Maintenance and Operation of Active Solar Heating Systems

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Maintenance and Operation of Active Solar Heating Systems

Maintenance and Operation of Active Solar Heating Systems
Distribution
Foreword
Notice
Abstract
Change Control Sheet
Table of Contents
Table of Contents -Cont.
Table of Contents -Cont.
List Of Figures
List Of Figures -Cont.
List Of Figures -Cont.
List Of Figures -Cont.
List of Tables
Introduction
Scope of This Manual
Review of Manual Structure
Chapter and Page Format
Basic System Configuration
Common Components
Common Components -Cont.
Common Load Connections
Process Water Heating
Space Heating
Space Cooling
Swimming Pool Heating
Figure 2-9 A Pool Heating System
Basic Configuration of Closed Loop Systems
Figure 2-11 A Closed-Loop Solar Heating System
Basic Configuration of Drainback Systems
Basic Configuration of Draindown Systems
Basic Configuration of Thermosiphon Systems
Basic Configuration of Integrated Collector-Storage System
Component Operation
Figure 2-17 A Typical Flat-plate Solar Collector
Pool Collectors
Pumps
Table 2-1. Pump Application Guide
Piping
Solar Fluids
Synthetic Oils
Heat Exchangers
Coil-in-Tank
Shell and Tube
Glass Lined
Stone Lined
Epoxy and Phenolic Resin Lined
Balancing Valves
Pressure Relief Valves
Temperature and Pressure Relief Valve
Fill/Drain Valves
Expansion Tanks
Figure 2-35 An Expansion Tank With a Diaphragm as Fluid Pressure Increases
Pressure Reducing Valves
Air Vents
Figure 2-38 An Automatic Air Vent
Air Eliminators
Collector Loop Control Valves for Draindown Systems
Figure 2-42 An Automatic Draindown Control Valve
Vacuum Breakers
Pipe and Tank Insulation
Table 2-2. Typical Solar Pipe Insulations
Figure 2-45 Closed Cell (Top), Fiber glass (Center), and Elastomer (Bottom) Insulation
Tank Insulation
Figure 2-47 Various Thermistor Sensors
Figure 2-48 A Pool System Collector Sensor
Figure 2-49 A Typical Differential Thermostat Showing High Limit Adjustment
Table 2-3. Control Features and System Types
Temperature
Pressure
Other Devices
Questions for self-study
Questions for self-study -Cont.
Questions for self-study -Cont.
Inspection
Solar Collectors
Figure 3-1 Condensation on a Collector Glazing
Frames
Seals Grommets and Gaskets
Mounting Hardware
Collector Flow Rates Balanced
Air Vents
Air Vents
Exterior Piping
Insulation
Interior Piping
Bypass and Balancing Valves
Pressure and Temperature Relief Valves
Pressure Reducing Valves
Flow Rate
Figure 3-11 Calibrated Gauges With the Pump Off and On
Figure 3-12 Gauges Out of Calibration With the Pump Off and On
Lubrication
Shafts and Bearings
Heat Exchangers
Draindown Tank/Heat Exchanger
Glycols
Figure 3-15 Dowfrost Test Kit
Controls
Figure 3-18 High Limit Dial (left) and Control Switch (right) on a Solar Control
Table 3-2: Characteristics of Available Controls (As of January, 1988)
Controls . Tester Method
Sensors: For Controls Without Digital Displays
Sensors: For Controls With Digital Displays
Table 3-3: Temperature vs. Resistance in Ohms for 10K Sensors
Table 3-4: Temperature vs. Resistance in Ohms for 3K Sensors
Storage Tanks
Sample Inspection Checklist
Solar System Inspection Checklist
Interior Piping
Closed-Loop Fluid, if used
Paperwork
Simplified Inspection Procedures for Small Systems
DHW System Inspection Checklist
Control and Wiring
Questions for Self-study
Questions for Self-study -Cont.
Questions for Self-study -Cont.
Troubleshooting
Less Likely. But Easy
Planning
Troubleshooting Chart
Troubleshooting Chart -Cont.
Troubleshooting Chart -Cont.
Sensor and Sensor Wiring
Controls With Digital Displays
Table 4-1: Temperature vs. Resistance in Ohms for 10K Sensors
Table 4-2: Temperature vs. Resistance in Ohms for 3K Sensors
Controls
Figure 4-3 Checking High Limit Function with a Single Resistor
Control Tester Method
About Accuracy
Table 4-4: Characteristics of Currently Available Controls (As of January, 1988)
Airbound Loops
Symptoms of an airbound collector loop in a Closed loop system include
Symptoms of an airbound storage loop in closed loop and drainback systems
Pumps
Table 4-5:Current Readings and Pump Problems
Flow Rates
Table 4-6: Flow Estimates from Temperature Changes
Water With Iron or Manganese
Figure 4-7 A Dowfrost Test Kit and a Dow Optical Refractometer
Make-Up Water Systems
Valves
Heat Exchangers
Storage Tanks
Questions for Self-study
Questions for Self-study -Cont.
Questions for Self-study -Cont.
Questions for Self-study -Cont.
Repair
Table 5-1: Typical Repair/Replace Choices
Table 5-1: Typical Repair/Replace Choices -Cont.
Table 5-1: Typical Repair/Replace Choices -Cont.
Table 5-1: Typical Repair/Replace Choices -Cont.
Handling and Moving Glass Glazings
Figure 5-2 Typical Glazing Assembly (Loosened for Clarity)
Frames
Figure 5-3 Weep Hole Locations
Mounting Hardware
Absorber Plates
Figure 5-6 Removing the Coupling Halves
Table 5-2: Repairability of Various Absorbers Manufactured for Use by Others
Table 5-3: Repairability of Various Absorbers
Figure 5-8 Repairing a Riser Leak
Frame Ground
Collector Sensor
Interior and Exterior Piping
Hangers
Valves
Collector Loop Flow Balancing
Pressure Gauges and Thermometers
Pressure Relief Valves
Expansion Tanks
Air Vents
Dry Rotor Pumps (Lubricated by Oil or Grease)
Motors and Motor Mounts
Couplings
Figure 5-18 Bearing Lubricated by Grease
Seals
Volutes (Pump Bodies)
Wet Rotor Pumps (Lubricated by System Fluid)
Bell and Gossett and Grundfos Pumps
Figure 5-23 Disassembling Taco Pumps
Heat Exchangers
Figure 5-24 Descaling a Heat Exchanger
Tubes and Bundles
Shells
Drainback Tanks
Reinhibiting Glycols
Figure 5-26 Fill/Drain Assembly (using check valve)
Automatic Water Make-Up
Figure 5-27 Fill/Drain Assembly with Charging Pump and Filter
Refilling (Recharging) Glycol or Oil Loops
Figure 5-28 Typical Charging Pump
Figure 5-29 Special Fill/Drain Assembly Fittings
Figure 5-31 Correct and Incorrect Pouring from a 5 Gallon Drum Without a Spout
Refilling (Recharging) Glycol or Oil Loops -Cont.
Determining the Final Fill Pressure
Determine the Number and Size of Expansion Tank
Solar Controls
Figure 5-32 Routing Sensor Wires
Controls
Storage Tanks
Drain Valves
Temperature and Pressure Relief Valves
Sensor
Back-Up Heating Element
Sample Repair Record Sheet
System Repair Worksheet
Questions for Self-study
Questions for Self-study -Cont.
Questions for Self-study -Cont.
Questions for Self-study -Cont.
Preventive Maintenance
Figure 6-1 Condensation (top) and Outgassing (bottom)
Broken Glazings
Tightening and Sealing Frames
Mounting Hardware
Lightning Protection
Frame Ground
Collector Flow Rates Balanced
Interior and Exterior Piping
Tempering Valves
Expansion Tanks
Pumps
Lubrication
Heat Exchangers
Temperature Change
Solar Fluids
Controls
Figure 6-9 Checking High Limit Function with a Single Resistor
Controls: Tester Method
Storage Tanks
Temperature and Pressure Relief Valves
Temperature and Pressure Relief Valves
Solar System Maintenance Checklist
Solar System Maintenance Checklist -Cont.
Solar System Maintenance Checklist -Cont.
Questions for Self-study
Questions for Self-study -Cont.
Questions for Self-study -Cont.
Bibliography
Appendix A Standardized System Designs
Figure A-1 Closed-loop System
Figure A-3: Draindown System
Figure A-5 Absorption Cooling System
Appendix B Rules of Thumb for Solar Systems
Table B-1 Suggested Flow Rates for Solar Applications
Table B-2:Flow Rates for Various Copper Tubing Sizes
Table B-3: Solar Collector Tilt Angles
Collector Orientation
Figure B-3: Collector Orientation
Appendix C Tool, Material and Spare Parts Lists
Table C-1: Recommended Tool List
Table C-1: Recommended Tool List -Cont.
Table C-1: Recommended Tool List -Cont.
Spare Parts List
Appendix D Product and Supplier Information
Appendix D Product and Supplier Information -Cont.
Appendix D Product and Supplier Information -Cont.
Appendix E Fluids and Materials Compatibility
Appendix F Answers to Questions for Self-study
Index
Index -Cont.
Index -Cont.
Index -Cont.
Index -Cont.
Index -Cont.
Index -Cont.
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Maintenance and Operation of Active Solar Heating Systems