SWH Maintenance And Repair
Solar Water Heater System Maintenance And Repair
Solar water heater systems require periodic inspections and routine maintenance to keep them operating efficiently. Also, from time to time, components may need repair or replacement. You should also take steps to prevent scaling, corrosion, and freezing.
You might be able to handle some of the inspections and maintenance tasks on your own, but others may require a qualified technician. Ask for a cost estimate in writing before having any work done. For some systems, it may be more cost effective to replace, shut off, or remove the solar system than to have it repaired.
Periodic Inspection List
Here are some suggested inspections of solar system components. Also read your owner's manual for a suggested maintenance schedule.
Flat Plate Collectors
• Collector shading
Visually check for shading of the collectors during the day (mid-morning, noon, and mid-afternoon) on an annual basis. Shading can greatly affect the performance of solar collectors. Vegetation growth over time or new construction on your house or your neighbor's property may produce shading that wasn't there when the collectors were installed.
• Collector soiling
Dusty or soiled collectors will perform poorly. Periodic cleaning may be necessary in dry, dusty climates.
• Collector glazing and seals
Look for cracks in the collector glazing, and check to see if seals are in good condition. Plastic glazing, if excessively yellowed, may need to be replaced.
Evacuated Tube Collector
• Cleaning
Regular rain should keep the evacuated tubes clean, but if particularly dirty they may be washed with a
soft cloth and warm, soapy water or glass cleaning solution, If the tubes are not easily and safely accessible,
high pressure water spray is also effective.
• Leaves
During autumn, leaves may accumulate between or beneath the tubes. Please remove these leaves
regularly to ensure optimal performance and to prevent a fire hazard. (The solar collector will not cause
the ignition of flammable materials)
• Broken tube
If a tube is broken it should be replaced as soon as possible to maintain maximum collector performance.
The system will still operate normally even with a tube broken. Any broken glass should be cleared away
to prevent injury.
• Plumbing, ductwork, and wiring connections
Look for fluid leaks at pipe connections. Check duct connections and seals. Ducts should be sealed with a mastic compound. All wiring connections should be tight.
• Piping, duct, and wiring insulation
Look for damage or degradation of insulation covering pipes, ducts, and wiring.
• Roof penetrations
Flashing and sealant around roof penetrations should be in good condition.
• Support structures
Check all nuts and bolts attaching the collectors to any support structures for tightness.
• Pressure relief valve (on liquid solar heating collectors)
Make sure the valve is not stuck open or closed.
• Pumps
Verify that pumps are operating. Listen to see if they come on when the sun is shining on the collectors after mid-morning. If you can't hear a pump operating, then either the controller has malfunctioned or the pump has.
• Heat transfer fluids
Antifreeze solutions in liquid (hydronic) solar heating collectors need to be replaced periodically. It's a task best left to a qualified technician. If water with a high mineral content (i.e., hard water) is circulated in the collectors, mineral buildup in the piping may need to be removed by adding a de-scaling or mild acidic solution to the water every few years.
• Storage systems
Check storage tanks, etc., for cracks, leaks, rust, or other signs of corrosion.
Preventing Scaling And Corrosion
Two major factors affecting the performance of properly sited and installed solar water heating systems include scaling (in liquid or hydronic-based systems) and corrosion (in hydronic and air systems).
Scaling
Domestic water that is high in mineral content (or "hard water") may cause the buildup or scaling of mineral (calcium) deposits in hydronic solar heating systems. Scale buildup reduces system performance in a number of ways. If your system uses water as the heat-transfer fluid, scaling can occur in the collector, distribution piping, and heat exchanger. In systems that use other types of heat-transfer fluids (such as glycol, an anti-freeze), scaling can occur on the surface of the heat exchanger that transfers heat from the solar collector to the domestic water. Scaling may also cause valve and pump failures on the potable water loop.
You can avoid scaling by using water softeners or by circulating a mild acidic solution (such as vinegar) through the collector or domestic hot water loop every 3–5 years, or as necessary depending on water conditions. You may need to carefully clean heat exchanger surfaces with medium-grain sandpaper. A "wrap-around" external heat exchanger is an alternative to a heat exchanger located inside a storage tank.
Corrosion
Most well-designed solar systems experience minimal corrosion. When they do, it is usually galvanic corrosion, an electrolytic process caused by two dissimilar metals coming into contact with each other. One metal has a stronger positive electrical charge and pulls electrons from the other, causing one of the metals to corrode. The heat-transfer fluid in some solar energy systems sometimes provides the bridge over which this exchange of electrons occurs.
Oxygen entering into an open loop hydronic solar system will cause rust in any iron or steel component. Such systems should have copper, bronze, brass, stainless steel, plastic, rubber components in the plumbing loop, and plastic or glass lined storage tanks.
Freeze Protection
Solar water heating systems, which use liquids as heat-transfer fluids, need protection from freezing in climates where temperatures fall below 42ºF (6ºC).
Don't rely on a collector's and the piping's (collector loop's) insulation to keep them from freezing. The main purpose of the insulation is to reduce heat loss and increase performance. For protecting the collector and piping from damage due to freezing temperatures, you basically have two options:
• Use an antifreeze solution as the heat-transfer fluid.
• Drain the collector(s) and piping (collector loop), either manually or automatically, when there's a chance the temperature might drop below the liquid's freezing point.
Using An Antifreeze Solution
Solar water heating systems that use an antifreeze solution (propylene glycol or ethylene glycol) as a heat-transfer fluid have effective freeze protection as long as the proper antifreeze concentration is maintained. Antifreeze fluids degrade over time and normally should be changed every 3–5 years. Since these systems are pressurized, it is not practical for the average homeowner to check the condition of the antifreeze solution. If you own this type of system, have a solar heating professional check it periodically.
Draining The Collector And Piping
Solar water heating systems that use only water as a heat-transfer fluid are the most vulnerable to freeze damage. "Draindown" or "drainback" systems typically use a controller to drain the collector loop automatically. Sensors on the collector and storage tank tell the controller when to shut off the circulation pump, to drain the collector loop, and when to start the pump again.
Improper placement or the use of low-quality sensors can lead to their failure to detect freezing conditions. The controller may not drain the system, and expensive freeze damage may occur. Make sure that the sensor(s) have been installed according to the manufacturer's recommendations, and check the controller at least once a year to be sure that it is operating correctly.
To ensure that the collector loop drains completely, there should also be a means to prevent a vacuum from forming inside the collector loop as the liquid drains out. Usually an air vent is installed at the highest point in the collector loop. It is a good practice to insulate air vents so that they do not freeze. Also make sure that nothing blocks the airflow into the system when the drain cycle is active.
Collectors and piping must slope properly to allow the water to drain completely. All collectors and piping should have a minimum slope of 0.25 inches per foot (2.1 centimeters per meter).
In integral collector storage or "batch" systems, the collector is also the storage tank. Placing large amounts of insulation around the unglazed parts of the collector and covering the glazing at night or on cloudy days will help to protect the collector from cold temperatures. However, water in the collector can freeze over extended periods of very cold weather. The collector supply and return pipes are also susceptible to freezing, especially if they run through an unheated space or outside. This can happen even when the pipes are well insulated. It is best to drain the entire system before freezing temperatures occur to avoid any possible freeze damage.
Solar water heater systems require periodic inspections and routine maintenance to keep them operating efficiently. Also, from time to time, components may need repair or replacement. You should also take steps to prevent scaling, corrosion, and freezing.
You might be able to handle some of the inspections and maintenance tasks on your own, but others may require a qualified technician. Ask for a cost estimate in writing before having any work done. For some systems, it may be more cost effective to replace, shut off, or remove the solar system than to have it repaired.
Periodic Inspection List
Here are some suggested inspections of solar system components. Also read your owner's manual for a suggested maintenance schedule.
Flat Plate Collectors
• Collector shading
Visually check for shading of the collectors during the day (mid-morning, noon, and mid-afternoon) on an annual basis. Shading can greatly affect the performance of solar collectors. Vegetation growth over time or new construction on your house or your neighbor's property may produce shading that wasn't there when the collectors were installed.
• Collector soiling
Dusty or soiled collectors will perform poorly. Periodic cleaning may be necessary in dry, dusty climates.
• Collector glazing and seals
Look for cracks in the collector glazing, and check to see if seals are in good condition. Plastic glazing, if excessively yellowed, may need to be replaced.
Evacuated Tube Collector
• Cleaning
Regular rain should keep the evacuated tubes clean, but if particularly dirty they may be washed with a
soft cloth and warm, soapy water or glass cleaning solution, If the tubes are not easily and safely accessible,
high pressure water spray is also effective.
• Leaves
During autumn, leaves may accumulate between or beneath the tubes. Please remove these leaves
regularly to ensure optimal performance and to prevent a fire hazard. (The solar collector will not cause
the ignition of flammable materials)
• Broken tube
If a tube is broken it should be replaced as soon as possible to maintain maximum collector performance.
The system will still operate normally even with a tube broken. Any broken glass should be cleared away
to prevent injury.
• Plumbing, ductwork, and wiring connections
Look for fluid leaks at pipe connections. Check duct connections and seals. Ducts should be sealed with a mastic compound. All wiring connections should be tight.
• Piping, duct, and wiring insulation
Look for damage or degradation of insulation covering pipes, ducts, and wiring.
• Roof penetrations
Flashing and sealant around roof penetrations should be in good condition.
• Support structures
Check all nuts and bolts attaching the collectors to any support structures for tightness.
• Pressure relief valve (on liquid solar heating collectors)
Make sure the valve is not stuck open or closed.
• Pumps
Verify that pumps are operating. Listen to see if they come on when the sun is shining on the collectors after mid-morning. If you can't hear a pump operating, then either the controller has malfunctioned or the pump has.
• Heat transfer fluids
Antifreeze solutions in liquid (hydronic) solar heating collectors need to be replaced periodically. It's a task best left to a qualified technician. If water with a high mineral content (i.e., hard water) is circulated in the collectors, mineral buildup in the piping may need to be removed by adding a de-scaling or mild acidic solution to the water every few years.
• Storage systems
Check storage tanks, etc., for cracks, leaks, rust, or other signs of corrosion.
Preventing Scaling And Corrosion
Two major factors affecting the performance of properly sited and installed solar water heating systems include scaling (in liquid or hydronic-based systems) and corrosion (in hydronic and air systems).
Scaling
Domestic water that is high in mineral content (or "hard water") may cause the buildup or scaling of mineral (calcium) deposits in hydronic solar heating systems. Scale buildup reduces system performance in a number of ways. If your system uses water as the heat-transfer fluid, scaling can occur in the collector, distribution piping, and heat exchanger. In systems that use other types of heat-transfer fluids (such as glycol, an anti-freeze), scaling can occur on the surface of the heat exchanger that transfers heat from the solar collector to the domestic water. Scaling may also cause valve and pump failures on the potable water loop.
You can avoid scaling by using water softeners or by circulating a mild acidic solution (such as vinegar) through the collector or domestic hot water loop every 3–5 years, or as necessary depending on water conditions. You may need to carefully clean heat exchanger surfaces with medium-grain sandpaper. A "wrap-around" external heat exchanger is an alternative to a heat exchanger located inside a storage tank.
Corrosion
Most well-designed solar systems experience minimal corrosion. When they do, it is usually galvanic corrosion, an electrolytic process caused by two dissimilar metals coming into contact with each other. One metal has a stronger positive electrical charge and pulls electrons from the other, causing one of the metals to corrode. The heat-transfer fluid in some solar energy systems sometimes provides the bridge over which this exchange of electrons occurs.
Oxygen entering into an open loop hydronic solar system will cause rust in any iron or steel component. Such systems should have copper, bronze, brass, stainless steel, plastic, rubber components in the plumbing loop, and plastic or glass lined storage tanks.
Freeze Protection
Solar water heating systems, which use liquids as heat-transfer fluids, need protection from freezing in climates where temperatures fall below 42ºF (6ºC).
Don't rely on a collector's and the piping's (collector loop's) insulation to keep them from freezing. The main purpose of the insulation is to reduce heat loss and increase performance. For protecting the collector and piping from damage due to freezing temperatures, you basically have two options:
• Use an antifreeze solution as the heat-transfer fluid.
• Drain the collector(s) and piping (collector loop), either manually or automatically, when there's a chance the temperature might drop below the liquid's freezing point.
Using An Antifreeze Solution
Solar water heating systems that use an antifreeze solution (propylene glycol or ethylene glycol) as a heat-transfer fluid have effective freeze protection as long as the proper antifreeze concentration is maintained. Antifreeze fluids degrade over time and normally should be changed every 3–5 years. Since these systems are pressurized, it is not practical for the average homeowner to check the condition of the antifreeze solution. If you own this type of system, have a solar heating professional check it periodically.
Draining The Collector And Piping
Solar water heating systems that use only water as a heat-transfer fluid are the most vulnerable to freeze damage. "Draindown" or "drainback" systems typically use a controller to drain the collector loop automatically. Sensors on the collector and storage tank tell the controller when to shut off the circulation pump, to drain the collector loop, and when to start the pump again.
Improper placement or the use of low-quality sensors can lead to their failure to detect freezing conditions. The controller may not drain the system, and expensive freeze damage may occur. Make sure that the sensor(s) have been installed according to the manufacturer's recommendations, and check the controller at least once a year to be sure that it is operating correctly.
To ensure that the collector loop drains completely, there should also be a means to prevent a vacuum from forming inside the collector loop as the liquid drains out. Usually an air vent is installed at the highest point in the collector loop. It is a good practice to insulate air vents so that they do not freeze. Also make sure that nothing blocks the airflow into the system when the drain cycle is active.
Collectors and piping must slope properly to allow the water to drain completely. All collectors and piping should have a minimum slope of 0.25 inches per foot (2.1 centimeters per meter).
In integral collector storage or "batch" systems, the collector is also the storage tank. Placing large amounts of insulation around the unglazed parts of the collector and covering the glazing at night or on cloudy days will help to protect the collector from cold temperatures. However, water in the collector can freeze over extended periods of very cold weather. The collector supply and return pipes are also susceptible to freezing, especially if they run through an unheated space or outside. This can happen even when the pipes are well insulated. It is best to drain the entire system before freezing temperatures occur to avoid any possible freeze damage.
