0.0289 = conversion factors.

tWill generally range from 0.8 to 0.9 for motor under load.

Installation - Manual
System Efficiency Test Appendix F - Pa!I..e10

Performance Data Sheet Notes I-P Units (Continued)

Item 23 - As determined from the followingequation:

For single phase: 0.0167 x Item 18 x At

For three phase: 0.0289 x Item 18 x At

where: At = duration of test period, min

0.0167, 0.0289 = conversion factors.

Item24 - As determined from the followingequation:

100 x (Item 21 - Item 22 - Item 23) + (Item 2 x Ac)

where: 100 = conversion factor.

Comments from performance test:

Installation Manual
System Efficiency Test Appendix F-PaKe 11

7.0 DATA ANALYSIS

7.1 Solar Energy Collected

Calculate system performance by using the equations given with the data sheets. If Btu meters are installed,
record their readings and compare with the calculated rates of energy collection and storage (Items 7 and 15)
and integrated energy to storage (Item 21).

7.2 System Operating Point

Calculate the system operating point for each data-taking period by the following equation:

Operating Point = (Collector inlet temperature - ambient temperature)/Insolation

(Item 4 - Item 3)/ltem 1.

~: This cannot be calculated without pyranometer readings, Item 1.

8.0 PERFORMANCE EVALUATION

8.1 Collector Operating Curve

Plot the instantaneous collector array efficiency calculated from the performance test as Item 8 against the
operating point calculated in 7.2 above for each data point taken. Repeat, plotting instantaneous system
efficiency, Item 19, against the operating point. If possible, plot these efficiencies on the collector test curve
supplied by the manufacturer.

The Item 8 collector efficiency should be within 70% to 100% of the efficiency on the collector test curve when
compared at the same operating point; the Item 19 system efficiency should be 5% to 10% lower than Item 8.

8.2 System Efficiency

The integrated overall system efficiency (Item 24) is a measure of the system's ability to convert solar energy
into net usable thermal energy. At the end of the test, Item 24 should exceed 35%. (This one-day test can
not be extrapolated to predict all-year performance, but it does provide a general indication whether the
system performance will approach the design goals.) This is the only efficiency that can be calculated if you
are using Table F-1.

NOTE:

Place the completed Performance Data Sheets in the Operation and Maintenance Manual for
the system and retain for comparison with future tests and performance calculations.

Installation Manual
Energz Collection Test Appendix G - Page 1

APPENDIX G

ONE-DAY ENERGY COLLECTION TEST

"Thisappendix provides guidelines for carrying out a short-term evaluation of the thermal performance of a
solar energy system that does not have Btu meters or a data acquisition system (DAS) installed. The evalu-
ation measures the temperature rise in the solar storage tank and the flowrate in the storage loop to calcu-
late the solar energy collected and stored over one day's operation.

1.0 Instrumentation

The followinginstrumentationmustbe installedinthe system:

Some form of flow-measuring device in the storage loop.

Some formof temperaturemeasurementinthe supplyand returnlinesof the storage loop.

2.0 Determining Flow Rates

Ifpossible, determine flow rates using two different methods, then compare the results. Record the flow rate
at the start and end ofthe test and once inbetween.
2.1 Visual Flowmeter

Read the flow rate directly from the visual flowmeter if one is installed.

2.2 Pressure Drop

Use permanentpressure gauges on the inlet/outletof pumpand heat exchangerwhere installed,or use a
pressure probe in prr ports inthose locations. Measurethe pressure on the inletand outletofthe pump,
subtractthe inletpressure fromthe outletpressure to determinethe pressure increase across the pump,then
use the graph of pumphead vs. flowrate suppliedby the manufacturerto estimatethe flowrate. This method
shouldalwaysbe used as a check on any otherflowrate estimate.
Alternatively,measure the pressure on the inletand outletsides ofthe heat exchanger,determinethe pres-
sure drop,then use the heat exchangerflowrate/pressuredropcharacteristicssuppliedbythe manufacturer
to estimatethe flowrate. Thisestimate is less accuratethan usingpumpL\Pbut is usefulifreadingsare
repeated regularlyto detect heat exchangerfouling.
2.3 Clamp-on Ultrasonic Flowmeter

Measurethe flowrate withan ultrasonicflowmeterwithclamp-onexternalsensors. (Usethis methodas a

last resort, as these flowmetersare difficultto calibrateand use, and are extremelyexpensive.)
3.0 Determining Temperatures
3.1 Installed Thermowells

Read the temperaturedirectlyfroman installedthermometer. Use bi-metalthermometers,not mercurytype,

inthe thermowell,

Installation Manual
EnergJ..Collection Test -
Appendix G Page 2

3.2 DTCReadout

Read tank temperatures directlyfrom the DTCdigital readout, ifavailable.

3.3 PIT Ports

Wherea PITportwas installed,use a probethermometerto measure temperature. Cautionshouldbe used

duringremovalofthe safetycap and insertionofthe probeto protecthands and eyes. Coatthe probewith
siliconegrease before insertion. Donot leavethe probeinthe portfor longperiodsoftime. Whenthe
temperature has been read, removethe probe and replacethe safetycap.
3.4 Surface Probe

Where there are no thermometers or PIT ports, use a digital thermometer. Coat the probe with heat-conduct-
ing grease and insert itunder the insulation. (Note: Ifthe piping has been insulated and jacketed correctly,
this may be difficultto do. Be prepared to remove and replace insulation and jacketing as required.) Be sure
the probe is in good physical contact withthe surface of the pipe, tank, etc., and is insulated from drafts.

4.0 Test Procedures

4.1 Test Conditions

Make the performance test on a clear day with moderate wind conditions, ambient temperature normal for
this time of year, and insolation averaging about 250 BtuIft2/h. Do not take data when insolation is below
200 BtuIft2/h. Isolate the solar energy system from the loadbeforestartingthe test.

4.2 Data Recording

Record data at 15-minute or 30-minute intervals over a 4-hour period, with at least two hours on either side of
solar (not "clock")noon. (See Appendix H for calculation of solar noon.) Use the sample Performance Data
Sheet, Table G-1, or equivalent to record the data. Note the time each data point was measured. (Make all
measurements for one data-taking period in as short a time as possibleto improve the validity of "instantane-
ous" energy flow calculations.) Record the following for each data-taking period. (Item numbers refer to the
data sheets.)

1. Storage tank inlet and outlettemperatures (Items 1 and 2).

Record the following at the start of the test, at solar noon, and at the end of the test:

1. Storage loop flow rate (Item 3).

Note where each temperature and flow rate measurement was made and how the flow rate was determined,
so the test can be duplicated six months or a year later.

5.0 Data Analysis

Calculatesolar energy collectedby using the equations given with the data sheet. Item 4 gives the energy
collected since the previousreading; shorter time intervals between readings give more accurate results.

Item 5 gives the total energy collected since the test started.

Installation Manual
Ener!a. Collection Test AppendixQ~ PaJ[e3

6.0 Calculation by Storage Tank Temperature Rise

This test can be run where no flow measurement is possible; it requires measuring only temperatures over
one day's operation. Procedures for measuring the data are the same as Paragraphs 1.0 - 4.0 above; record
the data on the Sample Performance Data Sheet, Table G-2.

7.0 Performance Evaluation

Place the completed Performance Data Sheet in the O&M Manual for the system and retain for comparison
with future tests. After a year's operation, test results can be compared with those of the previous year 2D...a
day/week with similar weather conditions to see whether the system's performance is falling off.

Installation Manual
~
~
~
;::
s-
Sunrise: ~
..,
Table G-1 Performance Data Sheet
Solar Noon:
f.
:=
Sunset: (Initials/Date) ~
;:::
Parameter Time of Data Reading
~
~
~
:=
<:;)
;::
Measured/ I-P Expected
-
;:::
~ Calculated Units Range ~
~
....

1. Storageinlet of
temperature
2. Storageoutlet of
temperature
3. Storage loop
flow rate gpm

4. Energyinput Btu
to storage
5. Integratedenergy Btu
input to storage

Calculations:

Item 4: Determined by the following equation:

Item 4 -
= 8.021 x ps x Cpsx Item 3 x (Item 1 Item 2) x H
where
H = time elasped since last reading, h
ps = storage tank fluid density., Ib/tt3
Cps = storage tank fluid specific heat., Btu/lb.oF
8.021 = conversion factor.

~
. Evaluate at average fluid temperature (see Figures F-1and F-2)
~~
Add Item 4 to integrated energy from previous data reading to get integrated energy stored up to that time, Item 5. ;::
a:
~
~
.HmI: Place the completed Performance Data Sheet in the Operation and Maintenance Manual for the system for I

comparison with future tests.

?
.a::...
 ~
Sunrise: ;:
Table G-2 Performance Data Sheet ~
..,
Solar Noon: (no flow measurement)
(Initials/Date)
Sunset: ~
<:>

Parameter Time of Data Reading ~

(')
:::to
<:>
Measured/ I-P Expected ;:
Calculated Units Range ~
~
1. Storage inlet Of
temperature
2. Storage outlet <>F
temperature
3. Average storage <>F
temperature
4. Energy input Btu
to storage
5. Integrated energy Btu
input to storage

Calculations:
Item3: Determinedby (Item1 + Item2) + 2
Item 4: Determined by the followingequation:
Item4 = Vx p x Cpx (Item32 -Item 31)+ 7.48
where
V = storage tank liquid volume, gal
p = storage tank liquid density*, Ib/ft3
Cp = storage tank liquid specific heat*, Btu/lb.oF
~
~ * Evaluate at average fluid temperature (see Figures F-1 and F-2)
Item 32: this reading
::
.~
~
is= Item 31: previous reading ;:
~.
c::>
7.48 = conversionfactor.
~
:=I
Add Item 4 to integrated energy from previous data reading to get integrated energy stored up to that time, Item 5. ~
I

~ '"
:=I
~
-
;:::
1::\
Note: Place the completed Performance Data Sheet in the Operation and Maintenance Manual for the system for
comparison with future tests.
<.f1
Solar Noon Appendix H - Page 1

APPENDIX H

CALCULATION OF SOLAR NOON

The following equation relates solar (or sun) time to standard (or civil) time:

TSOLAR= TSTD+ E + 4 (LST - LLOd

where T SOLAR = solar time

TSTD = standard time

E = equation of time (from Figure 1)

LST = standard meridian

Time Zone J.sr

Eastern 75°W

Central 900W

Mountain 105°W

Pacific 1200W

LLOC = site meridian

Notes: 1. "E" is a correction (in minutes) to account for perturbations in the earth's orbit
and rate of rotation that cause solar time (measured by a sundial) to run faster
or slower than civil time (measured by a clock).

2. (LST- LLOC)is the distance of the site from the standard meridian; the sun
takes four minutes to traverse one degree of longitude.

3. See following example.

Installation Manual
Solar Noon Appendix H - Page 2

EXAMPLE:

Solar noon at Madison, WI

Time zone = Central Date = February 2

Site meridian (LLOC)= 89.38°W

Standard meridian (lsT) = 900W

Equation of time (E) = -13.5 minutes

What is the local time at solar noon?

TSOLAR = TSTD+ E + 4 (LST - ~~

Rearranging equation algebraically,

TSTD = TSOlAR - E - 4 (LST - ~oc)

= 12:00 noon - (-13.5) - 4 (90.0 - 89.38)

= 12:00 noon + 13.5 - 2.48

= 12:00 noon + 11.02

= 12:11 p.m.
Thus, solar noon occurs at 12:11 p.m. central standard time at Madison, WI on February 2.

Installation Manual
Solar Noon -
Appendix H Page 3

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Installation Manual