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®
Solar Water Heater With Electric Backup
®
Solar Saver Heaters
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
S-SW2-60R6DS
S-SW2-75R6DS
S-SW2-115R6DS
Manual 238-47297-00A Save this manual for future reference
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Solar Water Heater With Electric Backup Table of Contents Page Service Procedure Introduction ………………………………………………………………………. 2 Tools……………………………………………………………………………… 2 General Information ……………………………………………………………… 3 - - - Sequence of Operation …………………………………………………………… 5 - - - Troubleshooting ……………………………………………………………….…. 6 - - - Line Voltage and High Limit (ECO) Testing…………………………………..… 8 RE-I Heating Element Testing ……………................................................................... 9 RE-II Thermos
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GENERAL INFORMATION Commonly Used Formulas Single Phase Amps = Watts Example 4500W/240V = 18.75A Volts Watts = Amps x Volts Example 18.75A x 240V = 4500W 2 2 Ohms = Volts Example (240V) / 4500W = 12.8 Ohms Watts Service Wire Configuration 240 VOLT BLACK RED GREEN Ungrounded Grounding Ungrounded 240 120 120 Wattage Limitation at 240 Volts Solar Water Heater with Double Electric Element Backup Series (Non-Simultaneous operation) Maximum Element Wattage Upper/Lower 5,500/5
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GENERAL INFORMATION Surface Mounted Thermostats Surface mounted thermostats are mounted into a bracket which holds the thermostat against the side of the tank. Surface mounted thermostats respond to tank surface temperatures to sense a call for heat, set point temperature settings and high limit (ECO) activation. It is important that the entire back surface of the thermostat is in full contact or flush with the tank. Improperly mounted thermostat will lead to improper heater operation. Manual EC
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SEQUENCE OF OPERATION Non-Simultaneous Operation Non-Simultaneous Mode: Allows only one heating element to operate at a time. For example, when the tank is cold, the upper element is energized first, heating the top of the tank. Only when the upper thermostat is satisfied, the upper element is de-energized and power is directed to the lower thermostat, energizing the lower element and heating the bottom portion of the tank until the lower thermostat is satisfied. As hot water is drawn off the ta
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TROUBLESHOOTING NOTICE This Service Manual is for servicing the solar water heater. If other components of an installed system requires service, those questions should be directed to the installer or the specific component manufacturer. Most common cause for improper electric backup operation can be linked to heating element failure. When troubleshooting an electric backup solar water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot Water”, it’s always a good idea to c
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TROUBLESHOOTING WARNING Quick Step Plan to Hot Water High voltage exposure. Use caution when making voltage checks to avoid personal injury. 1. TURN OFF power to water heater and solar controller. Check all wire connections to insure they are tight and corrosion free. NOTICE This Service Manual is for servicing the solar water heater. 2. Turn power “ON” and determine that service voltage is If other components of an installed system requires present and the high limit (ECO) has not actuated se
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SERVICE PROCEDURE RE-I Line Voltage & High Limit (ECO) Testing Line Voltage Testing WARNING High voltage exposure. Use caution when making voltage checks to avoid personal injury. 1. Turn “OFF” power to water heater. 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat. ECO reset button 3. Set multi-meter to volts AC. 4. Turn power “ON” to water heater. 5. Check voltage across terminals L1 & L3 of upper thermostat (see illustration 2). A) Ra
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SERVICE PROCEDURE RE-II Heating Element Testing Testing For Open Or Burned Out Element. WARNING High voltage exposure. Be sure power is turned OFF to water heater prior to performing this Step 1. TURN OFF POWER TO WATER HEATER. procedure. Step 2. Remove access covers from front of water heater. Remove insulation and plastic cover from thermostat. Step 3. Disconnect wires from heating element. Step 4. Set multi-meter to “ohms” setting. Step 5. Touch probes of multi-meter to screw terminals of hea
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SERVICE PROCEDURE RE-III Thermostat Testing WARNING Double Element, Non-Simultaneous, Single Phase High voltage exposure. Use caution to avoid Operation. personal injury during this procedure. Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC”. 4. Check across terminals L4 and T2 of upper thermostat (see illustration 6). A) Rated voltage NOT present, Recheck ECO.
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SERVICE PROCEDURE RE-III Thermostat Testing WARNING Double Element, Non-Simultaneous, Single Phase High voltage exposure. Use caution to avoid Operation (continued). personal injury during this procedure. Not Enough Hot Water (continued). 7. Check voltage across terminal L4 of upper thermostat and terminal 1 of lower thermostat (see illustration 9). A) Rated voltage NOT present, - check wire connection between thermostats. B) Rated voltage IS present, okay, go to step 8. 8. Adjust lower thermos
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SERVICE PROCEDURE RE-IV Thermostat Removal and Replacement Thermostat Removal WARNING High voltage exposure. Be sure power is 1. Turn power “OFF” To water heater. “OFF” when performing this procedure. 2. Remove access cover and insulation. 3. Remove plastic thermostat protector from thermostat. 4. Disconnect wires from thermostat terminals. It may be necessary to label wires for proper re-connection to new thermostat. 5. Note thermostat temperature setting for proper setting of new thermostat.
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SERVICE PROCEDURE RE-V Heating Element Removal and Replacement WARNING High voltage exposure. Be sure power is Heating Element Removal “OFF” when performing this procedure. 1. Turn power “OFF” To water heater. 2. Turn off cold water supply to heater. Connect hose to drain WARNING spigot of water heater and route to an open drain. Open Heater components and stored water may be a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater
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SERVICE PROCEDURE RE-VI Dip Tube and Anode Inspection and Replacement Dip Tube Inspection and Replacement WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Turn power “OFF” to water heater. Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain
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Generic Parts List 1. Integrated Mixing Device 10. Heating Element 2. Hex Head Anode 11. Thermostat Mounting Bracket 3. Junction Box Cover 12. Thermostat w/High Limit (89T33) 4. Cover Conduit/Ground 13. Element Gasket 5. ¾" Plug 14. T&P Relief Valve 6. Hot Water Outlet/Anode 15. Lower Thermostat Protector (Small) 7. Cold Water Inlet Dip Tube 16. Thermostat (59T) 8. Access Cover 17. Brass Drain Valve 9. Thermostat Protector (Large) 18. Kit Dairy Barn Leg Page 15 15
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