Solar Water Heating

Commercial Systems

Courtesy of DOE/NREL

Courtesy NREL Courtesy NREL

PG&E
Pacific Energy Center, San Francisco
Energy Training Center, Stockton
 Instructors

John Grose August Goers

HSC Commercial Solar Luminalt
www.2hsc.com www.luminalt.com
John@2hsc.com august@luminalt.com

Pete Shoemaker
PG&E Pacific Energy Center
(415) 973-8850
pjsy@pge.com
 Solar Water Heating Systems
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Disclaimer: The information in this document is believed to accurately

describe the technologies described herein and are meant to clarify and
illustrate typical situations, which must be appropriately adapted to
individual circumstances. These materials were prepared to be used in
conjunction with a free, educational program and are not intended to
provide legal advice or establish legal standards of reasonable
behavior. Neither Pacific Gas and Electric Company (PG&E) nor any
of its employees and agents: (1) makes any written or oral warranty,
expressed or implied, including, but not limited to, those concerning
merchantability or fitness for a particular purpose; (2) assumes any
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Note: Some images displayed in class may not be

printed here because of copyright restrictions.
Agenda

• Overview and definition of terms

• Unique commercial system issues
• Basic finances & examples
• Site analysis and targeting sites
• System design
• Case studies
 Overview
and Definition
of Terms

Courtesy ofNASA
Overview

Solar is
pre-heater
Existing
gas or
electric
system is
“backup”
or
“booster”
heater

Courtesy CCSE
Overview
Solar Fraction: Percentage of total water heating provided
by solar – the rest is provided by backup heater.

Solar 60% Backup 40%

Courtesy CCSE
Overview

Two types of systems:

1. Open Loop 2. Closed Loop

(Direct) (Indirect)

water glycol

Uses just the water Uses heat-transfer fluid

from the main. in “closed” system.
“Open” to outside Needs heat exchanger.
elements.
Overview

Two types of systems:

1. Open Loop 2. Closed Loop

(Direct) (Indirect)

one fluid Heat Potable

HX
loop water
water glycol

Uses just the water Uses heat-transfer fluid

from the main. in “closed” system.
“Open” to outside Needs heat exchanger.
elements.
Overview

Closed loop heat transfer fluid:

Typically water-glycol mix

• Food-grade glycol (non-toxic)
• Percentage depends on climate

Also can be water (drainback system)

Overview

Further categorized by “pumping” source:

1. Passive 2. Active (electric

(natural) pump)

Thermosiphon
Must have electric
process.
source.
Tank must be higher
Tank can be anywhere.
than collector.
Overview: Schematic Elements

Courtesy University of Central Florida

Overview: Collector Types

ICS (Batch) Flat Plate Evacuated Tube

Figures Courtesy of DOE/NREL

Figure courtesy NREL

Overview: Flat Plate Styles

Harp

Serpentine
Overview: Delta T (∆T)

Collector
temperature

Tank
temperature

Collector – Tank = Delta T

Overview: Delta T (∆T)
Ambient temperature
(outside)

Inlet – Ambient = Delta T

Fluid
temperature at
collecter inlet Out to house

In from main
Overview: Collector Choice

∆T Best collector
Small Pool (unglazed)

Medium Flat plate

Large Vacuum tube

Overview: Collector Choice
Using the Right Collector for the Job

Photo courtesy Fafco

Photo courtesy SunEarth

Photo courtesy Thermomax

Overview: SRCC Ratings
Systems must be SRCC certified: www.solar-rating.org

OG-100
Panel ratings

OG-300
System ratings
Overview: Energy Metrics

Gas Electricity

BTU: British Thermal Unit Watt

Energy required to raise 1 lb. of Energy of 1 amp current flowing
water 1 degree F. across 1 ohm resistance
Therm = 100,000 BTUs Kilowatt = x 1000 Megawatt
= x 1,000,000

BTU = .29 Watt-hours Watt-hour = 3.4 BTU

Therm = 29.3 Kilowatt-hours

= Kilowatt-hour = 3,413 BTU
kWh = .03413 Therms

No time factor Time factor

Usage is total embodied heat Usage is power over time (kWh)
 Horizon
in winter

Horizon in
summer

Source: Wikipedia
Overview: Tilt and Orientation
Tilt = angle from the horizon.
Orientation = Azimuth = direction north-south in
which the panels are facing.

tilt
Ex. 30º angleº
axis

Tilt Azimuth
Courtesy of Andy Black
Overview: Shade Tools

210
110

Courtesy: Solmetric, Corp.

Overview: Shade Tools

• Visually
demonstrates
seasonal sun
path and
shading
effects of
obstructions
• Summary
tabular data

Courtesy: Solmetric, Corp.

 Unique
Commercial
System
Issues
Courtesy of NASA
Usage Patterns – Draw Profile

Data from CSI Thermal commercial calculator

https://www.csithermal.com/calculator/commercial/
Balancing Flow

Water takes the path of least resistance.

AE

DP

TBV

BV2
BV1 PRV
SUPPLY
RETURN

So make sure all water has the same

resistance to flow—the same length path.
Reverse Return

Making the return piping the opposite of the

supply piping: short supply = long return and
vice-versa. Done to balance flow.

Long out
Short in

Short out

Supply Long in Return

Series Flow Path
How many times a molecule is heated in a heat
collection loop.
… or another way to put it …

How many collectors it goes through on its path

from the tank (heat exchanger) back to the tank.

One-collector path Three-collector path

Thermal Expansion

Need to guard against too much pipe

expansion due to heat – each collector has
limits on the number you can chain together.
AE

DP

TBV

BV2
BV1 PRV
SUPPLY
RETURN

1/8” 1/8” 1/8” 1”

Production: Kilowatt Thermal (kWth ):
Equates electrical energy (kW) with heat energy:
1 kW = 3,412 BTU
System capacity measurements based on collector
aperture area: 4 feet

= 32 ft.²
(10.8 ft.² = 1 m²)
8 feet
= 2.97 m²

Conversion factor of 0.7 kW th/m2 of collector space:

20 collector system = 20 x 2.97 m² = 59.4 m²
59.4 m² x 0.7 kW th/m2 = 41.58 kW th.
Rebate Program Metering Size Categories
Because of the metering expense, systems have
been given two categories according to size, with
the cutoff 30 kWth.
This is defined as 462 ft² of collector area.

SMALL LARGE
Less than 30 kWth 30 kWth or greater
1 to 9 panels (approx.) Over 9 panels (approx.)
Residential & small Large commercial
commercial
Storage Tank Sizes

Above 119 gallons requires extra engineering

and is much more expensive.
Unique Commercial Issues: Summary

• Draw profile
• Balancing flow
• Reverse return
• Series flow path
• Thermal expansion
• Kilowatt thermal
• Recirculation loop
• Tank sizing
 Basic
Finances

Courtesy ofNASA
 CSI Thermal Program Data
• Publicly available data: 
http://www.gosolarcalifornia.org/solarwater/
• ~235 commercial applications in CA to date
• Mix of glycol and drainback systems
• Average system size of ~800 ft2 – 20 4’x10’ 
collector system
• Average of $27,000 incentive
 Financial Considerations

Financial return on investment is function of:
• Total project installed cost
• System maintenance cost
• Fuel displaced and at what cost
• CSI thermal program rebate
• Federal Tax Credit
• Depreciation
 Project Costing Basics
• Typically based on dollar per square foot of collector 
space
• Pricing in CA ranges from $50/ft2 up
• Most projects in the $100/ft2  to $200/ft2  range ‐
$131/ft2  average
• Components of installed cost
– Main materials: collectors, tanks, racking, controls, etc
– Balance of system materials: piping, fittings, insulation, 
roof sealing, consumables, etc
– Design and permitting
– Installation labor
– Overhead and profit 
 Economics of Solar
What Fuel?

• Current Fuel Costs
–Natural Gas = @$1.20/therm
–Propane Gas= @$2.30/therm
–Electricity= @$5.80/therm
 CSI‐Thermal Program (2009 – 2017)

• Handbook: http://www.gosolarcalifornia.ca.gov/documents/CSI‐
Thermal_Handbook.pdf
• CSI‐Thermal Program $281M – 40% single family, 60% multi‐
family/commercial
– $180M for natural gas offset
– $100.8M for electric and propane offset
– $25M low‐income single‐family and multi‐family incentive added in 
February 2012 
• Program Goals
– NG:  Displace 585M therms (equivalent of 200K residential systems)
– Electric:  Displace 275.5M kWh (equivalent of 100.8K systems)
 CSI Incentives
– Calculated based on expected performance, 
using SRCC annual energy savings rating and 
solar orientation factor
– Not based on actual performance‐ there is no
Performance Based Incentive (PBI)  option
– 4 step declining incentive structure
– Different incentive amounts for natural gas vs
electric or propane displacing systems
CSI Incentives ‐ Gas
Single‐Family and Multi‐Family Low‐
Income Incentives
 To participate in the rebate program…

• Requirements similar to PV program
• Licensed contractor with CSLB
• Specific license requirements
• Self‐installs OK
In addition …
• License holder or self‐installer must attend CSI 
Thermal workshop (PEC class in SF or other loc.)
 CSI‐Thermal:  Customer Eligibility

• Gas water heating customers of PG&E, SDG&E, 
or SoCal Gas ‐ Retrofit and new construction
• Electric water heating customers of PG&E, 
SDG&E, or SoCal Edison ‐ Retrofit projects only
• Propane users are now eligible, but must be 
electric customer of the above utilities
 CSI‐Thermal:  Technology Eligibility

• Eligible: Domestic Solar Water Heating Systems
– Single Family Homes ‐ SRCC OG‐300 Required
– Multi‐family/Commercial ‐ SRCC OG‐100 Required
• Not Eligible: Pools and Spas
• May be added to the program at a later date: 
Non‐SWH gas displacing solar thermal 
technology
 CSI‐Thermal‐ Program Requirements

• SRCC OG‐300 for single family homes
• SRCC OG‐100 for multi‐family/commercial 
buildings
• 10 year warranty on collectors
• City or County Permit
• Program inspection ‐ first 3 of each contractor, 
then random
• Meter all systems over 30kWth (approx systems 
with 15 collectors or more) and a sample of 
others
30% FEDERAL TAX CREDIT
Installed  Cost of Solar System

http://www.dsireusa.org/
Fed 30% plus ???. 50% magic

Federal Incentives
 Depreciation
• The program allows business to expense $250,000 worth of 
equipment in the first year it is put in service. 
• Solar equipment qualifies, but companies may have used their 
deduction on other purchases such as vehicles or machinery. 
• A portion of the remaining amount over $250,000 may also be 
expensed in the first year, on equipment with a total cost up to 
$800,000. 
• Any amount the system costs, over $800,000, is deducted from the 
$250,000, so there is no amount available if a system’s total cost is 
over $1,050,000. 
• The result, that a business in the 35% tax bracket, that hasn’t used 
this deduction already could save almost $100,000 on a purchase of 
a $300,000 system. 
 Example: Financing page 1

MF/Commercial Propane Incentive for Average CA 
System
• 800 ft2 system at $131,000 total cost – 20 4’x10’ 
collector system
• Calculate CSI rebate and estimated performance 
from CSI calculator
• Simulate system to determine solar fraction and 
system savings (RETscreen etc)
Example: Financing page 2
Example: Financing page 3
Example: Financing page 4
Site Analysis
and Targeting
Sites
Courtesy ofNASA
CSI Thermal Program Data
 CSI Thermal Program Data
Data as of 2‐21‐13
• 1070 total applications
• Single‐family residential: 553
• Multi‐family/commercial:  358
• Multi‐family low income:  159
 CSI Thermal Program Data
Commercial Installs by Type by Number (517 total)

Apartments/Condos 390
(type not marked) 60
Coin-op Laundries 14
Other 12
Retirement/Nursing Homes 12
Meal Service Restaurant 10
Men's Dormitories 4
Office Buildings 4
Quick Service Restaurant 4
Hotels/Motels 2
Women's Dormitories 2
Schools 2
 CSI Thermal Program Data
By Bay Area city

50
San Francisco 47 45

Oakland 40 40

35
Mountain View 10 30

Pittsburg 9 25

20
Carmel 8 15

Berkeley 8 10

5
San Jose 5 0
San Oakland Mountain Pittsburg Carmel Berkeley San Jose Fremont
Fremont 4 Francisco View
CSI Thermal Program Data
Freeze protection
• Glycol:  310
• Drainback:  66

Configuration
• Separate tanks: 273
• Single tank: 90
• Storage with tankless backup: 14
 CSI Thermal Program Data
By size: collector square footage

100

Sq. ft. Number 90

0 ‐ 100 46 80

70
100 ‐ 200 53
60
200 ‐ 400 93 50

400 ‐ 600 65 40

600 ‐ 1000 41 30

20
1000 ‐ 2000 55
10
2000 + 21 0
0 ‐ 100 100 ‐ 200 200 ‐ 400 400 ‐ 600 600 ‐ 1000 1000 ‐ 2000 2000 +
 CSI Thermal Program Data
By cost per size range:

$200

Sq. ft. Cost/sq.ft. $180

$160
0 ‐ 100 $189
$140
100 ‐ 200 $156 $120

200 ‐ 400 $151 $100

400 ‐ 600 $150 $80

$60
600 ‐ 1000 $136
$40
1000 ‐ 2000 $142 $20

2000 + $117 $0
0 ‐ 100 100 ‐ 200 200 ‐ 400 400 ‐ 600 600 ‐ 1000 1000 ‐ 2000 2000 +
 Solar Water Heating Project 
Considerations
• Factors for successful projects:
– Large demand for hot water to reduce importance of fixed costs
– High energy costs (e.g. natural gas not available)
– No reliable conventional energy supply
– Strong environmental interest by building owner/operator
• Daytime hot water loads require less storage
• Lower cost, seasonal systems can be financially preferable to 
higher‐cost year‐round systems
• Maintenance similar to any plumbing system, but operator must 
be committed to timely maintenance and repairs
 Project and Site Evaluation
• Mechanical Room
• Solar Tank location
• Ideal Solar System
• Roof/Mounting considerations
 Starting with the ideal solar system
• Site has consistent daily hot water load
• Building owner pays for hot water heating, has 
tax appetite, and money available to pay for 
system
• Building is ideal for solar
– Has South facing roof (in good condition) with no 
shade
– Plenty of room for storage tanks and equipment
– Solar collectors located just above the solar tank and 
the water heater.
 Mechanical Room
• Size, dimensions
• Door size
• Electricity
• Piping access to solar 
collectors (roof)
• Relief valve to drain or 
outside?
 Mechanical Room
• What is the proximity of the solar collectors to 
the mechanical room?
• Preference is to have the solar tank in the 
mechanical room as near the water heater as 
possible.
• If mechanical room is on the roof, locating the 
tank on the roof is preferred, but a structural 
engineer evaluation will be needed to determine 
what measures if any are needed for the roof to 
support the tank.
Design

Courtesy ofNASA
 Design Principles
System
Usage
Production
Level 1
Daily/yearly  Daily/yearly 
average average
Level 2
Sophisticated 
Draw profile
modeling
 Software Tools
Level 1
• Take basic inputs (usage, location, orientation, etc.)
• Determine proper system size and components
• Give estimated output and savings

Level 2
• Take advanced inputs (shading, etc.)
• Look at hourly draw profile for modeling
• Use graphical interface to build systems
• Give detailed output and more accurate savings
• Much better for combination systems
Software Tools: Level 1
RETScreen

http://www.retscreen.net
 Software Tools: Level 1
RETScreen
• Free
• Based on Excel‐type spreadsheet 
• Good for roughly determining solar fraction, 
output, and simple financials
 Software Tools: Level 1
RETScreen
Sample input Sample output
Software Tools: Level 1
F‐Chart

http://www.fchart.com
 Software Tools: Level 1
F‐Chart
• Costs around $400
• Easy to use, widely accepted
• Good for sizing systems, making adjustments
• Outputs charts and graphs of monthly 
production, solar fraction, simple economics
 Software Tools: Level 1
F‐Chart
Sample input Sample output
Software Tools: Level 2
T*SOL

http://www.solardesign.co.uk
 Software Tools: Level 2
T*SOL

• $750 for Pro version
• Can download free trial
• Most popular in Europe
• Has graphical interface
• Allows for shading adjustments
Software Tools: Level 2
Polysun

hthttp://www.velasolaris.com
 Software Tools: Level 2
Polysun

• $1000 for Pro version
• Can download free trial
• Similar to T*SOL
• Has graphical interface, many different 
system configurations
Software Tools: Level 2
Polysun
Polysun Output
Software Tools: Level 2
TRNSYS

hthttp://www.trnsys.com
 Software Tools: Level 2
TRNSYS

• $4740 for single commercial user
• Can download free trial
• Widely used
• Sophisticated engineering tool
• Used as basis for CSI Thermal calculator
CSI Thermal Calculator

hthttp://www.csithermal.com/calculator
 CSI Thermal Calculator

• Free
• Must be used for the rebate program
• Drop‐down menus of permitted systems
• Uses SRCC database for production
• Selects appropriate freeze control for climate 
zone
• Calculates offset and rebate
• Based on TRNSYS
 System Design:
The 4 Magic Questions
• How Much Load and Frequency?
• How Much Room Available for Collectors?
• How Much Room Available for Storage?
• How Much Room in the Budget? $$$
One Will Be A Limiting Factor
 What determines system size?
• Hot water load
• How much area is available for the solar 
collectors?  This includes roof area, obstructions 
and shading factors
• How large a storage tank can we fit on site? Is 
there a mechanical room to try to fit it in? Can 
you roof mount it?  Is there a space for a pad on 
the ground?
• How much solar fraction does the 
customer/contractor want?
• CSI sizing criteria
 Hot Water Usage Data

Compiled by ASHRAE over many years
American Society of Heating, Refrigerating and Air Conditioning Engineers
Organized by building type
Hot Water Demand by Building
Hot Water Demand by Fixture Units
 Hot Water Usage Data
ASHRAE data used in Level 2 software programs.

• T*SOL
• Polysun
• TRNSYS
• CSI
 Basic Solar Sizing
• Determine Storage tank Size: load equals storage 
tank size

• Storage tank size divided by the factor 1.5 to 
determine collector square footage

• GPM is ¾ gpm to 1.0 gpm per 40 sq ft collector

• Calculate piping, heat exchanger, collector 
pressure drops to determine pump sizing
 Hot Water Needs for Apartment
• Number of 1 bedrooms units
• Number of 2 bedroom  units
• Other type of units
• Occupancy rate, percentage
• Daily hot water usage
• Hot water set point
• Operating days per week
• Laundry, coin op, commercial or residential
 Solar Thermal Sizing Apartments
• Assuming the CSI standard of 20 gallons 
per day per one bedroom apartment, a 
50 unit apartment would use 1000 
gallons of hot water per day.
• Go to F‐Chart, Retscreen, Polysun for 
sizing
Case Study

Courtesy ofNASA
 Case Study Process
Steps:
• Bid (Site Analysis, basic design, financials)
• Design (specific components, details)
• Permit (drawings, work with AHJs)
• Build 
Case Study 1
 60 Unit Apartment Complex 
Steps:
• Assess site and determine project goals
• Use RETScreen to perform system sizing
• Use CSI Thermal Calculator to determine CA 
rebate
• Run financial calculation for proposal to client
 Assessing Site and Goals
• 60 Unit new construction 3 story apartment 
complex in Oakland: 30 one‐bdrm., 30 two‐bdrm.
• Qualifies for multifamily low income.
• Central natural gas boiler unit – landlord pays 
water heating bills
• Plenty of good roof space
• Still early enough in planning stage to influence 
boiler room location and design
• Owner wants to maximize return on investment 
and needs to meet LEED requirements

Step 1: Site Analysis and Bid
Using RETScreen for basic sizing
Entering the load
Site Info
Collector Info
Balance of system
Calculating fuel savings
Run the financials
 Design Review
• Collect job site information for software
• Use sizing software
• System type:  Drain back versus Glycol
• System Piping
• Pump selection
• Storage tanks
• Collector piping

Step 2: Design Details
Gather Data
 Let’s do some sizing!
• Collectors
• Storage tanks
• Heat Exchangers
• Pumps
• Expansion Tanks
• Glycol
 Collector Piping
Key Criteria

• How many collectors per row?
• Balance flow
• Reverse return
AE

DP

TBV

BV2
BV1 PRV
SUPPLY
RETURN
 TANKS
Storage Tank Linings
• Glass Lined
• Epoxy Lined
• Cement Line
• Stainless Steel
• EPDM
• Polypropylene
Source: August Goers
Source: PG&E
Heat Exchangers: Home
Heat Exchangers: Commercial

Photos Courtesy Advanced Industrial Components Inc.

Solar 
Pumping Station

• Pre‐ Piped Circulating Pump and Control
• All Bronze Construction ‐ Insulated Enclosure
• Supply and Return Temperature Gauges
• Pressure Gauge and Pressure Relief
• Flow Meter in GPM
• Check Valves to Prevent Gravity Flow
• Expansion Tank Connection
• Drain / Fill / Purge Connections
Solar Pumping Station Features
Pressure Relief

Pressure Gauge

Expansion Tank Connection

Return Temp Gauge & Valve

Supply Temp Gauge & Valve

Air Eliminator & Vent

Standard 2 Bolt Flanged Circ

Fill Port Hose Connection

Flow Meter in GPM

Purge Port Hose Connection

Insulated Enclosure
 Expansion Tanks

Source: August Goers

Photo courtesy of Amtrol

Glycol
 Permitting
• All projects must be permitted by AHJ
• Check with AHJ during bid process to get 
requirements, costs, process, etc.
• Some require simple application but most 
require drawings

Step 3: Permit
 Permit Drawings
• Plot plan describing project and showing top view of 
building, property, and location of SHW equipment
• Plumbing schematic showing routing of piping, 
valves, and other equipment such as tank(s), pumps, 
and heat exchanger(s)
• Layout plan showing details of collector location and 
mounting method. It is also good to show collector 
weight per square foot and load per mounting point
• Equipment data sheets and installation instructions
Plumbing Layout Example
 Installation

Source: August Goers Courtesy of Best Power

Step 4: Build
Collectors

Source: August Goers
Racking

Source: August Goers
Roof Mounting
 Tilt Mount

Flat Roof

Flashed Curbs

UNI‐STRUT®       
Used
Courtesy of Solar Service
 Rack Mount

Collectors 
Attach to 
Installer 
Built Rack

Courtesy of Best Power
Insulating panel connection lines

Source: August Goers
Source: August Goers
Balance Flow

Source: August Goers
Mechanical Room

Source: August Goers
Pump Station

Source: August Goers
Drainback
Systems

Courtesy ofNASA
 Drainback Solar Hot Water
• Positive Freeze Protection
• No Stagnation Problems
• Pipes Must be Sloped Properly
• Use Water not Glycol
– Single wall heat exchanger OK
• More Pump Energy
– But not that much
Drainback System w/ Booster Pump
Drainback w/ Tank Heat Exchanger
Drain back tank
Pool heat exchangers, 
Drain‐back tanks
Case Study

Courtesy ofNASA
 Case Study #2, Hollister, Gateway 
Apartments
•18) 1 bedroom apartments
•18 units times 20 gallons per day = 360 gallons
•360 gallons per day = solar storage
•360 gallon of solar storage divide by 1.5 = 
collector sq footage of 240
•240 sq ft divided by 40 sq ft = 6) 4’x10’ collectors
Gateway Apartments, Hollister
 Case Study #2
• Site is three stories high
• New Construction
• Flat Roof, pitched for drain back
• Mechanical Room on first floor
 Case Study #2a Financials
• Cost of installed system: $43,500
• Less CSI Rebate @19.23/Therm ($12,461)
• No tax on rebate $0
• System Tax basis $31,039
• Fed Tax Credit at 30% rate ($9,312)
• Federal Depreciation ($9,000)
• State Depreciation ($1,117)
• System cost after incentives $11,610
 Case Study #2b Financials
• Cost of installed system: $43,500
• Less CSI Rebate @19.23/Therm ($12,461)
• Tax on rebate $4,361
• System Tax basis $43,500
• Fed Tax Credit at 30% rate ($13,050)
• Federal Depreciation ($12,919)
• State Depreciation ($1,566)
• System cost after incentives $7,865
Solar Fraction
 System payback
• System costs after incentives $7,865
• Annual fuel savings at $1.00/therm $653
• 12 year payback with no inflation factor
• 9.5 year payback with 4.7% inflation factor
• Other consideration, the installed system 
includes the hot water heating source
• How does the payback look now?
 Sizing Panel, Tank, GPM
• Gallons per day equals storage tank size
• Divide tank size by 1.5 for panel sq footage
• Divide panel sq footage by 40 or 32 for # of 
panels
• Number of collectors x 1 (or 0.75) = GPM
Sizing X‐Changer, Pump, Glycol, ET
• Calculate pressure drop of system first, (pd)
• Go to X‐Changer Sizing program
• Add up piping lengths, then times 1.4 for fitting 
pd.  Total up piping and ftg pd.
• Add piping dp to collector, and heat exch pd.
• Times 1.3 if using glycol (50/50)
• Use pd and gpm to select pump
• Use pipe lengths and collector volumes to 
calculate glycol and expansion tank.
Steep & Flat Curves
 "Head"
• A term for expressing pressure
• Piping creates pressure 
loss in a system
• Circulator needs to 
overcome that  2.31’
pressure loss
• A column of water 2.31
feet high has a gauge 
pressure of 1 PSI
• 1 PSI = 
? Feet of head
 
Physical Height 
of the  Head Pressure
Heating System  of the Pump in
Above the Boiler Feet of Water

• Circulator – not a pump
• Closed loop system
• What goes up… 
• …must come down
• Weight of water coming down 
is counterbalance
• Think “Ferris wheel”
 Lift water to collectors
• 1 PSI = 2.31’ head 
pressure
• 12 PSI x 2.31’ = 27.72’

Drain back system must lift 
27.72’
water to collectors to create 
siphon and then recirculate 
water.
 Additional
Components

Courtesy ofNASA
 Controls
• Differential Controls
• Variable Speed
• BTU Metering
• Internet
• Multi Tank
• Sensor Placement
Why Use Variable Speed?

Reducing the pump speed reduces flow through the collector allowing the water to stay
in the collector longer and gain more energy resulting in higher source temperatures.
Also by reducing the pump speed, the control is able to maintain the ∆T for longer
periods of time resulting in less short cycling and a smooth ∆T characteristic curve.
 Circulator with Integral 
Solar Control

• All‐in‐One Pump Design with Solar Control
• Variable Speed Collector Output
• External LED Status Panel
• Pre‐Wired Line Cord
• Holiday and Freeze Protection Modes
• Selectable Line Voltage Output:
Heat Exchanger, 1 or 2 Storage Tanks, Collector Sink, Tank 
Supplement & Drain Back w/ or w/o Booster Pump
 BTU Metering

• Properly Allocates Energy Usage
• Preserves Asset Values
• Increases NOI
• Reduces Energy and Water Consumption
• Makes it Fair for Tenants and Landlords
• Reduces Rent Increases
• Properly Allocates the Most Volatile 
Ownership Cost:  Energy
Source: PG&E
 What’s It Look Like?

In Line Piping for easy installations
 Touch Screen, Email 
server, WEB interface
Optional
Windows based 
WEB Browser

2 wire network LONWorks
What’s It Do?
 Solar Metering Requirements
• 480 sq ft or 12) 4’x10’ collectors and larger 
require BTU metering (on solar loop ok)
• 100) 4’x10’ collectors or higher require the 
BTU metering on the potable side of the solar 
system.  Sensor and meter in the CWS to the 
solar tank (s) and sensor on the hot outlet of 
solar tank. Also require remote 
communication, internet
Solar Space Heating: Combi Systems

• Time of Use
• Cost Benefit
• Multiple Load
System Charging: Glycol
 Useful links
• csithermal.com/calculator/commercial/ PGE
• Retscreen.net Solar sizing software
• Fchart.com/fchart Solar sizing software
• Solar‐rating.org/ratings/index.html SRCC
• Jtgmuir.com Solar supplies
• Askrod.com Solar supplies
• Taco‐hvac.com Pump, Exp Tank
• Solarskies.com Solar Panel
• Heliodyne.com Solar Panel
• Energystart.gov/taxcredits Fed Tax Cred
• Flatplateselect.com/site// X‐Changer
• Quatic.com Pipe Volume
• Irrigation.wsu.edu Pipe velocity
 Instructors

John Grose August Goers

HSC Commercial Solar Luminalt
www.2hsc.com www.luminalt.com
John@2hsc.com august@luminalt.com

Pete Shoemaker
PG&E Pacific Energy Center
(415) 973-8850
pjsy@pge.com