INSTALLATION OPERATION MAINTENANCE MANUAL OPEN LOOP/ OPEN LOOP PV Alternate Energy Technologies, LLC.
CONTENTS Introduction Basic Tools and Materials Collector Location Collector Orientation Collector Dimensions Mounting Hardware Mounting Hardware Spacing Pitch Pan Array Mounting Collector Piping Collector Piping Detail Sensor Mounting at Collector Piping Through Roof Storage Tank Placement Sensor Mounting at Storage Tank Open Loop Fluid Handling System Open Loop Differential Temperature Controller Open Loop Start-Up Open Loop Maintenance Open Loop PV System Operational Checklist Systems Parts List Collecto
PRE-INSTALLATION CHECKLIST Unlike other types of solar collectors, the AET solar collectors do not add a significant amount of weight to the roof. However, if the collectors are placed at a steeper pitch than the roof itself, the additional exposed flat surfaces could present extreme wind loading forces during sustained high winds. Check local codes for roof load requirements.
water shutoff valve must be installed above this connection so that water flow may be completely stopped in the event of a leak, repair, or maintenance. The hot water output to the house from the tank should be connected to the port labeled "Hot Outlet" on the top of the tank. Again, a dielectric union must be used where a connection is made between galvanized and copper pipes. A mixing valve must be installed at this point to limit the temperature of water delivered to the home.
COLLECTOR LOCATION Proper location and orientation of the solar collectors is important for maximum system efficiency. The collectors should be unshaded for the middle six hours of the day in each month of the year and should be located as close to the storage tank as possible to minimize heat loss in the piping runs. The best orientation is achieved when the collectors are facing due south and tilted at an angle from the horizontal of latitude + 10°.
LATITUDE COLLECTOR TILT ROOF PITCH FLAT 5° 1/12 9° 2/12 14° 3/12 18° 4/12 23° 5/12 27° 6/12 30° 7/12 34° 8/12 37° 9/12 40° 10/12 43° 11/12 45° 12/12 VERTICAL 25° N 35° A B 29 96 25 83 22 74 17 66 14 61 10 58 7 58 4 58 0 58 -2 58 -4 58 -7 58 -8 58 -44 30° N 40° A B 33 113 29 93 26 82 22 72 18 66 14 60 11 58 8 58 5 58 3 58 0 58 -3 58 -4 58 -41 35° N 45° A B 37 145 33 113 30 77 26 82 22 74 18 66 15 61 13 58 9 58 7 58 4 58 -2 58 0 58 -37 40° N 50° A B 41 145 37 132 34 110 30 92 26 81 22 72 19 66 17 58 13
MOUNTING HARDWARE Provided in the Eagle Sun package is specially designed mounting hardware to speed collector installation. This hardware consists of ten LOCK-TIGHT hinge sets, four roof brackets, two rear struts, and bolts (Figures 3, 4, and 5). a) After locating the mounting points from Table 1, the mounting bracket holes should be drilled. b) A heavy coating of sealant should be applied to the bottom of the flashing plate, which should fit flat against the roof.
There are three acceptable ways to secure the collector mounting brackets to the roof. 1. Spanner Mounting 2. Lag Bolt Mounting 3. J-Bolt Mounting SPANNER MOUNTING In spanner mounting after the brackets are positions on the chalk line, a 3/8” hole is drilled between the rafters. An aluminum flashing is positioned over the hole where the top of the flashing is extended up under the shingle above the 3/8” hole and extends down over it. Caulk is applied between the flashing and the roof.
Figure 7. Lag Bolt Mounting J-BOLT MOUNTING J-bolt mounting is done very similar to lag screw mounting except instead of drilling into the center of a rafter, a hole must be drilled directly beside a rafter. The size of the hole must be slightly larger than the bolt diameter. This is more easily accomplished if the attic man would drill a pilot hole through the roof along side the chosen rafter. Fit the bolt through the mounting brackets and insert the bolt (J side first) through the hole in the roof.
MOUNTING HARDWARE SPACING AE-Series Center Line to Center Line (in.) Model Size (ft) Outside Box Dim. (in.) AE-MH AE-FM AE-RM AE-21 3x7 35.1875 x 85.1875 88.4375 88.9375 86.9375 AE-24 3x8 35.1875 x 97.1875 100.4375 100.9375 98.9375 AE-26 4 x 6.5 47.1875 x 77.1875 80.4375 80.9375 78.9375 AE-28 4x7 47.1875 x 85.1875 88.4375 88.9375 86.9375 AE-32 4x8 47.1875 x 97.1875 100.4375 100.9375 98.9375 AE-40 4 x 10 47.1875 x 121.1875 124.4375 124.9375 122.
ARRAY MOUNTING ON TILE ROOFS Tile roofs are a little more difficult to mount solar collectors on but following this procedure will render a leak free installation. The solar panels are mounted on two rails located at the top and bottom of the solar collectors. The collectors are secured to the rails using the AE rack mount hardware (AE-RM). The 1-5/8” Aluminum unistrut rails are anchored to the roof by using six or ten inch stainless steel 3/8” hanger bolts.
COLLECTOR PIPING The piping of the system should be considered before a final decision is made on how the collectors are mounted. Piping should be made of copper tube of the type meeting local codes, insulated with Armaflex or similar, and painted or wrapped with aluminum tape where exposed to ultraviolet radiation. Care should be taken in the spacing of collectors as attachment of piping is easiest with properly aligned collectors.
SENSOR MOUNTING AT COLLECTOR The controller heat sensor is mounted to the nipple outlet of the collector (Figures 14). A stainless steel screw clamp should be used. The entire nipple should be wrapped thoroughly with insulating tape so that the sensor is isolated from the outside air. Figure 14 PIPING THROUGH THE ROOF Piping through the roof should be weatherproofed as shown in Figure 15. One inch holes are drilled through the roof on the same plane as the supply and return header nipples.
STORAGE TANK PLACEMENT To minimize expense and heat loss, the tank should be placed near the collectors and central to points of greatest water demand. It should be located in as warm a spot as possible. It should be located with adequate ventilation, with a minimum of 6-8 inches of clearance and with ready access to controls and serviceable parts. Provision should be made to prevent water damage in case of leakage.
Figure 16 www.aetsolar.
OPEN LOOP DIFFERENTIAL TEMPERATURE CONTROLLER NOTE: When instructions are provided in the controller package, follow those and disregard the following. The open loop differential temperature controller controls the pump to achieve maximum system efficiency. When one of the two heat sensors provided with the unit raises nominally 10° F above the other sensor, a power control relay is energized. Then, when the first sensor drops to within 5° F of the second sensor, the control relay contacts are opened.
OPEN LOOP START-UP After visual inspection of the complete system, it is ready for filling and pressure testing. All drain valves should be closed, all other valves opened. The air vent caps should be loosened two turns to allow air to escape the system. The cold water inlet valve should then be opened slowly and system checked for leaks as it fills.
Figure 18 www.aetsolar.
OPERATIONAL CHECKLIST Before the system is turned on, the piping and electrical systems should be evaluated to see if they match the supplied drawings. If you are satisfied that the system is installed correctly, it should be filled and powered according to the preceding instructions. When the system is in the operational mode, care should be taken to check all piping for leaks and to make sure sufficient insulation has been used to provide maximum system efficiency.
INSUFFICIENT HOT WATER If insufficient hot water is available a system malfunction may not be indicated. A low amount of solar radiation or heavy water demand can be the cause. If no excessive demands are put on the system and ample solar radiation is available, the system should operate properly. The pump should run each sunny day until a full supply of hot water is stored. If the pump does not run, there is a problem on the electrical end of the system.
SYSTEM PARTS LISTING (PV Controlled) COMPONENT Solar Collector(s) Water Storage Tank Circulation Pump Differential Control (PV) MANUFACTURER Alternate Energy Technologies, LLC Alternate Energy Technologies, LLC American Water Heater Richmond (Rheem) Water Heaters Laing Thermotech SunWise Technologies Yingli Solar MODEL AE-32 (-64 systems) or AE-40 (-40 systems) SE62-80H-045S or 81VR80-TC-1 D5Solar/090B OEM-10 or PV-10 COLLECTOR YARD MOUNT When no sunny roof area is available or for “show” systems, the co
