120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

LP-200 REV. 1.6.15

SuperStor Contender

Solar Supplement

OPERATION

MAINTENANCE

*With back-up heat exchanger **With back-up electric element

Drinking Water Act, Section 1417.

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LP-200 REV. 1.6.15

control information. It is important that this manual, all other documents included with this system, and additional publications including

Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, be reviewed in their entirety before beginning any

work.

“The solar energy system described in this manual, when properly installed and maintained, meets the minimum standards established

by the SRCC. This certification does not imply endorsement or warranty of this product by the SRCC.”

The design of the SuperStor Contender solar system is approved by the Solar Rating and Certification Corporation (SRCC). Any

deviation from the approved specified SRCC components may affect your ability to certify this system.

government installations, the commanding officer or departmental official may be the AHJ.

NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice.

FOR THE INSTALLER

INSTALLATION OR SERVICE OF THIS SOLAR WATER TANK IS REQUIRED TO BE PERFORMED BY LICENSED

PROFESSIONALS WHERE SOLAR, PLUMBING AND ELECTRICAL WORK IS REQUIRED.

The installer should be guided by the instructions furnished with the tank, local codes and utility company requirements. Preference

should be given to codes and requirements where they differ from the furnished instructions. Always use the latest edition of codes.

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LP-200 REV. 1.6.15

Solar Water Heating System Design and Installation Guidelines, SRCC OG-300, available from Solar Rating & Certification

Corporation, 400 High Point Drive, Suite 400, Cocoa, FL 32926-6630, www.solar-rating.org.

Code for the Installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New

York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70.

PART 1 - GENERAL SAFETY INFORMATION ........................................................................................................................... 5

A. PRECAUTIONS .......................................................................................................................................................................... 5

B. LOCAL INSTALLATION REGULATION ...................................................................................................................................... 6

C. CHEMICAL VAPOR CORROSION ............................................................................................................................................. 6

D. INSULATION BLANKETS ........................................................................................................................................................... 7

E. DOMESTIC HOT WATER TEMPERATURE ADJUSTMENT ...................................................................................................... 7

F. FREEZE PROTECTION .............................................................................................................................................................. 7

PART 2 – IMPORTANT INSTALLATION INFORMATION .......................................................................................................... 7

A. SCOPE OF MANUAL .................................................................................................................................................................. 7

B. LOCAL STANDARDS AND AUTHORIZED PERSONS .............................................................................................................. 7

A. SYSTEM DESCRIPTION ............................................................................................................................................................ 8

B. SOLAR SYSTEM DESIGN ......................................................................................................................................................... 9

C. SOLAR COLLECTOR INSTALLATION ...................................................................................................................................... 9

D. COLLECTOR ANGLE, PLANE, AND DIRECTION ................................................................................................................... 10

1. COLLECTOR DIRECTION ........................................................................................................................................................... 10

2. COLLECTOR ANGLE (TILT) ........................................................................................................................................................ 10

3. COLLECTOR PLANE (HORIZONTAL OR VERTICAL) ................................................................................................................ 10

E. COLLECTOR PIPING ............................................................................................................................................................... 10

F. COLLECTOR LOOP PIPE INSULATION .................................................................................................................................. 11

G. COLLECTOR SENSOR PLACEMENT ..................................................................................................................................... 11

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LP-200 REV. 1.6.15

L. WIND STRESS.......................................................................................................................................................................... 11

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Table 1 – Chemical Contaminants

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LP-200 REV. 1.6.15

and Installation Guidelines, SRCC OG-300.

An ASSE 1017 rated mixing valve to avoid severe burns or death from scalding

In order to meet health and safety regulations, solar system antifreeze fluid should be food grade polypropylene glycol, FDA rated as

“generally recognized as safe” (GRAS). The recommended glycol is DOWFROST or equivalent. Using proper concentrations of glycol,

solar systems can be operated at ambient temperatures as low as -60

o

F. Freeze tolerance limits are based upon an assumed set of

environmental conditions. Refer to the specification sheet included with the glycol for recommended concentrations. A glycol/water mix

must not exceed 50%, unless the manufacture specifies that a different ratio is recommended for use with solar water heaters. Glycol

system controller, valves, and other plumbing components, should be provided separately by their respective manufacturers.

NOTE: This manual is primarily a reference document for authorized persons, as the solar water heater is not permitted to be installed

by non-authorized persons.

Installation must be completed in accordance with local standards and regulations.

Installation must also be completed by a qualified tradesperson who holds relevant industry licenses or certificates. The term

“authorized person(s)” refers to a suitably qualified professional. Unless otherwise specified, no part of the HTP solar water heater may

be inspected, repaired, or maintained by anybody other than an authorized person.

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LP-200 REV. 1.6.15

pump.

tank to accommodate HTF expansion. The system should be designed to minimize stagnation after the tank temperature has been met;

extensive stagnation may increase pH levels and glycol deterioration.

The expansion tank and plumbing must be properly sized so that the safety pressure relief valve will not activate except in the event of

component failure or extreme conditions. The pressure release must be set at no more than 90 psi. (There may be exceptions in

engineered designs for tall buildings.)

Water quality is very important. Water in direct flow through the solar collectors must first meet potable water requirements; any fluid

circulated through the collectors should be non-corrosive to copper. In addition, water quality must meet the following requirements.

Sodium: Less than 20 mGL

requirements. The glycol content of the liquid must not exceed 50%, unless the manufacturer specifies that a different ratio is

recommended for use with solar water heaters. Glycol should be checked periodically to prevent it from becoming acidic. Please refer

to guidelines provided by the glycol manufacturer regarding glycol maintenance.

Both copper and stainless steel are susceptible to corrosion when, amongst other factors, high concentrations of chlorine are present.

NOTE: Leakage of the solar water heater due to corrosion caused by improper water quality IS NOT covered by product warranty.

Freeze protection must be implemented in any regions that may experience freezing conditions at any time throughout the year.

used (e.g. requiring pump to circulate if the manifold temperature approaches freezing). In an open loop system, a freeze valve (which

opens to allow water to dribble out) could also be considered.

Closed loop systems: In areas with temperatures falling below 23

protection. Please refer to glycol manufacturer’s specifications about the temperature ranges the liquid can withstand. Only food grade

NOTE: HTP DOES NOT WARRANT THE SOLAR WATER HEATER AGAINST FREEZE-RELATED DAMAGE.

PART 3 - GENERAL SOLAR INFORMATION

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LP-200 REV. 1.6.15

systems operate at high pressures.

exchanger and other system components, regular scheduled maintenance must be established to monitor and maintain proper HTF pH

levels.

LP-200 REV. 1.6.15

Wire Cutters Black Latex Outdoor Paint

Adjustable Wrenches 8” & 10” 7/8” x ¾” and 1 1/8” x ¾” pipe insulation

heater as centrally to the domestic piping system and near the

solar collectors as possible. The water heater must also be

located in an area where it will not be exposed to freezing

temperatures. All piping should be insulated to protect against

freezing and heat loss.

LP-200 REV. 1.6.15

water heater. If not detected in a timely manner, a drip or leak may cause serious damage to the tank’s electrical components, or, in

extreme cases, cause the tank to leak from the outside in.

excess of 2,000 ppm will accelerate lime and scale formation on the element or heat exchanger. Water heater failure due to total

dissolved solids in excess of 2,000 ppm is a non-warrantable condition. Failure of a water heater due to lime scale build up IS NOT

covered by the warranty.

Hardness: 7 grains

Chloride levels: 100 ppm

pH levels: 6-8

LP-200 REV. 1.6.15

Only copper, cast iron, or brass are to be allowed in the collector piping loop due to transient operating temperatures that may reach as

high as 300

o

F. PEX, PVC, CPVC, and other polymers are expressly prohibited in the piping network of closed loop systems.

LP-200 REV. 1.6.15

exchanger are 1” NPT. Do not apply heat directly to the heat exchanger thread connection when sweating fittings.

proper system operation. On a sunny day, the hot water return line should be approximately 5 – 12

o

F warmer than the water in the

collector supply line. Compare the temperature readings in the two line thermometers. The ¾” cold water supply line to the storage tank

than 5’.

Make sure the sensor is secured on the stud located in the lower section of the water heater. Secure the sensor by packing Armaflex

insulation behind it. This will also help the sensor react to temperature change.

use a higher glycol to water concentration than necessary, as this will adversely impact heat transfer efficiency. See the DowFrost

Data Sheet in the back of this manual for recommended concentrations. A copy of the MSDS sheet must be left with the end user of

Absorbs and transfers the sun’s energy into the solar heat exchanger located on the bottom of the solar water heater.

o

*Remove and cap the solar air release vent after commissioning the system.

Solar Collector Sensor

This sensor is wired to the solar controller and automatically turns on the circulator pump when the differential set point is reached

between the solar water heater and collector.

Tank and Heat Exchanger Temperature and Pressure Gauge

The temperature and pressure gauge on the solar piping will show the user the actual temperature and pressure supplied and returned

to the solar collector.

Valve #6 and 11 (for solar collector isolation) isolates the collector loop from the solar water heater.

Pressure Relief Valve (for Solar System)

Releases pressure in the solar loop when it exceeds 150psi. Contact your installation contractor immediately if this valve opens

and releases fluids.

System Fill Valve (Valve #8)

Fills the system with HTF. Also eliminates air from the system.

Expansion Tank

Used to direct the flow of HTF and to pressurize and eliminate air from the solar system.

Ball Valve (for circulator) Valve #12

Used to isolate the circulator pump for service. Close both ball valves to isolate pump.

LP-200 REV. 1.6.15

Circulates the HTF from the solar collector into the solar heat exchanger.

Drain Valve (Tank) (Valve #14)

Flushes sediment which may accumulate on the bottom of the solar water heater and also provides a means of draining the tank.

Tank Sensor

Is wired to the solar controller to measure the temperature on the bottom of the solar water heater in conjunction with the solar collector

Solar Controller

The solar controller turns on or off the circulator depending on heat gained from solar operation. The controller also limits overheating in

Hot Water Outlet

Each solar water heater has a hot water dip tube outlet which draws water from the top of the heater. This helps to keep heat trapped

inside the highly insulated storage tank.

Solar Tank Temperature and Pressure Relief Valve

The relief valve must comply with standards for relief valves (ANSI Z21.22) by a nationally recognized lab that maintains periodic

inspections of production listed equipment. No valve of any type should be installed between the relief valve and tank. Local codes

govern installation of relief valves.

The relief valve outlet must be piped to a suitable open drain so that the discharge water cannot contact live electric parts to eliminate

Automatically blends hot and cold water feed lines to control discharge to an acceptable and safe temperature. This also increases the

amount of hot water drawn from the solar water heater by not allowing incoming cold water to fully temper the hot water stored inside

the tank. To help prevent injury due to scalding, it is recommended that the mixing valve be set at 120

F.

The back-up electric element will only activate when the desired minimum set point temperature set on the back-up thermostat cannot

be satisfied by the solar gain achieved from the solar collector.

The back-up boiler will only activate when the desired minimum set point temperature set on the back-up thermostat cannot be satisfied

by the solar input from the solar collector.

Boiler Back-up Aquastat

The cold water shut off valve should be used in the event of an emergency shutdown.

LP-200 REV. 1.6.15

the solar loop.

3. If there is a check valve on the cold water feed line, a thermal expansion tank suitable for potable water must be sized and installed within this piping

system between the check valve and cold water inlet of the solar water heater.

4. An ASSE 1017 mixing valve is required per SRCC OG-300.

5. A minimum of 12 diameters of straight pipe must be installed upstream of all circulators.

6. Make sure tank is fully purged of air before power is turned on to the backup heat source.

7. Circulators shown in the above hydronic piping should have an integral flow check or alternately use a stock pump with an external spring type check

LP-200 REV. 1.6.15

FIGURE NOTES:

system between the check valve and cold water inlet of the solar water heater.

4. An ASSE 1017 mixing valve is required per SRCC OG-300.

5. A minimum of 12 diameters of straight pipe must be installed upstream of all circulators.

7. Circulators shown in the above hydronic piping should have an integral flow check or alternately use a stock pump with an external spring type check

LP-200 REV. 1.6.15

The boiler heat exchanger connections are located in the

size when connecting zone valves or circulators.

operate at 8 feet of friction.

LP-200 REV. 1.6.15

by your local electric utility. All wiring must conform to local code and the National Electric Code. Grounding can be accomplished by

using approved conduit and fittings or other approved conductive material. A grounding wire is provided on the junction bracket. This

LP-200 REV. 1.6.15

o

power to the heater.

This heater is equipped with a combination thermostat and high limit safety. If for any

reset manually. However, THE CAUSE OF THE OVERHEATING CONDITION MUST

result in a hazardous health condition.”

o

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LP-200 REV. 1.6.15

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LP-200 REV. 1.6.15

DOWFROST inhibited glycol-based fluid has an effective operating temperature range of -50

F. At temperatures below -50

increased viscosity (>1,000 centipoise) can make use of DOWFROST impractical unless larger pumps are installed. At the upper end of

exceed 300

o

F. DOWFROST fluid can tolerate brief temperature excursions up to 100

temperatures. However, extended exposure of the fluid to temperatures in excess of 50

within 50

pressure exerted by the fluid to avoid localized boiling and resulting precipitation. At temperatures above 150

appearance and odor. Any drastic variation from the initial fluid specifications, such as a black or dark-grey color, presence of an oily

narrow range pH paper, such as pHydrion Control paper with a 7.2 to 8.8 pH range, is an easy and reliable way to read your pH level. A

desirable pH range should fall between 8.0 and 10.0. Adjustments can be made using a 50% solution of sodium hydroxide or potassium

hydroxide if the pH is approaching the acidic range (below 8.0). An inexpensive pH tester is available from Misco Products. The

accuracy of this product is +/- 0.5 pH. Contact Misco Products at 1-800-358-1100 and ask for the Dow discount.

EYE: May cause slight transient (temporary) eye irritation.

Corneal injury is unlikely. Mists may cause eye irritation.

being absorbed through the skin in harmful amounts. Repeated exposure may cause flaking and softening of skin.

INGESTION: Single dose oral toxicity is considered to be extremely low. No hazards anticipated from swallowing small amounts

incidental to normal handling operations.

LP-200 REV. 1.6.15

Table 8

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LP-200 REV. 1.6.15

LP-200 REV. 1.6.15

The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After

reading the important notes at the bottom of the page, please also sign this document.

IMPORTANT NOTES: