Install an active drainback solar thermal system.
- First determine that the roof and utility room space are suitable for solar hot water components.
- Follow the requirements for all local codes.
- Choose an accredited solar water heating installation company.
- Size the system according to the home’s hot water demands.
- Mount the system on an unshaded, southern exposure if possible.
- Ensure that the roof mounting system avoids water intrusion and damage to the roof structure.
- Choose an active drainback solar thermal system if you need to protect the heat transfer fluid from outdoor freezing temperatures by draining the fluid into conditioned space. Drainback systems are also common in warm climates because they drainback when the system has met a maximum set temperature in the storage tank. This automatic safeguard against overheating avoids problems when hot water demand is very low, such as during vacation.
See the Compliance Tab for related codes and standards requirements, and criteria to meet national programs such as DOE’s Zero Energy Ready Home program, ENERGY STAR Single-Family New Homes, and Indoor airPLUS.
Drainback solar thermal systems (Figure 1) are a common choice for freeze-prone areas in the U.S. These systems include an unpressurized drainback reservoir tank (10-20 gallon) that stores via gravity all of the solar loop fluid when the circulation pump is not operating. The fluid can be plain distilled water, water with anti-corrosive additives, or glycol (propylene) for systems that do not reside in conditioned spaces.
Premium drainback tanks are made of stainless steel to prevent corrosion by interaction from bronze pumps and other ferrous components in the circulation loop. Sealed and vented drainback system designs are offered by various manufacturers. A fill port connection and boiler drain valves are provided for maintenance. A drawback of drainback systems is that they require increased pump head capacity to lift the fluid at start-up. Most drainback systems transfer the heat from the collector-drainback loop into the larger storage tank via a secondary pump. The heat exchanger is typically internal to the drainback tank. Vented drainback systems require periodic maintenance to verify that the fluid level is adequate per manufacturer design.
Solar collectors are usually mounted at an angle equal or close to the geographical latitude of a given site. In some situations, collector mounting may require brackets or racks to provide optimal inclination or southern exposure direction. Some manufacturers offer roof integrated collector designs; however, these require planning ahead for structural roof membranes that may be custom-specific to the installation. Generally, there are three methods for attachment to the roof: spanner, truss lag bolt and J-Bolt. The truss lag bolt requires the least amount of components for the mounting assembly.
Metal and tile-type roofs may require specialized mounting depending on their architectural design.
Active solar systems with a circulation loop require a controller that determines pump operation. This is accomplished by a couple of sensors – one installed at the collector outlet and one at the bottom of the storage tank. A temperature differential of eight degrees (8°F), with the collector hotter than the tank, is usually the turn-on setting to activate the pump. A correct positioning and secured attachment of the temperature sensors for optimal temperature conduction is critical in addition to the wiring connection method. A water-tight connection on temperature sensors is important for an uninterrupted signal to the controller and to provide long-term reliable operation. Figure 7 (left) shows the correct type of weather-proof connector that should be used with exterior wire connections. Common electrical wire twist ties are not suitable to withstand the outdoor elements. Wiring used for sensors installed outdoors should have a UV-rated exterior jacketing.
Ball valves are the preferred design type for use in solar system isolation and servicing. Ball valves featuring a full bore internal diameter do not present added flow restriction in the solar hot water circulation loop.
Providing system documentation in form of a durable “Customer Manual” with instructions on proper operation and maintenance is highly advised. Written proof of warranty and product registration is also recommended.
Maximizing Savings and Monitoring Feedback
Minimizing electric auxiliary heating element activation of a storage water heater is of key importance for achieving maximum energy savings. A digital or mechanical timer can be benefit to cut-off heating element activation during selected daytime hours. Some installers provide a dedicated water heater auxiliary heat element cut-off switch (240 VAC, 2-pole, 30A) as a simple means to allow home owner to increase savings. An in-line sight glass with a visual level indicator installed is usually installed in the drainback tank to verify proper amount of fluid. Builders and homeowners may also inquire about controllers with built-in monitoring capabilities and energy metering devices (e.g., Stecca, Metrima).
To ensure that other components of the home are ready for a solar thermal system, use the following guides:
- Utility Room Space
- Mounting Surface for Pumps and Gauges
- Solar Bypass Valve
- Solar Plumbing and Wiring Chase
- Architectural Drawing
Install an Drainback Solar Hot Water System
- Select an approved manufacturer that has been certified and listed by an accredited institution such as the Florida Solar Energy Center – FSEC. Solar systems certified by SRCC (OG-300) may qualify for tax credit or additional rebate incentive programs. The North Carolina based organization Database of State Incentives for Renewable Energy (DSIRE) maintains a data base map for state, local, utility and federal incentives and policies that promote solar renewable energy.
- Size the solar thermal system accordingly to provide at least 50% of the homes’ water heating energy needs. Solar system selection should be certified by the Solar Rating Certification Corporation (SRCC), the International Association of Plumbing and Mechanical Officials (IAPMO), or be labeled with Energy Star.
- A solar thermal collector is preferably mounted on an unshaded southern exposure orientation; however, eastern or western orientations are not to be ruled out. The use of a sun chart or approved analysis tool is recommended to determine seasonal shading.
- Solar water heating system installations should comply with national building and local plumbing codes. Installation should be executed by a trained certified installer. The North American Board of Certified Energy Practitioners (NABCEP) provides a national database on their website that lists certified solar contractors. In addition, the Solar Energy Industry Association (SEIA) provides a map listing of products, companies and solar services.
- Collector mounting on a roof substrate requires special attention to avoid water intrusion or damage to the roof structure. Builders and installers should take into consideration mounting and positioning of the collector to comply with wind zones, particularly in coastal areas.
- Plumbing lines to the collector are to be kept at minimal length, preferably at 25 feet, and are usually routed through attics where they are continuous with sleeved insulation. Exterior plumbing lines are also possible with an architectural chase for better appeal.
Installation of a solar thermal system is no more difficult than the assembly of any other building component when proper design precautions are taken into consideration. Builders are encouraged to work with solar installers and manufacturers to select a package for high for consumer acceptance. Building aesthetics and minimal use of floor space are a high priority to customers in new homes.
Selection of a solar contractor should be based on credentials, local company service territory, years of experience and trust. Warranty and maintenance agreement of at least two years is recommended.
The DOE Zero Energy Ready Home PV-Ready Checklist (Revision 07) is required only under the following condition related to climate (See the Compliance Tab for other exceptions):
- Location, based on zip code, has at least 5 kWh/m2/day average daily solar radiation based on annual solar insolation using the PVWatts online tool. See map below.
Water heating energy use varies according to the region and amount of hot water gallons used in a residence.
Overheat and Freezing
Solar thermal water heating system failures may originate from extreme cold and hot temperature conditions. Collector and pipe freezing is another major obstacle that solar thermal systems face to avoid operation interruption and to ensure a long-term service life. Increased probability for pipe freezing is higher in mid and northern states, as shown in the figure below. Pipes should be insulated with a minimum of ¾” insulation (closed cell preferred) and those exposed to UV should be protected by using a form of jacketing (UV inhibited ABS, PVC or aluminum).
The Compliance tab contains both program and code information. Code language is excerpted and summarized below. For exact code language, refer to the applicable code, which may require purchase from the publisher. While we continually update our database, links may have changed since posting. Please contact our webmaster if you find broken links.
Installation of a solar thermal system requires building code compliance. Requisites for code compliance may differ by area, city, or county. Refer to the local governing code ordinance for specific plumbing and electrical rules.
Exhibit 1 Mandatory Requirements.
Exhibit 1, Item 1) Certified under the ENERGY STAR Qualified Homes Program or the ENERGY STAR Multifamily New Construction Program.
Exhibit 1, Item 7) Provisions of the DOE Zero Energy Ready Home PV-Ready Checklist are Completed.
DOE recommends but does not require solar thermal water systems. See the DOE Zero Energy Ready Home Solar Hot Water-Ready Checklist (Encouraged).
Section R401.3 A permanent certificate shall be posted on or near the electrical distribution panel that lists types and efficiencies of water heating, heating, and cooling equipment, as well as insulation R values, and window U and SHGC factors.
Section R101.4.3 (in 2009 and 2012). Additions, alterations, renovations, or repairs shall conform to the provisions of this code, without requiring the unaltered portions of the existing building to comply with this code. (See code for additional requirements and exceptions.)
Chapter 5 (in 2015, 2018, 2021). The provisions of this chapter shall control the alteration, repair, addition, and change of occupancy of existing buildings and structures.
M2301 Solar Energy Systems (Solar Thermal Energy Systems in 2015, 2018, and 2021 IRC) - See requirements for solar water heating systems.
Appendix U (Appendix T in 2018 IRC and Appendix AT in 2021 IRC) Solar Ready Provisions - Prepare the home for solar installations in accordance with these specifications.
Section R102.7.1 Additions, alterations, or repairs. Additions, alterations, renovations, or repairs shall conform to the provisions of this code, without requiring the unaltered portions of the existing building to comply with the requirements of this code, unless otherwise stated. (See code for additional requirements and exceptions.)
Appendix J regulates the repair, renovation, alteration, and reconstruction of existing buildings and is intended to encourage their continued safe use.
Consult a structural engineer and manufacturer guidance to determine if the existing roof can carry the load.
Ensure that all penetrations through the roof are adequately sealed to prevent water leaks. New flashing should properly integrate with existing roof underlayment and cladding layers.
See the U.S. Department of Energy's Standard Work Specifications for more information about solar water heating.
See Compliance tab.
Access to some references may require purchase from the publisher. While we continually update our database, links may have changed since posting. Please contact our webmaster if you find broken links.
Solar water heaters use energy from the sun to naturally heat water. These systems usually include one or two collectors that typically sit on a house’s roof. System designs can vary depending on many factors such as aesthetics, rigor of freezing conditions and cost. Homes ready for solar water heating systems should be designed with adequate space on the roof that is unshaded and with enough space in the utility room for a water storage tank and any needed pumps and controls.