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Solar Water Heater Building Instructions


Solar Water Heater Building Instructions

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									                              Solar Water Heater Building Instructions

The size of this panel is 1M x1M. This is an arbitrary size and can be
adjusted to suit individual applications. All quantities, dimensions and
lengths will have to be adjusted accordingly.
Where glue is specified, silicone can be substituted.


            7 x 44mm cover strip to secure
                                                            4mm sheet glass
                    7 x 22mm rail (A) to support 4mm
                                                                15mm Copper

                                                                              4.5mm Aluminium
                                                                              Collector Plate

                    7 x 22mm rail (B) to
                    support Collector
                    Plate                                                 12mm exterior/marine

                      2 x 7 x 22mm rail (C)                               backboard

                      to support

                                                        50mm insulation

     144 x 22 SAP

Refer to materials and cutting lists in Appendix A
Cut the 144mm x 22mm SAP into 2 x 1000mm (Sides D & E) and 2 x 1045mm
(Top & Bottom).
Cut the 44mm x 7mm coverstrip into 16 x 950mm x 22mm x 7mm and then cut
lengthwise into 32 x22mm x 7mm.
Mark Sides D & E and Top & Bottom to position rail (A) 4mm (thickness of
Glass) from top.
Center, glue & nail the 950mm x 22mm x 7mm rail (A) in place.
Mark Sides D & E and Top & Bottom to position rail (B) approximately in the
Center, glue and nail the 950mm x 22mm x 7mm rail (B) in place.
The rail (C) to secure the backboard is made up of 2 x 950mm x 22mm x 7mm
strips glued and nailed one over the other.
Mark Sides D & E and Top & Bottom to position rail (A) 12mm (thickness of
Backboard) from bottom.
Center, glue and nail 2 x 950mm x 22mm x 7mm rail (C) in place.
Finish with 1 coat of universal primer/undercoat; allow to dry for 2 days and
then apply 2 coats of black roof paint or black Exterior PVA.

Cut the 15mm copper tubing into 15 x 850mm and 28 x 45mm lengths.
Using a pipe
bending           Fig
spring or a       1
bend a small
angle 75mm from both ends of the 850mm lengths of pipe so that both ends
are deflected in the same plane approx 15°. (Fig 1)
Fix the “T” couplings to both ends of the 850mm pipes and couple them
together with the 45mm lengths of pipe. Don’t tighten beyond finger tight
until assembly is complete. (Fig 2)

                                      45mm pipe

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Hot water

“T” couplings                                           Down pipes

                                                                               Fig 2


                                                                     Cold   water

    The bottom left hand and top right hand joints will be elbow joints. The
    bottom right will be the inlet and the top left will be the outlet. These
    positions are reversible depending on the application.

    Assembling the Collector
    Lay the completed piping assembly on the collector plate and centralise by
    eye. Mark the position of each down pipe with a felt tip pen. Measure
    50cm from the top of the plate and mark a horizontal line across the down
    pipe markings. Draw similar lines 30cm from top and bottom of plate.

                   Fig 3

      30 cm
      end                                                                              50 cm
                                                                                       from end

    Drill 3mm holes where horizontal lines cross             vertical lines ( in Fig 3)

                         This Document is printed on 100% recycled paper
Clean pipework and plate with methylated spirits.
Spray pipework and plate with gray primer and then 2 coats of matt black
spray paint.
When properly dry, lay the pipework back on the collector plate lining up
with the holes previously drilled and the “T” joints not in contact with the
plate. Thread 2 strands of wire down though the left hand hole and back up
the right hand hole secure the pipework to the plate with a twist.

Final Assembly
Make up the basic frame by gluing
and screwing one of the sides inside
the top and bottom assemblies (Fig
                                                                               Glue &
Screw and glue the backboard into                       Backboard              screw
Test-fit the Collector Plate
assembly and locate and drill holes
to accommodate inlet and outlet          Fig 4

pipes. Remove Collector Plate
Place the insulation on the backboard.
Slide the Collector plate assembly back into position on the middle rail (B)
and secure with 19mm screws.
Fix the remaining side of the frame in position and attach to the backboard
and collector plate.
Locate and tighten the inlet and outlet pipes.
Apply a bead of silicone around the rebate formed by the top rail (A) and fit
the sheet glass.
Secure the glass in place with suitably mitred coverstrips sealed with silicone
and secured with panel pins.
Counter sink all panel pins and screws and fill the holes with plastic wood or
silicon to stop them rusting.
Pipe a bead of silicone around the joint between the coverstrip and the
glass to ensure waterproofing.
Apply a final coat of paint to match your roof, paying special attention to
joints and the covering of the screws and panel pins.

               This Document is printed on 100% recycled paper
Appendix A


                              SIZE              QTY
Paint & Glue
Paint Brushes                 Set of 4           1

Black EXT PVA                 500ml              1

Turps                         750ml              1
Pink Primer                   1l                 1
Clear Silicon                 300ml              1

Cold Glue                     250ml              1

Matt Black Spray Paint        300ml              2
Grey Metal primer             300ml              2

Panel Pins                    49g x 25mm         1

Screws                        20 x 4.0 x 38mm    3
Coil Wire                     0.9mm x 500g       1

Glass                         1M x 1M x 4mm      1

Plumbing Hardware
Straight Conex Coupling       15mm               2

Copper Tubing                 5.5M x 5mm         3

Equal Tee Conex Coupling      15mm              28

90 Elbow Coupling             15mm               2

SAP PAR                       2.4M x 142 x 22    2

Pine Coverstrip               40 x 9mm           4
Exterior Plywood              1M x 1M x 12mm     1

Aluminium Plate               1M x 1M x 4.5mm    1

                   This Document is printed on 100% recycled paper

15mm Copper Tube              860mm             15
15mm Copper Tube              45mm              54

15mm Copper Tube              300mm             2

142 x 22 SAP                  1045mm            2
142 x 22 SAP                  1000mm            2

40 x 9 Coversrip              20 x 9 x 950mm    16
40 x 9 coverstrip mitred      40 x 9 x 1000mm   4

Tools and Equipment

Pipe Cutter

15Mmm Pipe Bender spring
Jig Saw

Electric Drill & bits

Screw Driver

30cm Shifting Spanner

Vice Grip Pliers

Std Pliers

Wire Cutters


Set Square


Tape Measure

                   This Document is printed on 100% recycled paper

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