Echo Solar System Operation October 2010.pdf

Echo™ Solar System Operation Is Complementary To The Home

The Echo ™ solar system is in addition to the home’s regular heating and cooling systems, it is not a

replacement for those systems. The system does not interact with the regular heating and cooling

systems in such a way that the failure of one system can cause the failure of the other system. If the

solar system experiences any mode of failure, it will revert to an idle mode that does not interfere with

the operation of the buildings’ primary heating and cooling systems. On those days when there is no

solar energy available, the solar system remains idle and the furnace, water heater, and air conditioner

maintain home comfort. This paper briefly summarizes how the normal operation of the home is not

impacted by the operation of the Echo solar system.

Echo does not interfere with the operation of the HVAC system

Echo delivers home heating and home cooling through the homes’ existing duct system or optionally

through its own dedicated air registers. Air is never supplied through the furnace or air conditioner,

which remain isolated from the solar system. The management of the air is accomplished by the Energy

Transfer Module (ETM), which behaves nearly identically to a mechanical ventilation system (it provides

pre-heated ventilation air on winter days and pre-cooled ventilation air on summer nights). The ETM

employs a “normally closed” damper system, which in the case of power failure or other failure isolates

the system from the home: the unit reverses to an idle mode with the blower off and the dampers

isolate the system from the home. In the worst case, the home loses the mechanical ventilation supplied

by the ETM.

Design and Materials: The design of the ETM is very similar to that of conventional air handlers 1

. The

ETM employs a highly efficient and reliable European motorized impeller rated at over 35 thousand

hours MTBF (mean time between failure), which is over 20 years of service in standard operation. This

unique motor design affixes the rotor (the motor shaft) and spins the outer motor housing. It increases

the bearing surface area by over 300% which reduces wear and provides an extremely smooth and

accurate spin. Unlike motors designed for standard air handlers which are designed for 77 ˚F air, the

ETM’s special blower has been designed to operate with air temperatures of 155 ˚F on a standard basis

and as high as 200 ˚F on an intermittent basis.

To promote efficient heat transfer to the water-heating system, the ETM incorporates a standard 3-row

hydronic coil. This type of coil is extremely reliable and is commonly found in residential and commercial

air handlers with 20+ year operating lives. The coils utilize a generous 11 FPI fin spacing that is highly

resistant to clogging and requires no maintenance cleaning.

1 For example, those made by Carrier, Lennox, Magic Air or First Company

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Echo does not interfere with normal water heating

Echo provides water heating that is supplemental to the operation of the regular water heater. On those

days when there is no solar energy available for water heating, or in the case of a system failure, the

regular water heating equipment is still in place to carry the full water heating load of the home.

Design and Materials: The methods of connection, and the components used for water management,

are identical to those used by standard solar water heating systems. Modern solar water heating

practice and components have been proven “tried and true” through decades of use and thousands of

installations (approximately 25,000 systems are sold annually in the US and approximately 300,000 are

sold annually in Europe). The Echo solar system uses top quality Grundfos circulating pumps and Rheem

storage tanks. Both companies have 50 plus year records of performance in the building trades.

Where electric water heating is used:

The Rheem solar storage tanks used in the system come standard with a 4.5kW heating element in

the upper portion of the tank. This element is identical to those used in standard electric water

heaters. If in any case the solar system fails, or there is no solar contribution, this heating element is

capable of carrying the full water heating load for the home with exactly the same performance as a

standard electric water heater . Tank life is subject to the same conditions as a non-solar tank and

lifetime is dependent on water quality.

Where gas water heating is used:

The system works with either traditional storage type gas heaters or tankless gas water heaters as

shown below.

In standard operation the system provides pre-heated water to the backup gas heater at

temperatures which range from 80-125 F. If the system fails, the standard gas backup heater is

capable of supplying the full water heating load to the home without a solar pre-heat.

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Extensive reliability data for these solar water heating components has been assembled by the Hawaiian

Electric Company (HECO) and is illustrated in the figure below. Of the more than 27,000 systems

installed over the 8-year period by HECO, the failure rate of the tanks and pumps was approximately

0.1% with an estimated product lifetime of 10-15 years.

Advanced controls ensure proper system commissioning and rapid repair

Every Echo solar system employs a robust embedded system controller that carries a full ETL product

listing and certifications. The controller enables the optimization of energy production and advanced

system functions, including real time performance monitoring.

The controller also enables on-site system commissioning and provides on-going remote diagnostics

capabilities. This ensures that every system is fully functional from ‘Day 1’ and any issues that might

develop over the life of the system are identified immediately and accurately.

On-Site System Commissioning and Diagnostics : We provide our installation crews with

commissioning terminals that connect to the system controllers on site and allow them to run

through a 15-minute diagnostic sequence to ensure the system is working at 100% capacity. It is

during this sequence that all the sensor inputs are verified and mechanical systems are

physically cycled to ensure efficient operation and flow rates within the design parameters.

Remote Diagnostics: The controller communicates with PVT Solar enterprise servers which

record and store all operating parameters at 15-minute intervals. This data is used to remotely

identify and diagnose systems for under-performance or failure. Normally this type of capability

exists only for high-end commercial building systems but our controllers and enterprise systems

enable it to be applied cost effectively on residential homes.

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