Alternate Energy Technologies AE-Series Instruction manual

INSTALLATION
OPERATION
MAINTENANCE
MANUAL
AE-Series, MSC-Series
Solar Collectors
Alternate Energy Technologies, LLC.
1345 Energy Cove Court · Green Cove Springs, FL 32043
PH: 800-874-2190 · Fax: [phone] · Email: [e-mail]

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Introduction
The installation of this solar collector should only be performed by personnel qualified in plumbing and roofing.
The installation should comply with local building codes, permits and OSHA requirements. The collector
installation can be retrofitted to existing buildings or integrated into new construction projects.
Theory of Operation
A solar collector is simply a heat exchanger designed to convert the sun's radiant light energy into thermal
energy to be stored for later use. This collector uses flat plate technology to heat the fluid media passing
through the selectively coated tubing manifold. The fluid media is circulated, via a pump, through the collector
and into a storage tank located within the home/building.
Collector Orientation
The performance of solar collector in the Northern Hemisphere is optimized when the collector is mounted
facing true south (Figure 1). Performance, however, suffers very little when the collector is oriented no more
than 45° East or West of True South. The collector should be un-shaded by any permanent obstacle between
9:00 a.m. and 3:00 p.m. on any day of the year.
Figure 1
Collector Tilt
Optimal annual efficiency is achieved by tilting the solar collector at an angle that equals your latitude plus an
additional 10°. This tilt angle favors the lower winter sun when collector performance is at its lowest and
minimizes overheating during the hottest summer months. The solar collectors in a two collector staggered
mount installation must be spaced far enough apart to prevent winter shading. The Table and Figure to follow
show the correct spacing between collectors to prevent shading on December 21, when the sun is at its lowest
angle. The Trigonometric Functions of Angles can be found in Appendix A of this document.

Solar Collector Dimensions
Model No.
AE-21
AE-24
AE-26
AE-28
AE-32
AE-40
MSC-21
MSC-24
MSC-26
MSC-28
MSC-32
MSC-40
Length (l)
85.187
97.187
77.187
85.187
97.187
121.187
86.125
98.125
78.125
86.125
98.125
122.125
Width (w)
35.187
35.187
47.187
47.187
47.187
47.187
35.875
35.875
47.875
47.875
47.875
47.875
Height (h)
3.137
3.137
3.137
3.137
3.137
3.137
3.082
3.082
3.082
3.082
3.082
3.082
Area
20.82
23.75
25.29
27.91
31.85
39.71
21.46
24.45
25.97
28.63
32.62
40.60
Weight
74
84
90
99
113
153
76
87
91
102
116
151
MOUNTING HARDWARE SPACING –Centerline to Centerline (in)
xx-MH
MSC-MH
86.187
98.187
78.187
86.187
98.187
122.187
88.233
100.233
80.233
88.233
100.233
124.233
xx-FM
MSC-RRM
88.663
100.663
80.663
88.663
100.663
122.663
87.375
99.375
79.375
87.375
99.375
12.375
xx-RM
MSC-RM
86.835
98.835
78.835
86.835
98.835
122.835
87.333
99.333
79.333
87.333
99.333
123.333
Dimensions shown (length, width and height) are nominal and listed in inches, area in ft² and weight in lbs. Use the formulas
below for tilted applications.
To calculate the length of the support strut use the formula as follows:
S = 2 x L x sin((- ) ÷ 2)
Add two (2) inches to the calculated length to allow for the pre-drilled holes, positioned ± 1.0 in from each end
of the support strut.
To calculate the recommended spacing between collectors use the formula as follows:
X = L x cos(–) + L x sin(–) x tan(90 ––)
This would be spacing distance required to insure collectors do not shade one another in stacked arrays or saw-
tooth type mounting configurations.

Basic Mounting Procedures
The solar collector(s) should be mounted in the vertical orientation on the roof (Figure 2). Freeze protection is
strongly recommended; therefore, the collector should always be mounted in a vertical orientation. It is still
important to slope the collector just slightly to allow for complete drainage during off mode. The required slope
is at least 1/4" vertical rise per foot of horizontal run.
Figure 2
To ensure proper water drainage from the glazing, the collector must maintain a minimum angle from horizontal
of at least 10°. Never mount the collector directly or parallel to a flat roof surface. Use the universal tilt mount
kit and 1" aluminum square tube to rack the collector to the proper angle.
The collector should be mounted as close to the storage tank as possible to minimize heat loss in the piping
runs. If the home has limited attic access, mounting the collectors nearer the roof peak provides for additional
attic workspace. The solar collector should be mounted on the roof in accordance with these general principles.
The most important structural consideration is to securely anchor the solar collector and the mounting
hardware to the structural members of the roof with stainless steel lag bolts, "J" bolts or threaded rod as
depicted in Figures 3, 4, and 5.
Figure 3 - Lag Bolt Figure 4 - "J" Bolt

Figure 5 - Threaded Rod
The collector must be raised from the roof surface to allow for rainwater and debris to pass under the collector
and for proper ventilation of the roofing material. There should be at least 1 1/2" of clearance between the roof
surface and the underside of the solar collector.
In selecting mounting hardware and fasteners it is extremely important to avoid galvanic corrosion resulting
from the direct contact of incompatible metals. Use the "Quick-Lock" mounts with stainless steel hardware and
a stainless steel lag or hanger bolt with lock washers and round washers as recommended. In climates subject to
severe winters or high humidity, the use of galvanized fasteners is prohibited.
Preserving the integrity of the roof membrane is the most important roofing consideration. Ensure that all roof
penetrations, required to plumb and mount the solar collector, are properly flashed and sealed in accordance
with standard roofing practices. Tremco's "POLYroof" is the recommended elastomer for sealing roof
penetrations. Henry Co. 204, 208 or 209 roof mastic or Dow Corning Glazing Sealant also are acceptable
sealants.
If the region is subject to high wind or hurricane conditions, additional steps may be required to secure the
collector and mounting hardware to the structural members. In certain areas of the country, local building codes
may require collector wind load testing or prescribe specific mounting procedures. Consult your local building
department.
Collector Plumbing
This installation requires the use of [copper][brass][stainless steel] fittings in the collector loop plumbing. Cast
iron is acceptable for pump volutes and flanges. Couplings rather than unions should be used to join the
collectors to avoid leaks and fluid loss. Use only lead-free solder. Use of 50/50 lead solder is expressly
prohibited. Use of galvanized steel, CPVC, PVC, or any other type of plastic pipe is prohibited. The minimum size
for the "To" and "From" collector piping is 5/8" OD copper.
Piping in new solar installations can be covered with dirt, grease, solder flux or other impurities that over time
affect the quality of the heat transfer fluid (HTF). A thorough cleaning is required before charging the system. A

50:50 vinegar/water or 1/8:1 - trisodium phosphate/water solution is recommended to remove solder flux and
other impurities from the fluid passageways. Circulate for 15 mins, drain, rinse, recharge with desired HTF.
Collectors are designed to be installed in the vertical position (Figure 6). All vertical piping between the storage
tank and the collector shall be supported at each story or at maximum intervals of ten (10) feet. Copper
plumbers tape or tube strap is required. The pipe insulation may not be compressed or crimped by the strapping
material. It is not recommended that collectors be mounted with the parallel flow tubes in the horizontal
position. In the event this is the only option, the collectors must slope downward toward the collector inlet by
no less than ¼" per foot.
Figure 6
The "To" and "From" Collector plumbing lines should also slope ¼" per foot from the collectors back to the tank.
The installation of all horizontal and vertical piping may not reduce the performance or rating of any structural
member or fire rated assembly. Adhere to all applicable local codes and ordinances.
This solar collector is leak tested at the factory. Once the collector has been installed as part of a domestic solar
water heating system, the system should be filled, pressurized and checked for leaks. Repairs should be
corrected and the system retested prior to insulation installation.
Pipe Flashings
Pipe flashings are used to transition through the roof membrane and into the attic space for subsequent
connection to the interconnect plumbing. All roof penetrations are to be sealed in accordance with standard
roofing practices. Make roof penetrations between trusses to allow for thermal expansion and slight flexing of
the pipe from wind buffering.
Standard plumbing roof vent stack flashings can be used, however, the rubber or plastic boot must be protected
from the sun. Figure 7 details an all copper flashing which uses a "coolie" cap soldered to the interconnect
plumbing. This connection should be made prior to insertion through the flashing base.

Figure 7
Collector Loop Pipe Insulation
The collector loop cold supply and hot return lines must be well insulated with a high quality flexible closed cell
insulation to minimize heat loss. The wall thickness of the pipe insulation should not be less than 3/4". A 1" wall
thickness is required in all areas prone to annual hard freeze conditions. When it comes to pipe insulation the
rule is simple: thicker is better. The specified insulation material is Rubatex Insul-Tube 180 or equal.
To the extent possible, slide the insulation material over the pipe without cutting or taping. All butt joints must
be sealed with contact adhesive. The use of rigid polyethylene pipe insulation is prohibited. The temperatures
generated by your collector in the summer months or under stagnation conditions can melt this type of
material.
Any above ground exterior pipe insulation is subject to ultra-violet (UV) degradation and must be wrapped with
foil tape or painted with two coats of high quality water-based acrylic resin coating as supplied by the insulation
manufacturer. Rubatex UV Protective Coating or its equal is the required coating material.
Collector Sensor Placement
(When Differential Controller is used)
The collector sensor must be located on the hot water return line as close to the collector as possible. Sensors
are typically accurate to +/- 1/2°F if properly installed and weatherized. To maximize sensor accuracy, attach the
flanged portion of the sensor to the solar collector header pipe, as close as possible to the collector outlet, with
a stainless steel hose clamp. Wire nuts used to connect the sensor and low voltage wiring shall be all plastic,
sealed with silicone and thoroughly wrapped in electrician's tape.

The sensor "bundle" must be placed under the rubber pipe insulation covering the collector header. Thoroughly
wrap and weatherize the insulation with electrician's tape or insulation tape as provided by the manufacturer
(Rubatex Insul- Tape or equal). See Figure 8 for collector sensor installation detail.
Figure 8
Low Voltage Wiring
Low voltage wiring is used to connect the collector sensor to the controller and should be a minimum 18 AWG.
The wiring should be stranded bare or tinned copper, two-conductor type.
The wiring should be PVC insulated, with a PVC UV rated gray jacket suitable for exterior use. Use Eastman Wire
& Cable No. 5704, Belden Wire and Cable No. 8461 or equivalent.
This completes the system installation procedure.
Collector Maintenance
Collectors operate best when the glass is clean and unobstructed. If they become dirty wash them with mild
soapy water and rinse. Remove any branches or leaves that do not naturally fall off or are blown away by the
wind. Collectors installed at the proper angle anywhere in the continental United States should not have either
of these problems. Dust and dirt build can be a problem in dry desert climates where there is little rain to wash
the glass.

Specifications
Collector Frame and Battens: Type 6063-T6 extruded aluminum frame and battens with architectural bronze
powder-coat finish.
Backsheet: Type 3105-H14, 0.019” stucco
embossed aluminum sheet (bronze) pop-riveted to
aluminum frame.
Corner Brackets: Architechtural aluminum angles
inside with aircraft-grade pin grip rivets to insure
high stability.
Insulation: Polyisocyanurate foam board insulation.
Foil-faced, glass fiber-reinforced, rigid board
Thermax sheathing (1-1/4” in the bed / 3/4” in the
sidewalls).
Absorber Plate: Manufactured by Thermafin™ Mfg.,
a 100% copper absorber plate, high frequency forge
welded to create a crystalline homogenous
connection between the fin and riser tube.
Absorber Coating: Exclusively by Thermafin™
Manufacturing,
Selective Crystal Clear Coating α ≈ 0.96 ε ≈ 0.08
Glazing: Low-Iron Tempered Glass exclusively using
our new “High-T” tempered glass with a total solar
energy transmission of 90%.
Gasket, Grommets: A UV durable EPDM, U-channel
gasket with molded corners which prohibits water
penetration and assures long life. Extruded Silicone
Grommets, 1-1/8” bore, seal the plumbing ports.
Fasteners: 5056 Aluminum Rivets secure the
backsheet. Batten screws are 18-8 SS, 10-24 x 3/8”,
Hex head screws black oxide coated.
Working Pressure: 165 PSI
Flow Rate: 0.5 to 1.8 GPM (recommended)
Warranty: 10 Year Full
Design Life: 30 Years