Cemline Corporation - Solar Water Heaters

Stainless Steel Instantaneous Packaged Water Heater

Solar Water Heaters

Cemline developed Storage Plate Heaters to work with condensing hydronic boilers. The plate heat exchanger allows the boiler water temperature drop to be as great as 100°F allowing the water heater to use less gallons per minute of boiler water than a traditional U-bend coil water heater. The Storage Plate Heater is a perfect fit for solar water applications because the plate heat exchanger offers high efficiencies, compact size, and close approach temperatures.

The Solar Water Heater is a dual energy source unit using either boiler water, steam, or electric as the back-up energy source for times when solar energy is not enough or unavailable. Boiler water applications use a brazed plate heat exchanger or a U-Bend submerged coil. Steam applications use a U-Bend submerged coil, and electric
applications use incoloy immersion electric elements (208, 220, or 480 VAC).

The Solar Water Heater control system controls both the solar water and the boiler water.On the solar water side the control turns on/off a solar water pump based upon differential between the tank temperature and the solar water temperature. On the boiler water/steam side the control system modulates a electronic control valve to allow boiler water/steam to enter the heat exchanger and heat the tank. On an electric unit the control opens/closes contactors to turn on/off elements to maintain proper temperature control. Cemline Corporation © Solar Water Heaters are available with Cement Lined STONESTEEL© or 316-L stainless steel vessel in sizes 120, 200, 300, 500, and 680 gallon capacity. The time tested STONESTEEL lining is a unique formulation of hydraulic cement that is durable, reliable, trouble-free lining know for hot water storage. Optionally, the 316-L stainless steel is corrosion resistant and with solid 316-L stainless steel vessel no lining is required.

NOTE: Solar collectors and solar pumps are supplied and installed by others in the field.

OPERATION SEQUENCE

Solar Only
SW1—Solar water sensor from solar panel
DS1 —Domestic tank water sensor
SW2—Solar water sensor to solar panels
SWP—Solar water pump
DWP—Domestic water pump

SWP + DWP turns ON if the temperature
difference (Delta T between SW1-DS1) is
15° F or greater.

SWP + DWP turns OFF if the Delta T
decreases to 5° F or lower.

Dump valve will open when the tank
temperature reaches 170° F allowing cold
water to enter tank and reduce solar
panel temperature. Dump valve will close
when tank temperature falls below 165° F.

The Solar Heater can also be used to
recover energy from condensate systems.
In this application, the solar water pump
would be replaced by a condensate
pump with receiver (CP).When the CP
receiver fills, the CP and the DWP turn ON
and when the receiver empties the CP and
DWP are turned OFF. This is can be used to
recover energy before dumping the condensate
to drain or sending condensate
back to the boiler feed system to make
pre-heat hot water or used in combination
with boiler water, steam, or electric energy
sources in one vessel.

Solar / Boiler Water
SW1—Solar water sensor from solar panel
DS1 —Domestic tank water sensor
SW2—Solar water sensor to solar panels
SWP—Solar water pump
DWP—Domestic water pump
CT1 —CEM-TROL® Sensor 1
operating temperature
CT2 —CEM-TROL® Sensor 2
high limit temperature

SWP + DWP turns ON if the temperature
difference (Delta T between SW1-DS1) is
15° F or greater.

SWP + DWP turns OFF if the Delta T
decreases to 5° F or lower.

Dump valve will open when the tank
temperature reaches 170° F allowing cold
water to enter tank and reduce solar
panel temperature. Dump valve will close
when tank temperature falls below 165° F.

The CEM-TROL® controller will be set to
maintain a set point on the top 1/3 of the
tank, typically between 120-140° F, for times
when solar heater is offline or unable to
keep up with the demand. CEM-TROL®
modulates control valve open/closed
aloowing boiler water/steam to enter heat
exchanger maintaining desired setpoint.

STANDARD EQUIPMENT

ASME Code Constructed National Board Registered storage tank

CEMLINE® tanks are designed and constructed in accordance with the latest A.S.M.E. Code regulations using pressure vessel quality plate and certified welders. An A.S.M.E. code certificate is provided and all vessels are registered with the National Board of Boiler and Pressure Vessel Inspectors. Vessels are normally built for 125 psig maximum working pressure but can be furnished for pressures as low as 15 psig and as high as 500 psig.

STONESTEEL lining

CEMLINE has held the original patent for STONESTEEL hydraulic cement lining since 1936. This proven design prevents rust and corrosion common to metal tanks. The STONESTEEL lining is applied as a continuous arch against the metal wall and has the same thermal coefficient of expansion as the steel tank shell. This is an advantage in that even extreme and rapid temperature changes have no ill effect on the STONESTEEL lining. Tanks 36" and larger in diameter are provided with wire mesh welded to inside tank walls to insure a permanent bonding of the lining to tank.

Stainless steel vessel

CEMLINE SPH water heaters can be constructed with a solid 316-L grade stainless steel vessel. 316-L stainless steel is acknowledged as the most corrosive resistant stainless used for water heaters. A CEMLINE SPH water heater with a 316-L stainless steel vessel will give the customer many years of service without concern of corrosion or tank failure.

Stainless steel threaded connections

CEMLINE STONESTEEL tanks are manufactured with stainless steel threaded openings and all non-corrosive piping. This design insures that the water never contacts corrosive metal, and offers the owner the guarantee of exceptionally long tank life.

3" Fiberglass insulation

CEMLINE heaters are furnished with 3" thick Fiberglass insulation. This high quality insulation conforms to the latest ASHRAE standards for commercial water heaters, and has proven to be an extremely reliable means of minimizing heat loss.

20 gauge steel jacket with hammertone enamel finish

CEMLINE packaged units are neatly and attractively covered with a 20 gauge steel jacket over the Fiberglass insulation. The jacket protects the insulation, and is professionally painted with superior quality enamel to allow the added importance of an easy to maintain surface.

Structural I-beam support Skid Base

CEMLINE heaters are mounted on structural I-Beam support skids designed as a permanent base. This skid is pre-engineered to allow correct support for the heater.

ASME Relief Valve- pressure and temperature

CEMLINE packages are provided with ASME pressure-temperature relief valves sized to relieve the total BTU input of the heating coils.

Digital Thermometer

CEMLINE heaters are provided with a digital tank thermometer with LCD readout to monitor temperature of the water within the vessel. The thermometer will be console mounted with a compound steam pressure gauge to monitor steam pressure at the coil. (Units heated with boiler water will be supplied with a boiler water thermometer to monitor temperature of incoming boiler water).

Water Pressure Gauge

CEMLINE packaged heaters are supplied with a large, easily readable pressure gauge.

Control Valve

CEMLINE package units are offered with several options of control, depending on specific requirements or desired preferences. Valves can be provided of the pneumatically operated or electronic type. Control valves are factory sized and installed so the owner may rest assured that the valve provided with the heater is correctly fitted and engineered to meet the specific job requirements.

Solar Brazed Plate Heat Exchanger

Plate heat exchangers are extremely efficient allowing for close or cross temperature approaches between the boiler water and heated water. Cemline offers a brazed plate style for single wall applications and a plate and frame style for double wall applications.

Secondary Energy Supply

The Solar Water Heater is a dual energy source unit using either boiler water, steam, or electric as back-up energy source when solar energy is not enough or unavailable. Boiler water applications use a brazed plate or U-bend heat exchanger, steam uses a U-bend heat exchanger, and electric applications use incoloy immersion electric elements (208, 220, or 480 VAC)

Integral bronze circulator

Bronze fractional circulating pump circulates the water over the coil, thereby maximizing the heat transfer efficiency of the coil. The pump is selected to match the operating conditions of the water heater.

Single safety system

This is an over-temperature safety system which will close the main control valve upon an over-temperature condition. This system utilizes a digital electronic adjustable thermostat with LCD readout which monitors the temperature of the water and if an over-temperature condition is detected, sends an electric signal to the valve, thereby closing the valve. This system requires a 120 volt 5 amp circuit.

Solar controller

The Cemline Solar Water Heater incorporates a solar controller that turns on/off a solar water pump based upon a differential between the tank temperature and the solar water temperature.
NOTE: Solar collectors and solar pumps are supplied and installed by others in the field.

Solid State operating control

The CEMLINE CEM-TROL® incorporates operating and limit functions in one solid state controller. The controller features a LED display of the temperature and on board operating PID temperature control along with high temperature safety cut offs and alarm indications. The CEM-TROL® simplifies the control of the Packaged Water Heater, enhances the look of the product, and follows industry trend to solid state controls.

Alarm Bell

An alarm bell is furnished to sound an alarm in the event that either the primary or secondary high temperature limit is exceeded. An alarm silencing relay allows manual pressing of a button to silence the alarm bell, but red warning light remains on until the alarm condition is corrected.

Remote start/stop

This feature allows the Packaged Water Heater to be started or stopped from a remote location. Typically this would be accomplished from the Building Automatic System (BAS). Requires a dry contact suitable for 24 Vac and 1 amp.

Cem-trol^®

CEM-TROL^® interface

Built-in PID Control Signal

PID Control Signal used to modulate an electronic control valve or to control I-P transducer modulating an air operated control valve. The PID controller allows for precise temperature control of the water heater.

Built-in On-Off Switch

Allows for local on-off and is convenient for service in the unlikely event service is required.

Built-in Alarm Horn

The alarm horn will sound and fault LED will light on high temperature or secondary high temperature. The CEM-TROL also features an alarm silence relay which will silence the alarm but not the fault light when the generator is being serviced. When the fault is cleared, both the alarm and fault light will automatically reset.

Built-in Single Point Wiring

Only one 120 VAC connection required to the unit, integral circulation pump is pre-wired to the control panel.

Built-in Operating Temperature Readout

The CEM-TROL^® features an easy to read LED digital readout of the operating temperature.

Built-in High Temperature Set Point

In the event of high temperature, the CEM-TROL will close the source steam or HTHW supply valve and sound an alarm.

Built-in Secondary High Temperature Set Point

In the event of the secondary high temperature set point has been exceeded, the CEM-TROL^® will open an optional water solenoid to dump over heated water down the drain.

Built-in Remote Temperature Setting

Building Automation System can remotely set the operating temperature using a 4-20 mA signal.

Built-in LED display of functions and alarms

The CEM-TROL^® is designed for the user to tell at a glance how the system is operating. The built in LED displays make troubleshooting simple.

Power ON
Primary High Temperature
Secondary High Temperature

Built-in contact to notify BAS (Building Automation System) of functions and alarms

This control allows for simple and reliable interface with the BAS via dry contact closures so the BAS can monitor the packaged water heater from a remote location. The BAS can also start and stop the packaged water heater.

Power ON
Primary High Temperature
Secondary High Temperature
Operating Temperature (4-20 mA)
Any Limit

TECHNICAL INFORMATION

BOILER WATER

STANDARD EQUIPMENT

CONTROL VALVE

Electronic Control Valve

Electronically operated control valves use a solid state temperature sensor which is wired to an electronic control module. The electronic control module has an adjustable set point. The control module compares the set point with the sensed temperature and sends an electric signal to a magnetic linear actuator on the control valve. The magnetic linear actuator modulates the control valve and regulates the amount of boiler water through the valve to maintain the set point of the controller. When the set point is achieved, the controller sends a signal to the valve actuator and the valve closes. In the event of high temperature or loss of building power, the limit control closes the electric power to the controller which closes the valve.

Two way configuration

A two way valve modulates from fully closed to fully open varying on the amount of hot water circulated through the heat exchanger to maintain the desired output temperature. When closed, the two way valve may cause a change in the heating water loop pressure, The two way valve will provide lower return temperatures to the boiler allowing the condensing boilers to condense, but varying flow rates back to the boiler.

Three way configuration

A three way valve modulates from directing all heating water through the heat exchanger to directing no heating water through the heat exchanger, varying the amount of hot water circulated through the coil to maintain the desired output temperature. The pressure drop in the heating system will be relatively constant with a three way valve. The return temperatures to the boiler will vary, but the return flow to the boiler will be constant.

STEAM

STANDARD EQUIPMENT

CONTROL VALVE

Pilot Operated

A pilot operated valve can only be used with steam as the energy source. Pilot operated valves use steam pressure as the energy source to modulate the control valve. Steam from upstream of the valve is directed into a pilot valve. This pilot valve has an adjustable set point and temperature sensing bulb in the heated water. The pilot valve compares the set point to the sensed temperature and regulates the amount of steam passing through the pilot to the diaphragm in the bottom of the control valve.The steam pressure on the diaphragm opens to the downstream side of the valve. When the pilot valve senses the desire temperature is reached it closes; this does not allow any more steam to pressurize the diaphragm in the bottom of the control valve. The bleed line allows any steam pressurizing the diaphragm to be relieved and the valve closes.

In the event of high temperature or loss of building power the limit control closes the steam line from the pilot to the control valve which closes the valve. With a supply pressure of up to 15 PSI, 3 PSI is the minimum pressure drop permitted.

Pneumatic (air) operated Control Valve

ir operated valves use building control air pressure to modulate the control valve. The air signal is brought to an adjustable set point temperature sensing controller with a temperature sensing bulb in the heated water. The temperature sensing controller compares the set point to the sensed temperature. The controller regulates the amount of air that passes to the pneumatic actuator of the valve to modulate the valve. This allows steam to pass into the heater coil to maintain the set point of the controller. When the set point is achieved, no air is passed through the temperature sensing controller and the valve is closed. In the event of high temperature or loss of building power, the limit control shall close the air line to the valve and vent any air in the actuator to atmosphere which closes the valve.

Electronic Control Valve

Electronically operated control valves use a solid state temperature sensor which is wired to an electronic control module. The electronic control module has an adjustable set point. The control module compares the set point with the sensed temperature and sends an electric signal to a magnetic linear actuator on the control valve. The magnetic linear actuator modulates the control valve and regulates the amount of boiler water through the valve to maintain the set point of the controller. When the set point is achieved, the controller sends a signal to the valve actuator and the valve closes. In the event of high temperature loss or loss of building power, the limit control closes the electric power to the controller which closes the valve.

Steam Traps

CEMLINE provides float and thermostatic traps for both the drip and main trap. Float and thermostatic traps are acknowledged as the correct traps to use with continuously modulating control valves. Float and thermostatic traps provide immediate drainage of condensate and include a built in thermostatic air vent for venting air. The drain orifice is designed to provide a water seal and eliminate the loss of any live steam under all load conditions. Float and thermostatic traps should not be used to lift condensate.

Inlet Stream Strainer

Strainers are "Y" type with blow down connection and easily removable stainless steel strainer screen.

U-Bend heating coil, rolled into copper lined tube sheet

CEMLINE manufactures a complete line of boiler water, steam, and high temperature hot water heating coils, which are constructed of copper or copper nickel or stainless steel tubing. The tube sheets for these coils are copper lined, and units provided with circulating pumps are designed with a copper wrapper surrounding the coil to provide an efficient means of providing the best heat transfer from the coil to the water to be heated. Recovery systems are quickly and efficiently sized to handle specific load requirements to meet any need.

Source Steam Pressure Gauge

Large, easily readable pressure gauges to read both the source and generated steam pressure.

Vacuum breaker

A vacuum breaker will be mounted in the coil head and will break any vacuum which might occur when the steam is condensed.

ELECTRIC

STANDARD EQUIPMENT

Electric Control System

Cemline elements are controlled by immersion thermostats adjustable to the desired temperatures and magnetic contactors. In our basic arrangement, the thermostat sensing bulbs are located at the various levels in the tank. As hot water is drawn out of the top of the heater, the level of cold water rises, turning on one thermostat at a time, which in turn energizes the contactors and elements in sequence. When the hot water consumption decreases, hot water accumulates in the tank from the top downward and the elements are in turn de-energized. Progressive engerizing and de-energizing of the heating elements in this manner balances the electric demand to hot water consumption. The element and heater load is normally divided into small increments which come on and go off in the manner described above. This means if a small amount of water is drawn from the tank only a small percentage of total load will come on to recover it. If, however, a large demand is experienced, a greater percentage of the load will come on to recover this usage. This system is extremely reliable, simple and automatic.

Contactors

Cemline electric water heaters are equipped with magnetic contactors to close and open circuits as required for load control.

Fuses

Cemline EHB Series heaters utilize "Class J" type fuses. Each contactor line is protected by an individual fuse, which is designed to interrupt power in the event of an overload condition.

Wiring

Cemline EHB Series electric water heaters are factory wired, utilizing heat resistant, color coded copper wire. All components are factory wired to a generously sized terminal strip for solderless connections. Heaters furnished with circuit breaker or disconnect switch are factory wired to load side of breaker or switch.

Low Water Cut Off

Cemline electric units are furnished with electronic low water cut off, wired to open the control circuit on a low water condition.

Electric Control Cabinet

Cemline electric elements and controls are mounted in a NEMA 1 enclosure with a key lock door.

Final Assembly & Testing

Cemline packaged electric water heaters are thoroughly tested prior to shipment. All components and workmanship are guaranteed for a period of one year from dated of start-up or eighteen months from the date of shipment, which ever comes first.

UL Listing

Cemline electric water heaters are listed and labeled as required by Underwriters' Laboratories

OPTIONAL EQUIPMENT

Double safety system

An optional safety system, which will deactivate the main control valve as described in solenoid safety system, will also activate a solenoid valve to drain excessively heated water. The controller is designed to permit different set points for the valve closure and draining.

Double wall brazed plate heat exchanger

Double wall brazed plate or plate and frame heat exchangers have inner and outer plates with a vented leak path. If either the inner or outer plate fails, no cross contamination of potable water is possible and a visible indication of the leak will show.

Solar Water U-Bend Heat Exchanger

A U-Bend heat exchanger can be provided for the solar water. Solar U-Bend heat exchanger coils are constructed of copper or copper nickel or stainless steel tubing. The tube sheets for these coils are copper lined. The U-Bend coil can be double walled tubing either copper inner/outer, 90:10 copper nickel inner / copper outer, or 90:10 CuNi inner / outer. The submerged tube bundle provides heat exchange between the solar water and the domestic water with the solar water inside the tubes and the domestic water on the outside of the tubes.

Boiler Water Pump

Cemline can provide as an option a thermostatically controlled boiler water pump. The pump will run when the when the domestic water temperature is below the controllers set point and the pump will turn off when the temperature setting has been satisfied. This pump will replace the modulating control valve and will be factory mounted.

Solar Water Pump

Cemline can provide a factory mounted solar water pump. The factory supplied solar controller that turns on/off this optionally supplied and mounted solar water pump based upon a differential between the tank temperature and the solar water temperature.