Solar Hydronics

PROJECT EARTHBILLY

Funded by:

Hadley Sawmill, New Stone Age Jewelry

All owned/operated by Mark & Rita Hadley
www.hadleysawmill.com www.missouridreamstone.com

Solar Hydronic domestic hot water system.

It seems the original tank sensor may have been faulty. I replace it 2/2009 and all problems highlighted below, before this date, have disappeared. UPDATE 5/4/2009, I replaced the entire controller with a MADE IN USA "Eagle 2" and now the solar hydronic system works much better. The Thermomax SMT100 finally failed completely on 4/25/09. The Eagle's operation is much better than the Thermomax, for us. Thanks to G2power in St. Louis for turning us on to the Eagle 2!

This is the second system I have used. Back in the late "70"s, I had an Earth Enterprise system installed. The collector enclosures failed after many years of service. The new collectors look like they are superior.

4/6/08 We installed the 100+ gallon stainless steel tank and unpacked all the hardware but the two solar collectors.

4/9 installed the controller and expansion tank on the wall next to the storage tank. Making a list of hardware to buy the next time we leave our valley. Begin the preparations for installing the panels on our roof.

4/12 Pretty much have the routing of pipes figured out. Not an easy task with 12" to 36" thick concrete and masonry walls, floors and ceilings everywhere. Also need to coordinate wood heat liquid tie in.

5/5 Mounted wooden rib to concrete wall to strap tank for earth quake survivability.

5/9 Ready to install spar extensions to beams for mounting panels.

5/21 Put up the solar hydronic panels today.

5/28 Have a week of meetings to coordinate. Just need the pipe to plumb system together.

6/9 Some of the fittings, 1" to 3/4" connectors, are special ordered and will take several days to arrive.

6/11 The hot water storage tank is connected, full of water and pressurized. Still missing two fittings for the panels, but I should be able to completely plumb the PEX and insulation tomorrow. I need one 1" fitting for a air bleeder and one 1" fitting for a cap and pressure relief valve. Have everything else ready to install tomorrow.

6/12 Finished plumbing and insulating system. Just waiting on two special fittings due in Monday Morning.

6/14 Put temporary plugs on two fittings and flooded panels, bled air and turned on system for first time. Had to work out a few changes to thermometers for proper metering but now heating water properly. Took my first shower with solar hydronic hot water in 27 years. Well that's not true, many hot baths in China using solar hot water. It looks like it is imperative to install a pressure relief valve...the water was boiling in the panels today before I could turn on the circulator pump. We will debug the system and operate for a while before adding auto engine antifreeze to system.

6/21 Solar hydronic system is now fully installed with check valve, pressure relief valve, thermostat sensor properly placed and pressurized. It is automatic and fully functional. It uses 60 watts for a circulation pump from 10:30 to 18:00 on a partly cloudy to sunny day.

6/25/08 THE PROOF! 60 DEGREE C. IN THE HOLDING TANK! THAT'S 140 F.

1/7/09 There seems to be a bad habit with this controller to fault the tank temp and shut off the pump, then the panels boil and release fluid onto our south porch. I believe the problem is within the connection between the PLC and the back board. If I wiggle the tank sensor connection no difference but if I wiggle the PLC the tank temp changes. A persistent problem since installing and not going away. Right now I feel when the wood boiler is installed the solar hydronic system is coming out! The solar hydronics don't work well in winter anyway. They heat water if the sun is out and not hazy. But that doesn't happen but about one day a week, not enough to maintain hot water. We will see what is decided soon.

1/15/09 A third collector would not go to waste in this system for winter time. Still having trouble with the controller internal connection block.

1/19/09 Made a major change. Connected the demand of the solar heater tank to the supply of the electric heater tank. I have to heat most of my water with electric anyway this winter so at least the solar hydronic will act as a pre heater for the supply to the electric heater.

1/30/09 I replaced the tank sensor and the system now works perfectly. That has been the problem for the last 7 months.

5/4/09 The SMT failed completely a week ago and I ordered an Eagle Sun Control and installed it yesterday.

5/5/09 I like the Eagle 2's operation much better! Just ordered a third sensor to put on the electric heating tank to monitor temperature of it too. COOL! Now, if I just had the foresight to buy a two coil + electric storage tank, everything would be Zen! I could not have known that I could use the tank as a power dump for the Sunny Island inverters during times of over production of power, until I built and used the whole system. I highly recommend this and still may upgrade my tank. I can put a electric heating element in the remaining open 1" connector, but still can't easily incorporate a separate wood fired water heater without the second coil in the tank. There is a way with check valves and T'ees, as long as both the solar hydronic and wood backup don't run simultaneously. It would be a cheaper way to make it work, considering I already have a grand in this storage tank.

5/12/09 installed a sensor on our electric water heater to show Fahrenheit temperature.

1/4/2010 Building a heating loop for our Fire Chief wood furnace. It will be controlled by a second Eagle 2 controller, so it will automatically operate if there is a fire in the furnace and stop circulating if the fire goes out. In addition, in case of excess hot water, a loop will circulate through the upstairs bathroom floor, this loop is optional with manual valves. While the system is apart I will remount the AET solar panels and add two electric elements as power sinks to protect the batteries in case of grid drop and excess generation by the addition of a second wind turbine, which is ordered.

3/21/2010 Cancelled the water loop for our indoor wood heater, bought a Central Boiler 5036, and am installing it with separate loop for hot water operating with the differential controller from the solar hydronic system. I am planning to take down the hydronic panels and heat all water with wood. DISPATCHABLE HEAT!! Possibly thinking of reinstalling the AET hydronic panels to directly heat water in the wood boiler for summer wood-fire-less hot water. A way to heat water without electricity in winter, the hydronic's fall way short, should make a great difference in meter change during short sun days. I have a whole new concept for the domestic hot water system including a backup load dump for the turbine and PV during grid outage and to meet new code for wind turbine backup control.

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