Detailed Assembly Instructions. ATS Evacuated Tube - Solar Panel Units ATS10 / ATS20 / ATS30

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Julianna Cunningham
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1 Detailed Assembly Instructions ATS Evacuated Tube - Solar Panel Units ATS10 / ATS20 / ATS30 Release: 2/2012 1

ATS-10, ATS-20, and ATS-30 tube collectors are all setup using a similar method.

Unpack the glass as instructed only after the frame is assembled and plumbed; WARNING some components may have sharp edges handle with caution and

shown, in this picture. The open end of the tab is toward the top. Push the Footer down into the notch as shown on both side rails.

2 ATS-10, ATS-20, and ATS-30 tube collectors are all setup using a similar method. Carefully unpack the boxes removing all support structure components. Unpack the glass as instructed only after the frame is assembled and plumbed; WARNING some components may have sharp edges handle with caution and wear gloves to protect hands. Any glass has a potential to break and cause very sharp pieces and must be handled accordingly. Always Wear Safety goggles. The two long support bars are the side rails of the unit; the tube support rail (Footer) is attached to the lower portion of the side rails as shown, in this picture. The open end of the tab is toward the top. Push the Footer down into the notch as shown on both side rails. The Footer must be installed as shown to allow the plastic tube supports to snap in and face correctly. The slightly deeper notch side is towards the top of the unit. The plastic tube support slips into the deep notch first and then snaps into the shallow notch. The Footer is held in place using (2) large special stainless steel clamps, the channel shaped piece is inserted over the head of the bolt to prevent the bolt from rotating inside the side rail. 2

Each of the two mid support rails are installed with (2) smaller special

If you are installing a stand the two lower feet can be installed now.

from over tightening and will be difficult to remove if they become over

The solar manifold is placed on the top of the side rails, centered, and

Two large special clips are used to attach the solar manifold to the side

3 Each of the two mid support rails are installed with (2) smaller special clamps each as shown. If you are installing a stand the two lower feet can be installed now. Do not over tighten the bolts, stainless steel hardware can become damaged from over tightening and will be difficult to remove if they become over tightened. The solar manifold is placed on the top of the side rails, centered, and then pushed into its notches. Two large special clips are used to attach the solar manifold to the side rails. The proper location of the upper cross support rail is as shown Stand Assembly Attach support feet to the two rear legs of the support stand, and adjust to the correct height by determining which holes to line up between inside and outside rail pieces. 3

Proper location of the lower cross support is shown.

ATS-10 ATS-30 This ATS-10 is set at a 30 degree angle, ideal for providing snow buildup

4 Proper location of the lower cross support is shown. Install the plastic tube supports, by first installing lip towards the top of the unit, and then pushing down into the notch. The edge of the first cap will line up with the rubber end cap and each plastic cap will be inserted flush to the next unit. Using an angle finder tool can provide the ideal angle for your installation project. ATS-10 ATS-30 This ATS-10 is set at a 30 degree angle, ideal for providing snow buildup protection on a 5/12 roof. The setting used was one hole above the lowest position of the rear leg settings. Much lower angles can be attained by simply cutting the rear legs to the exact height required. Cross bracing can be eliminated on very low angle settings. 4

5 The additional supports are installed when the unit is set to higher angles; 50 degrees angle is shown above. The additional two supports attach from the middle of the side rails and brace back to the rear legs, as shown. Note these can t be physically installed at some of the lower angle settings and are not required. NOTE: Typically the tubes are NOT INSTALLED until the entire system has been plumbed and is operating correctly without tubes. The system should be online with the controller setup and the system should be tested for leaks using water. Warning: Whenever domestic hot water is getting heated by an exchanger in a closed system only non-toxic antifreeze solutions should be used in the transfer fluid; Cryo-Tec, DowFrost, Xceltherm CE, Corn Glycol, and Dynalene Solar Glycol 50 are various fluid options. Before installing Glycol the entire system should be flushed out and cleaned by using a small amount of TSP dissolved in hot water. This solution would be pumped into the system using a pump to fill the system. The circulator should circulate the solution for at least 15 minutes before flushing out the system with clean water. A garden hose works great to flush out the system, and does not require a pump. Glycol should be mixed in accordance with the manufactures recommended procedures. The rating should allow the system to still pump at the lowest anticipated temperature in your area. Some types of non- toxic anti freeze solutions require annual PH testing because when glycol breaks down it becomes acidic. Running your system at hi temperatures can cause the glycol solutions to break down. 5

Removing the tubes from the carton (One at a time) The evacuated tubes are carefully packaged with foam spacers to prevent damage.

Avoid touching the tip when working in full sun and wear leather gloves to protect your hands.

The silver color of the tube indicates that the tube is good; a milky white color will be produced if the vacuum was to ever fail in the tube, and

This material is rated for temperatures of up to 400F degrees.

6 Removing the tubes from the carton (One at a time) The evacuated tubes are carefully packaged with foam spacers to prevent damage. The copper tip of the evacuated heat tubes can become very hot so extreme caution should be used. Avoid touching the tip when working in full sun and wear leather gloves to protect your hands. The bottoms of the tubes have a protective cap, which is supported within the plastic tube supports on the Footer. The silver color of the tube indicates that the tube is good; a milky white color will be produced if the vacuum was to ever fail in the tube, and it would be easily determined. A tube of thermal conduction paste was included with your purchase. This material is rated for temperatures of up to 400F degrees. Apply a small amount to the sides of the copper tip on each tube before inserting into the manifold to improve the thermal conduction. Use a small brush like a flux application brush to apply the compound; DO NOT USE YOUR FINGERS to avoid getting burned. Some people use liquid soap to lubricate the rubber seal, which is often very helpful. NEVER apply anything other than liquid soap to the rubber seal or it may damage it. 6

If the tube does not slide directly into the manifold DO NOT FORCE IT. 1.

Just bend it back carefully and try to reinstall it 2.

To remove any debris that could be in the port we suggest using a 5/8 diameter

7 If the tube does not slide directly into the manifold DO NOT FORCE IT. 1. Sometimes while inserting the tube the copper tip gets bent slightly. Just bend it back carefully and try to reinstall it 2. Sometimes a small piece of solder or other debris can get into the manifold port. To remove any debris that could be in the port we suggest using a 5/8 diameter wire brush (used to clean plumbing fittings) clean out the port and then reinsert the tube. After inserting the tube, install the bottom of the tube into the support bracket, and snap it closed. A small setscrew is located on each tube support to snug it into place. ATS-10 ATS-30 7

Shortly after you have finished installing the tubes, your controller unit should be indicating an increased temperature in your panels (weather permitting).

8 Shortly after you have finished installing the tubes, your controller unit should be indicating an increased temperature in your panels (weather permitting). With a properly installed controller and probes, the circulator pumps should start when the temperature differential set point is reached. Free heat from the sun is now being produced. ATS Solar Collector Addendum Side Mounting Directions Sometimes it is desirable to mount the solar collector on the side of a building. To accomplish this, a hole needs to be drilled into the side and center rails (if applicable). When installing a collector on the side of a building the mounting foot is attached to the top of the "side rail". This will require the installer to drill new holes into the top of the "side rail". A hole is to be drilled ½ from the top edge. If the new holes are not made the feet will be obstructed by the rail itself when attempting to mount to the existing hole. TIP: The bottom of one side rail can serve as a template for the exact location of the new 5/16 hole. Drilling into tempered, 304 stainless steel will require high quality Cobalt drill bits and a spring loaded center punch. The first hole should be a 3/16 pilot hole. Using a drill press is suggested but with care a hand drill can provide good holes in the field. Note: stainless steel burrs can be extremely sharp and must be removed before installing the collector to prevent possible injuries. Always use gloves and safety glasses. Always follow generally accepted safety procedures when performing any work. In the standard installation the mounting feet are attached directly into the 5/16 hole located ½ from the bottom edge of the rail. That hole now serves another purpose 8

After attaching the top mounting feet, the rear legs get attached to the bottom of the "side rail" using the holes that are normally used for the bottom feet.

9 After attaching the top mounting feet, the rear legs get attached to the bottom of the "side rail" using the holes that are normally used for the bottom feet. The length of the rear legs (stand) will set the outward distance from the building; shorter legs will provide a steeper solar angle. Diagonal bracing may need to be attached to the rails in a location that will require additional drilling. This depends on the angle the unit is mounted. 9

For our present, For their future. Version 11.03

For our present, For their future. SFB-AL (SF-B) series Installation Manual All-glass Evacuated Tubular Solar Collector with Heat Pipe Contents http://www.sunflower-solar.com/ 1. SOLAR COLLECTOR SIZE AND