Permit Solar System 940 Paradise Cir 2011 (2) INSTALLATION
OPERATION
MAINTENANCE
MANUAL
DX- DRAINBACK
Eagle
Sun TM
Systems
..
nergy Technologies, LLC
REVIEWED FOR CODE COMPLIANC 1 PO Box 61326
CITY OF ATLANTIC BEACH ksonville, FL 32236
SEE PERMITS FOR ADDITIONAL 904- 781 -8305
REQUIREMENTS AND CONDITIONS. '.0. ')%
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REVIEWED BY: // DAT . 1 2 l E / l
INTRODUCTION
"Conservation for today... Energy for tomorrow..."
Alternate Energy Technologies, LLC., (AET) would like to extend our congratulations on your purchase of the
DX Drainback System. Years of research and development, backed by critical engineering, has brought you the
forest solar products you can buy. Please take time to read this booklet thoroughly. Each step is outlined
completely and clarified by diagrams where necessary.
"The solar energy system described in this manual, when properly installed and maintained, meets the
minimum standards established by the SRCC. This certification does not imply endorsement or warranty of
this product by SRCC."
The DX Drainback has been designed to be a complete solar appliance that incorporates ease of installation and
maximum efficiency for years of trouble -free service. The DX Drainback system uses the sun's energy to heat
your water, reducing your electricity consumption. The DX Drainback will pay for itself many times over the life
of the system. All installations require a connection to your home water system. Only a qualified person or
someone thoroughly familiar with standard plumbing and electrical practices should do the installation. If you
have questions on the proper methods to make these connections, consult a qualified plumber or solar contractor
for prescribed methods in your area. In most cases your installing solar contractor is familiar with the codes and
their application. The codes are intended to protect the health, safety, and welfare of the public.
The component that makes the DX Drainback system unique is the drainback reservoir with built -in heat
exchanger. This allows the use of a lightweight glass -lined storage tank. The system collects heat by circulating
water between the reservoir and collectors and simultaneously, between the storage tank and the heat exchanger
inside the reservoir. Since only thermally efficient pure water is used, maximum safety and performance is
assured. The DX Drainback system is ideally suited to cold regions with many freezing days each year or areas
with aggressive water conditions. Freeze protection is provided by draining the collector loop liquid back into the
drainback reservoir when the system is not operating. The simplicity of the drainback method provides reliable
operation that makes this system an asset to any home located in the colder climes.
YOUR DRAINBACK SYSTEM
Your DX Drainback system consists of a collector array, a drainback reservoir that incorporates a heat exchanger,
a storage tank, two pumps and a system controller, pre - engineered system.
COMPONENT MODEL #
SYSTEM NUMBERS: DX- 80 -40, DX- 80 -52, DX- 80 -64, DX- 80 -80,
DX- 120 -64, DX- 120 -80, DX- 120 -96
COLLECTOR: MSC or AE Series collectors
CONTROLLER: Eagle 1(Plus) or GL30 -LCO (controllers include sensors)
PUMPS: Taco Model # 009F5 and 003B or Grundfos UP15 -100F and UP15 -10B7
TANK: Solar HE or EagleSun Contender (tanks include T &P relief valve)
and UL listed conventional water heater for retrofit systems.
DX RESERVOIR W /INT
HEAT EXCHANGER: DB -10 -10X, DB- 15 -15X (reservoirs are sight glass equipped)
PRESSURE RELIEF VALVE: Wilkins P1000A (Valve "C" on system schematic)
ISOLATION VALVES: B6001 Series
DRAIN VALVE: BD Series
ANTI -SCALD VALVE: AM101C or 34A -104 -1
THERMOMETERS: T -60
Job site conditions will require the installation contractor to supply some, or all of the following:
• plumbing connections
• piping and insulation
• valves between your oWn water system and the DX Drainback solar system
2
INSTALLATION INSTRUCTIONS
3
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. The mounting hardware supplied with your DX Drainback system has been designed for specific
wind loads, but only if adequate support structure is present with sufficiently strong structural members (such as
engineered trusses). Most building permit offices may be able to help you with recommended roofing practices for
your area.
Obtain all applicable permits. Structural members penetrated by the solar system components must meet local
codes. The installer is to run the piping in such a way that the performance of any fire rated assembly is not
reduced. This applies to the collector mounting as well as the installation of any other system components.
Inspect the roof. If it is in poor condition, it is advisable to replace all or part of the roof where the system will be
attached.
Locate a roof area facing as close to due south as possible for the placement of the solar collectors. The plumbing
runs must be planned in advance so that the shortest possible route between the storage tank and collector is made.
Make sure you have no low points in the sloped horizontal pipe runs. This could trap water and in freezing
weather cause the pipe to rupture.
NOTE: All collectors are to be mounted vertically, sloped in order to be completely void of fluid when
drained, and oriented in such manner as described below under COLLECTOR LOCATION.
Make sure you have all the necessary plumbing materials, tools, and accessories before beginning work.
Wear gloves when handling the solar collectors! They get extremely hot when left exposed to the sun. The bright
orange plastic caps should be removed prior to placing the collectors on the roof otherwise they may get so hot
that they melt in place. Also, never try to lift the collectors by the pipe nipples. These bend when hot and would
damage the collector. You should have a tarp handy to keep the collectors covered during the entire installation
process. This will prevent the collectors becoming too hot to handle as you make your final adjustments and
connections.
Use only lead -free solder. Use of 50/50 lead solder is expressly prohibited. Use of galvanized steel, CPVC, PVC,
PEX or any other type of plastic pipe is prohibited.
BASIC TOOLS AND MATERIALS
Electric Drill Torch and Striker
Drill Index (w/ 'A" and 3/4" Wood Bits) Putty Knife
Hack Saw High Temperature Pipe Joint Compound
Tubing Cutter Wire Nuts or Connectors
Tin Snips Miscellaneous Copper Pipe & Fittings (3/4 ")
16' Tape Measure Solder Flux
24" Level Emory Paper
Flashlight Silicon Caulk and Roof Tar
Extension Cord 'A" I.D. and 3/4" I.D. Type M Copper Tubing
Slip Joint Pliers 5/8" x 'A" wall & 7/8" x 'A" wall Armaflex or
Needle Nose Pliers Rubatex Insulation
Pipe Wretches, 10" & 14" Angle Iron
Open End Wrenches, 9/16 & 7/16 Threaded Rod, Nuts, & Washers
Screw Driver 6" Flat Blade Stainless Screw Clamps
Screw Driver 6" Philips Thermal Adhesive
Wire Stripper or Knife Aluminum Flashing Sheet
Wire Cutters Black Latex Outdoor Paint
Adjustable Wrenches 8 "& 10
4
INSTALLATION
The DX Drainback storage tank module is as easy to install as any normal electric hot water heater. Any
experienced plumber or solar contractor may accomplish this installation. In addition to the normal cold water in,
and hot water out connections, there are only two other connections required. Provision should be made to
prevent water damage in case of leakage. Check with the local regulatory authority for catch pan requirements.
Dielectric nipples must be used on all connections to the tank. These are used wherever copper and galvanized
lines are connected together. This is a requirement of the Uniform Plumbing Code. Typically, galvanized pipe
nipples are used for all connections into the tank, which has ferrous female standard pipe thread, 3/4" nominal
(3/4" inside diameter). One side of a dielectric union fits a standard galvanized pipe nipple, and the other side is
brass or bronze for soldering to a copper pipe.
With solar tanks, the cold input from the pressurized supply line to the house (either city water or well water)
must be fed into the tank inlet. This is marked "Cold Inlet" and is located on top of the tank. There is a long plastic
tube attached internally to this connection so that incoming cold water is directed immediately to the bottom of the
tank, and therefore does not mix and cool down the hot water. A cold -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.
All hot water lines should be insulated with at least 1/2" thick heat resistant rubber tubing insulation such as
Armstrong Armaflex.
In most instances, the solar collectors can be attached to the roof using the standard mounting hardware provided
with the DX Drainback system. Certain types of roofing will require special attention for proper mounting. For
example, a clay tile or cement tile roof. Complete roofing attachment methods of solar collectors for these various
types of roofs are beyond the scope of this manual. The manual will describe and illustrate some of these
approved mounting techniques. A competent contractor should be used to ensure that all roof penetrations and
attachment points are not a source of rainwater leakage later on. Standard plumbing roof jacks or solar industry
copper flashings may be used for plumbing penetrations in most cases.
The collectors should be canted toward the inlet side to ensure they drain completely when the pump is not
running.
CAUTION!
Solar collectors become very hot when in direct sunlight with no fluid being circulated through them.
Extreme caution should be taken when standing near, or handling solar collectors in this state. The circulating
pump becomes very hot when running. Do not touch before allowing sufficient time to cool down.
COLLECTOR LOCATION
The collectors should be located on a south - facing roof, with the collector facing as close to south as possible. The
collector should not be shaded from the sun by trees or other obstructions. It is strongly recommended that the
collector be mounted in the portrait orientation with its longest side traveling directly up the roof if possible.
The Collector should be mounted at an elevation angle above the horizontal equal to your latitude plus 10 °. The
procedures for determining this angle at your location are explained below.
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 °. The figure below
shows many alternatives for collector mounting. When roof mounting, place the collectors as close as possible to
the peak of the roof. This will make installation easier due to increased attic access.
5
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4#47 0 e •• E 'V d ir v.--
Rout. t
COLLECTOR ORIENTATION
Proper tilt angle for solar collectors is latitude plus 10 °. This favors the winter sun because ambient temperatures
are lower during the winter and collector efficiency suffers. This 10° additional tilt equalizes year round
performance. Spacing can be determined from Table 1 below.
When collectors are mounted one behind the other, they are spaced apart so that in the morning and afternoon on
December 21, when the sun is at its lowest altitude, the collectors will not shade each other and cause efficiency
loss. .
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Fiw+r* p 1 Meer to Tabh 1
LATITUDE 1 25' N 30 N 35' N 40' N 45' N 1 50' N
COLLECTOR TILT 35 40 4 5 0 50 55 60
A B AB I A B AB A B AB
FLAT 29 96 33 113 37 145 41 145 44 145 48 145
5 1/12 25 83 29 93 33 113 37 132 41 133 44 141
9 2/12 22 74 26 82 30 77 34 110 38 115 41 118
14 3/12 17 66 22 72 26 82 30 92 34 95 38 98
18 4/12 14 61 18 66 22 74 26 81 30 85 34 87
23 5/12 10 58 14 60 18 66 22 72 26 74 30 77
ROOF 27 6/12 7 58 11 58 15 61 19 66 23 68 27 70
PITCH 30` 7/12 4 58 8 58 13 58 17 58 21 58 25 58
34 8/12 0 58 5 58 9 58 13 58 17 58 22 58
37 9/12 -2 58 3 58 7 58 11 58 15 58 19 58
40 10/12 -4 58 0 58 4 58 8 58 13 58 17 58
43 11/12 -7 58 -3 58 -2 58 6 58 10 58 14 58
45 12/12 -8 58 -4 58 0 58 4 58 8 58 13 58
VERTICAL -44 -41 -37 -33 -29 -25
Table: All Lengths in inches
6
MOUNTING HARDWARE
The system package includes a specially designed mounting hardware, to speed collector installation. This
hardware consists of four hinge sets, four roof brackets, two rear struts, and bolts.
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. It is necessary for the plate to slide under the above shingles to insure proper drainage
of water.
c) The bottom of the roof bracket and the area around the threaded rod should also be thoroughly coated
with tar sealant. When the bracket is set in place, alignment with the collector hinges is necessary before
final tightening of the nuts. This should be completed before the sealant has time to set.
d) The threaded rod is fastened through a 2' x 6" wood or 2" x 2" x 1/4" steel angle bracket under the roof as
shown.
The rear struts should be cut and drilled to conform to Table 1. All bolts should be tightened securely. A stainless
steel washer should be placed where the threaded rod passes through the aluminum bracket.
It is very important that the penetrations through the roof be well sealed. It should be carefully checked that all
bolts are coated with tar and that no leaks are possible.
140101411 ♦�! , -I' COU.SCTOR
STRUT
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/ OO ACT THMIo
ONT MONK
out moue
41111 4r1010'
Rgurs 3
Flour. 4
HINGE MOUNT
♦/ _ 1/4' lock BOLT
li
TILT MOUNT STRUT �t
1'X1'XQ1'SQ.
ALUNINUN TUBE 3/8' x 4' BOLT
LENGTH AS REQUIRED
TRIANGLE BRACKET":' 0
Q
d i * tt
3 /B' x 1 -3/4' BOLT
FIGURE 5
7
AE- Series Center Line to Center Line (in.)
Model Size (ft) Outside Box Dim. (in.) AE -MH AE -FM AE -RM
AE -21 3 x 7 35.1875 x 85.1875 88.4375 88.9375 86.9375
AE -24 3 x 8 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 4 x 7 47.1875 x 85.1875 88.4375 88.9375 86.9375
AE -32 4 x 8 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 122.9375
MSC -Series Center Line to Center Line (in.)
Model Size (ft) Outside Box Dim. (in.) MSC -MH MSC -FRM MSC -FM
MSC -21 3 x 7 35.8750 x 86.1250 90.5 87.375 37.125
MSC -24 3 x 8 35.8750 x 98.1250 102.5 99.375 37.125
MSC -26 4 x 6.5 47.8750 x 78.1250 82.5 79.375 49.125
MSC -28 4 x 7 47.8750 x 86.1250 90.5 87.375 49.125
MSC -32 4 x 8 47.8750 x 98.1250 102.5 99.375 49.125
MSC -40 4 x 10 47.8750 x 122.1250 126.5 123.375 49.125
ST -32 4 x 8 46.125 x 96.125 - 97.75 -
Table: Distance between centerlines of top and bottom mounts for all AE, MSC, ST series
MOUNTING THE COLLECTORS ON THE ROOF
For flush roof mount installation, AE -FM brackets are attached to the bottom of the collector and secured directly
to the roof.
1. The 4 x AE -FM mounting brackets should be attached to the collector frame using the 1/4" lock -bolt on
the bracket underside. Two brackets should be used at each end, at 6 to 12 inches from the corner of the
collector. The 1/4" lock -bolt should be tightened snugly against the collector frame bottom.
2. The AE -FM are now attached directly to the roof with 3/8" SS mounting bolts (not supplied) extending
all the way through the roof trusses or 3/8" lag bolts (not supplied) drilled directly into the roof trusses as
shown. Thoroughly check the tightness of all bolts and screws.
STANDARD MOUNT (AE - MH)
The AE -MH hardware kit allows the greatest flexibility in collector elevation angle when mounting the collectors
on tilt or flat roofs.
1. The 4 x AE -Clips should be attached to the collector frame uses the 1/4" lock -bolt on the bracket
underside. Two brackets should be used at each end, at 6 to 12 inches from the corner of the collector.
The 1/4" lock -bolt should be tightened snugly against the collector frame bottom.
2. The two front AE -Clips are attached to the two front Tilt Mount Triangle Roof Mounting Brackets, with
two 3/8" x 1 -3/4" SS bolts.
8
3. The two front Tilt Mount Triangle Roof Brackets are now attached to the roof with two 3/8" SS
mounting bolts (not supplied) extending through the roof trusses, or two 3/8" lag bolts (not supplied)
drilled directly into the roof trusses.
4. The two rear AE -Clips are attached to the rear Tilt Mount Triangle Roof Mounting Brackets via the Tilt
Mounting Struts, using a 3/8" x 1 -3/4" SS bolt at the bottom and a 3/8" x 4" SS bolt at the top of each
strut.
Note: The Tilt mounting Struts should be cut to length to provide the required collector elevation angle as
described in the following section.
A;P
DUEL TOP LENGTH j
DEG. \
i
-
CDLLECTOP EL VATION ANGLE
\
Pppf ELEV TIpN ANGLE
I
1
COLLECTOR ELEVATION ANGLE
Ideally, the collector should be mounted at an elevation angle equal to the latitude of the collector location plus 10
degrees. Estimate your latitude based on your location in the United States.
If your roof elevation is within +/- 10° of the ideal elevation, then it is recommended that the collector be flush
mounted with the roof. If not, then you will have to determine the length of the Tilt Mounting Struts required
providing the ideal elevation for your roof and location as follows:
Calculating the Length of Strut Required:
a. Determine the correct latitude column for your location.
b. Now locate the correct row for your roof elevation angle.
c. At the intersection of the column and row will be two strut lengths, in inches.
d. Select the appropriate length based on the orientation of the collector on your roof. Use the long column
if the collector is mounted portrait style. Use the short column if the collector is mounted landscape style.
e. Cut the struts to length and drill a 7/16" hole at 3/4" from each end of the strut.
f. Assemble the strut bottom to the triangle bracket with the 3/8" x 1 -3/4" SS bolt supplied, and the strut top
to the base of the collector using the two AE -Clips and the 3/8" x 4" SS bolt supplied. Secure the tilt
mount triangle brackets directly to the roof using two 3/8" SS mounting bolts (not supplied) extending
through the roof trusses, or two 3/8" SS lag bolts (not supplied) drilled directly into the roof trusses.
g. Thoroughly check the tightness of all bolts and screws.
9
DETERMINING THE STRUT LENGTH REQUIRED
Method:
1. Determine the latitude of your location to the nearest 5 °.
2. Locate the correct latitude column in the table.
3. Locate the correct roof pitch / elevation angle row in the table.
4. At the intersection of the row and column locate the strut lengths in inches.
5. Use long figure if the long side of your collector runs up the roof.
6. Use the short figure if the short side of your collector runs up the roof.
7. Cut the strut to the appropriate length.
8. Drill a 7/16" hole 3/4" from each end of the strut.
9. N/A = Ideal Collector Elevation not possible at this roof angle.
10. If length is in BOLD then heavier struts are required, see section 8 or contact AET.
Latitude 25 ° N 30°N 35 ° N 40 °N 45 - 50 °N
Ideal Collector Tilt 35 40 45 50 55 60
Angle
Collector Orientation Long Short Long Short Long Short Long Short Long Short Long Short
Roof Roof
Pitch Angle
Flat 0 59 25 70 30 84 36 100 43 120 51 145 62
1/12 5 48 21 59 25 70 30 84 36 100 43 120 51
2/12 9 41 18 50 22 61 26 73 31 87 37 104 44
3/12 14 32 14 41 18 50 22 61 26 73 31 87 37
4/12 18 26 11 34 15 43 18 52 22 63 27 76 32
5/12 23 18 8 26 11 34 15 43 18 52 22 63 27
6/12 27 12 5 19 8 27 12 36 15 45 19 55 23
7/12 30 7 3 15 6 23 10 31 13 39 17 48 21
8/12 34 1 1 9 4 16 7 24 10 32 14 41 18
9/12 37 N/A N/A 4 2 12 5 19 8 27 12 36 15
10/12 40 N/A N/A 0 0 7 3 15 6 23 10 31 13
11/12 43 N/A N/A N/A N/A 3 1 10 4 18 8 26 11
12/12 45 N/A N/A N/A N/A 0 0 7 3 15 6 23 10
Table: Determining the strut length required
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
In spanner mounting after the brackets are positions on the chalk line, a 3/8" hole is drilled between the rafters.
Aluminum flashing is positioned over the hole where the top of the flashing is extended up under the shingle
above the3 /8" hole and extends down over it. Caulk is applied between the flashing and the roof. The bracket is
then positioned over the 3/8" hole using sealant between the bracket and the flashing. A piece of 3/8" all- thread is
then inserted through the hole. A washer and nut secures the all- thread to the bracket (be sure the seal underneath
the washer and on top of the nut). The all - thread rod should extend about 4" below the roof rafters. Drill a 3/8"
hole in a 2 x 4 and insert the all- thread rod through it. The 2 x 4 should span 2 rafters. With a washer and double
nut secure the all- thread to the 2 x 4. Tighten down until the bracket is tightly secured to the roof. Be careful not
to over - tighten and bell out the roof underneath the bracket.
10
Mounting
Foot
- Roofing
Roofing Sealant
AL
Felt _ Shingles
I Plywood Ilr
Decking Sparer
2' x 4'
2' x 4'
Truss - russ
Threaded Roel -1 2' x 2' x 114'
Steel Angle
Figure: Spanner Mounting
In lag bolt mounting you must locate the center of the rafters along the top and bottom chalk lines. One method is
to have one man on the roof and another in the attic. Using a hammer the man on the roof can tap the roof and
determine where it is denser sounding. The roof man can drill a pilot hole while the attic man helps with distance
corrections.
Then the attic man can call of the distance to the next rafter while the roof man drills corresponding pilot holes.
Flashing the brackets is done as previously described. Secure the brackets to the roof using a 'A" x 3" stainless lag
screw, a flat washer, and a lock washer.
Mounting
I I Foot
` !
Roofing
Seulun l Iwu Shingles
Plywood Roofing
Decking
Felt
Lag ---- -►
Screw
2' x 4'
Truss
Figure: Lag 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. Work the J
underneath the rafter. Pull the J -bolt snug against the rafter before tightening the nut. Use double nuts or lock-
washers to securely fasten the mounting bracket to the J -bolt.
11
Mounting
1 i Foot
Roofing
Sealant ISI /— Shingles
Plywood Roofing
Decking Felt
x 4'
"J' Bolt 2'
Truss
Figure: J -Bolt Mounting
PITCH PAN
The pitch pan is necessary any time standing water is encountered. The purpose is to provide an adequate seal
around any penetration in the roof. Pitch pans are commonly used on flat roofs.
a) The pitch pan is placed in the proper position and flat on the roof.
b) Its flange is sealed with roofing felt and hot tar.
c) The holes are sealed on the inside with roofing tar to a sufficient level to insure a permanent seal.
iWNTaRi
FOOT
4/ Ai 11E
*%%'
PITCH PAN
MEMO MOO
tITADLEii STEE • TICANCELAR T
PACK
PAN PITCH
SPACER
AS REIE1IREG
SIFTER
ICE IER
PITCH PAN DETAIL
WANNER NGIERRG SFOYN
Figure: Pitch pan
ARRAY MOUNTING
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
unistruts are secured to the rails using the AE rack mount hardware (AE -RM). The 1 5/8" Aluminum rails are
anchored to the roof by using six or ten -inch stainless steel 3/8" hanger bolts. These bolts are lag screw on the
bottom and 3/8 NPT thread on the top. A ten -foot length of unistrut should be anchored at three points, the
middle and both ends.
12
Procedure:
a) Cut 12" x 12" square pieces of lead flashing.
b) Locate the roof rafters beneath the tile where the hanger bolts will be attached. Drill a 3/8" hole through
the tile. Slide the 12" x 12" lead flashing under the tile located above the 3/8" hole, then drill through the
lead flashing into the hole.
c) Screw lag portion of the 3/8" hanger bolt into the rafter.
d) Cut strips of the lead flashing about 1 '' /z" long and wide enough that when you fold it into a tube is
slightly larger in diameter as the hanger bolt.
e) Using an acid core solder, weld the seam of the tube together.
f) Slip this tube over the top of the hanger bolt protruding from the roof, then solder it to the 12" x 12" lead
flashing.
g) Thread down a stainless 3/8" nut to the bottom of the thread and seal the top of lead tube to the nut with a
polybutylene caulk. Slip a 3/8" stainless washer on top o the nut.
h) Place the 1 5/8" aluminum unistrut rail on the hanger bolt and secure with another 3/8" stainless washer
and net.
The rail is now secured, weather tight to the tile roof. Next, mount the AET solar collector to the rail using the
AE rack mounts (AE -RM). See Figure below.
SIDE VIEW
,T 114
SQL.AR COLLECTOR
. ... �..
...."' STAINLESS
BOLT v/LOEXVASHER
L FLAT 'ASMER
SOLAR COLLECTOR
MOUNTING
CLIP Ad
3 /O'XI' STADM.ESS
BOLT v /LOCxwASHER
srAtNLESf 4�c L FLAT vASHER
:mama NUT NT ;4 S
Amman ALUMINUM C ... ,,
A
SOLAR STRUT °�
S.S. NUTS . ROOFING
I. WASHERS - .t SEALANT
At
- "' -- 5_ co C - LEAD FLASHIN +„
HOLE LX 's - '�?'_5
— �`.. _ iOLT am. HA R DOLTTEEL'�" `;.
INSTALLATION
■ DRILL PILOT HOLE � ~`
ROOF SHEATHING
�- _
.7$ DOL,T D[A ��`° Ate ..,,
'�',�� ... A Mt FELT
1 9EAM R ��� ■AIR SPACE FORM
�_„� RAf TE D ti T ILE CO CRE E
T
�� TILE
Figure: Rail mounting
COLLECTOR PIPING
All collectors and piping must be sloped a minimum of 3/8" per foot for drainage. All piping must drain without
any fluid "traps." Soldered connections should be made with 95/5 solder.
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 not less than 1/4" I.D. copper tube of the type meeting local codes, insulated with
Armaflex or similar, and painted with exterior latex paint or wrapped with aluminum tape where exposed to
ultraviolet radiation. Piping is be supported using plumbers strap and should be installed in such a manner as to
not crush the insulation.
13
SINGLE PANEL MULTIPLE PANEL
MINIMUM OLIVE 1/4• PER FmT MINIMUM 4LJPE I/4' PER FOOT
Figure: Single Figure: Multi
COLLECTOR PIPING DETAIL
The outlets of the collector are 3 /4" copper nipples. They should be piped as shown below.
COLLECTOR
ADAPTER
ELBOW
O
y't
Figure: Copper nipples
PIPING THROUGH THE ROOF
Piping through the roof should be weatherproofed as shown in Figure below.
a) One inch holes are drilled through the roof on the same plane as the supply and return header nipples.
Do not drill the hole above the supply header of the collector. This will prevent the collector from
draining. Placing the hole below the supply header is acceptable, but it is more aesthetic if it is located
on the same plane. A copper flashing is placed around the hole with its base cemented to the roof and its
upper edges slid under the adjoining shingle. Placing the flashing under the shingle is preferred.
b) The copper tube supply and return line is then pushed up through the hole in the flashing.
c) A "coolie cap" is then slid over the copper tube till it meets the flashing. After piping to the collectors is
completed, the "coolie cap" is soldered to the copper tube.
d) Polybutylene adhesive is placed on the top and bottom of the flashing, providing a weatherproof seal.
e) The sensor wire should also be run through the return flashing which is equipped with a special wire
chase (tube). Once the wire is in place, fill the wire chase with clear silicone caulk to weatherproof.
NOTE: The sensor wire should not be in direct contact with the return plumbing. Secure the sensor wire
to the outside of the return pipe insulation.
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