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									SOLAR HEATING PRODUCT INSTALLATION




             DOCUMENTATION




  GREAT LAKES ELECTRIC – SOLAR ENERGY




     Controlled Document maintained by: GLE Solar Energy 12/30/2009

                   5744 Cleveland Ave

                  Stevensville, MI 49127

                 Phone: (269) 408-8276

                   Fax: (269) 408-8233

          Website: http://www.gl-electric.com
                               Documentation for Solar Heating Product Installation


                                           TABLE OF CONTENTS
                 Section                                                         Page

                       Preface                                                   3

           1.0             Foundation Setup                                      5

           1.1             Determining Collector Location                        5

           1.2             Layout and Ground Preparations                        5

           1.3             Setting Posts and Footings                            7

           1.4             Unpacking Collector Base                              8

           1.5             Setting Up Collector Base                             8

           1.6             Multiple Collector Installation                       8

           2.0             Pipeline Building                                     8

           2.1             Determine System Configuration                        8

           2.2         Installing Supply and Return Lines                        8

           2.3             System Pressure Testing                               9

           2.4             Finalizing Piping                                     9

           2.5             Drain Detail                                          9

           3.0             Electrical Wiring and Controller Connections          12

           3.1         Wire Routing and Connection                               12

           3.2             Alternate Wire Routing and Connection                 13

           4.0             System Setup and Air Purge                            14

           4.1         Initial Fill and Air Purge                                14

           4.2             Fill and Purge Sequence                               14

           4.3             Confirmation Sequence                                 14

           5.0         Installing Glass Collector Tubes                          14

           5.1             Unpack Glass Tubes                                    14

           5.2         Individual Placement of Tubes                             14

           6.0         Install Optional Privacy Slats                            15
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                            Documentation for Solar Heating Product Installation

                                                    Preface


        Warning!

       For safety reasons, please read this entire document carefully before beginning the installation process
       to reduce the risk of personal injury or property damage.

       Safety Precautions:




               Please Read Before Starting!
       Use Solar Water Heater System only as directed and described. Other use or mis-use will void all
      warranties and may lead to personal injury or property damage.

      Solar Water Heater System must be properly installed as described in the installation documentation
      before it is used.

      Do not cover or obstruct unit in any way as this may reduce or prevent proper performance.

      Do not store or place combustible materials on or near the Solar Water Heater System.

      Always wear appropriate safety equipment during installation or maintenance of unit such as safety
      glasses and protective gloves.

      Use caution when handling glass evacuated tubes and follow installation documentation explicitly.

      After unit is installed, return water line may be hot!

      Ensure that all Solar Water Heater System components are kept away from children and animals.

      Though durable, evacuated tubes are glass and will break if dropped or hit with force. Use care in
      handling.

      Units must be installed in compliance with all national, state and local Mechanical and Plumbing Code
      Standards.

      Always call your local utility companies before digging to ensure location of any pre-existing
      underground utilities.

      System may weigh as much as 300 pounds prior to installation in packaging. Appropriate resources
      should be utilized to handle system to reduce risk of damage or injury.

      Always handle the unit by the end steel posts, never by the stainless steel tanks.

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                              Documentation for Solar Heating Product Installation




Note Before Starting:
      Installation of this Solar Water Heater System requires resources necessary to lift and handle the Solar
         Water Heater System which weighs as much as 300 pounds in packaging.

      It is recommended that installation be scheduled for a cloudy day if possible.

      Evacuated tubes are to remain in closed packaging out of direct sunlight until they are to be installed.
        (Tubes are highly efficient radiant heat capturing devices and will become extremely hot on the inner
        surface if left in the sun.)




       Glass Collector Tube                                                                Decorative
                                                                                           vinyl post
                                                                                           cover




               Mounting
                                                                                         Privacy slats
               Brackets




                           Figure 1: High Efficiency Solar Water Heater, mounted
                           in a fence configuration with optional privacy slats
                           installed

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                             Documentation for Solar Heating Product Installation

   1.0       Foundation Setup:
     1.1 Determine Collector Location

         1.1.1   GLE representative should have worked with you to determine the appropriate size and number
                 of collectors needed. If not, please contact your local representative. Their contact information
                 can be found at http://www.gl-electric.com or call (269) 408-8276.

         1.1.2 GLE representative should assist in identifying the optimum location and orientation for the
             collectors. Optimum orientation based on best practices is with the faces of the unit facing East
             and West longitudinally so as to achieve the most direct sunlight collection. An alternately
             efficient orientation is with the faces of the unit facing North and South     longitudinally.

         1.1.3   Best practice dictates location in an area with greatest solar exposure and limited
                 shading from buildings, structures, trees, and other objects of shading.

         1.1.4 It is also recommended that the shortest length of piping should be applied to facilitate an
             efficient installation. Increased piping lengths may be applied in order to locate in an area of
             greatest solar exposure without significant impact on performance with            appropriate
             insulation.

         1.1.5 Ensure there are no existing underground utilities prior to ground preparations by calling your
             local utilities.

     1.2    Layout and Ground Preparations

         1.2.1    After area to be used has been cleared by local utilities to dig, using dimensions as
                 shown in Detail Base-1 below, Collector Fence Detail below, and Piping Entry End
                 Detail on page 7, layout fence post positions and optional collector base bore holes.




  Capture Tube                                                                      Concrete Base,
  Housing Seals                                                                     pre-fab or poured
  (Typ. 2 per
  tube)



  4-point
  Mounting Base                                                                    ¾” NPT Hot Water
  Rail (See Detail                                                                 Outlet Connection
  B-1)                                                                             (Red)



  ¾” NPT Cold Water                                                            Tank Temperature
  Inlet Connection                                                             Sensor (Black Wires)
  (Green)

 Figure 2: Solar Collector Base setup on pre-fab concrete pads, showing 1 of 4 bolting positions.


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                            Documentation for Solar Heating Product Installation




                                                  Optional




     Figure 3: High Efficiency Solar Fence details for mounting. Shown with optional Privacy Slats and
     Decorative 4x4 post covers.
       1.2.2     Using a powered or manual bore tool, bore fence post holes to described depth or in
               accordance with local code requirements.

       1.2.3     Dig optional foundation pad holes and frame 12” square or us 12” Diameter “Sonotube” or
               equivalent product with 1/2” anchor bolts as shown in Detail Base-1 on page 5,
               Collector Fence Detail above, and Piping Entry End Detail on page 7. Verify foundation
               frame or tube are level and square. If not using foundation, pre-fab concrete pads should be used.



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                           Documentation for Solar Heating Product Installation




     Figure 4: End View Detail of Collector Base showing optional Mounting Footing and Post



   1.3 Setting Posts and Footings

      1.3.1.   Pour concrete foundation pads and secure anchor bolts. As an alternate method, drop-in
               anchors or Tapcons may be used. Allow concrete to cure.

     1.3.2.    Insert 4x4 posts as described in Collector Fence Detail on page 6. Pour concrete into post holes
               and allow to cure. Verify that posts level and square to the foundation pads.



   1.4 Unpacking Collector Base

     1.4.1.    Prior to opening container, inspect for obvious external shipping damage. If no damage
               proceed with installation. If package is damaged, contact your GLE representative
               immediately. With appropriate resources based on panel size, remove collector base from
               shipping container. Properly dispose of shipping materials.
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                             Documentation for Solar Heating Product Installation

      1.4.2. Inspect unit for any obvious damage or missing parts. If unit is damaged, contact your GLE
             representative immediately. If no damage proceed with installation.



   1.5 Setting Up Collector Base

     1.5.1.     If optional foundation is used, with appropriate resources based on panel size, place collector
                base over foundation bolts and secure to pad with appropriate hardware.

     1.5.2.     Attach unit to 4x4 posts with appropriate hardware. If using vinyl post covers, put vinyl post
                covers on, then attach unit to 4x4 posts with provided hardware.



   1.6 Multiple Collector Installation

     1.6.1.     If installing multiple collector units, repeat steps 1.2 through 1.5.2. Note: When installing
                multiple collectors, series piping connections must be made as the installation
                progresses. Use flexible tubing for these connections to serve as expansion and
                movement isolators.

     1.6.2.     Ensure that End units and Middle units are installed in the proper locations and that only two (2)
                units are connected in series together.

     1.6.3.     If only installing one unit with plans to install additional units later, a Middle unit can be
                installed with a loop back connection appropriately applied.




   2. Pipeline Building
  2.1 Determine System Configuration

       2.1.1     Once collectors are mounted, begin installation of supply and return piping. (See
                 series and parallel piping diagrams shown on page 9).

        2.1.2    Some systems will be setup with a combination of series and parallel configurations.
                  Custom system design can be coordinated with GLE Engineering.

      2.2     Installing Supply and Return Lines.

        2.2.1. Utilize CPVC piping rated for pool heating applications.

            2.2.2.      If routing pipe above ground, pay close attention to water traps and provide
                        appropriate drain and vent ports using standard industry practices. If installing
                        underground piping, apply piping in accordance with local codes and standards.
                        Insulate piping with a minimum 3/8” wall Armaflex or equivalent insulation in
                        either case.




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       2.3 System Pressure Testing.

         2.3.1.    After piping installation is complete, but prior to back fill or enclosure, pressure test system
                   with a minimum of 30 psig and a maximum of 75 psig.

       2.4 Finalizing Piping

         2.4.1.   After completing a successful pressure test, back fill or enclose piping accordingly.

       2.5 Drain Detail




     Figure 5: Detail for safe drain for hot water providing protection against unit over heating and
     scalding.

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                           Documentation for Solar Heating Product Installation




 Figure 6: Parallel Piping Detail for Pool Application


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                          Documentation for Solar Heating Product Installation




      Figure 7: Series Piping configuration for swimming pool application



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   3. Electrical Wiring and Controller Connections
       3.1 Wire Routing and Connection

           3.1.1.     Connect two (2) black Collector Thermistor wires to Controller as described in    Detail
               E-1.

           3.1.2.     Connect two (2) black Pool Thermistor wires to Controller as described in Detail E-1.

           3.1.3.     Ensure that all wires are routed and fixed such that there is significant space
                      between sensor wires and any 120 volt or higher wires.

           3.1.4.     Use only single strand shielded wire between 14 and 18 Ga.




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       3.2     Alternate Wire Routing and Connection

             3.2.1.    If required, connect pump wiring to Controller as described in Detail E-2.

             3.2.2.    Ensure that all wires are routed and fixed such that there is significant space
                       between sensor wires and any 120 volt or higher wires.

             3.2.3.    Use only single strand shielded wire between 14 and 18 Ga.




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   4. System Setup and Air Purge
       4.1 Initial Fill and Air Purge

           4.1.1.      The system should now be ready for initial fill and air purge.

           4.1.2.      Confirm all piping and electrical connection.

       4.2 Fill and Purge Sequence

           4.2.1.      Following Detail P-1 on page 9, Open Valve “A” and purge air until a column of water is
                       present to the point of Valve “C”.

           4.2.2.      Close Valve “A”, “B”, “E”, and “F”.

           4.2.3.      Open Valve “C” and “D”.

           4.2.4.      Using appropriate hoses or temporary piping, connect one (1) to Valve “C” and to water
                       supply and connect one (1) to Valve “D” and route to drain location.

           4.2.5.      Using line pressure (non pumped), begin to fill system through Valve “C”. Air will begin to
                       exit Valve “D” and hose. Note: If using only series connection, Valves “E” and “F” will not
                       be present. If parallel piping system is applied, then open Valve “E” and purge until air is
                       eliminated. Once Valve “E” is clear of air, close Valve “E” and open Valve “F”. Continue
                       until all air is eliminated from system.

           4.2.6.      Close Valve “D” and set Delta P Valve to ¼ turn and open valves “A” and “B”.

           4.2.7.      Open Valves “E” and “F” (in parallel application).

       4.3 Confirmation Sequence

           4.3.1.      Start System pump and check again for leaks.



   5. Installing Glass Collector Tubes
       5.1 Unpack Glass Collector Tubes

           5.1.1.      Carefully remove Tubes from shipping containers and properly discard packaging.

           5.1.2.      Only remove one tube at a time to prevent tube heating prior to handling.

           5.1.3.      Remove top rail from Collector Base by removing four (4) screws as described in
                       Collector Fence Detail-1 on page 6.

       5.2 Individual Placement of Tubes



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                           Documentation for Solar Heating Product Installation

           5.2.1.     (Ensure to utilize appropriate resources based on the size system for this step.)Slide
                      each glass tube onto a separate stainless steel tube, being careful not to scratch the
                      inside of the glass tube and lowering slowly into place. Repeat until all tubes are in
                      place.

           5.2.2.     Apply upper and lower rubber seals as shown in Collector Fence Detail-1 on page
                      6. Repeat until all rubber seals are in place.

           5.2.3.     Replace top rail and four (4) screws. Unit should be complete and ready to heat water.

           5.2.4.     Repeat steps 5.1 through 5.5 for each panel.

   6. Privacy Slats (Optional)
       6.1 Unpack Slats and Retainer Clips

           6.1.1.     Remove all Privacy Slates and Retainer Clips, ensuring that there are two (2)
                      Retainer Clips for each Slat.

           6.1.2.     Properly dispose of packaging

       6.2 Install Lower Retainer Clips

           6.2.1.     Place one (1) Retainer Clip at the base of the unit as shown in Figure 1 between the
               Glass Collector Tubes.

           6.2.2.     There are two (2) sets of Retainer Clips specifically designed for each end, upper
                      and lower. These will only fit in these locations and must be installed at this time.

       6.3 Install Privacy Slats and upper Retainer Clips

           6.3.1.     Place the bottom of a Privacy Slat onto the previously installed lower Retainer Clip

           6.3.2.     Snap upper Retainer Clip in place. Privacy Slat should not fall if installed properly.

Note: Each collector requires 2.75 gpm flow rate. Multiply the total number of collector panels by 2.75
gpm for the total water flow required through each collector bank. Do not exceed two (2) collector
panels per bank. Each two (2) collector panel bank equals a total of 5.5 gpm. If initially, the total flow
rate is not met, then increase closure of the Delta P valve until total flow is met.

Using the Novatech “Flow Indicating Device” utilize the Delta P valve to balance the flow rate in the
series application or valves “E” and “F” in the parallel application.

Manually activate collector bypass valve to ensure proper operation.

Set control to desired pool temperature.




Submitted by GLE Solar Energy                 Pg. 15                          Confidential Document

								
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