Connection procedure:
1. Position the middle two collectors on either side of roof-penetration with connection tubes pointing
out (Fig. 6.4.4). Temporarily use center-flashing to achieve correct spacing of middle collectors and
secure them to C-channel.
2. As described in two-collector procedure, install custom flare fitting unions to upper tubes and
position and secure outermost collectors.
3. Line-set connections from roof-penetration to flare fitting tees each require 1
–
2 ft. (304.8 mm
–
609.6 mm)
of tube. Four additional insulated sections of tube, each approximately 5 ft. (1524 mm)
in length, are required to connect collectors to push-fitting tees.
4. A proper tube-bending tool is required for tight bends.
5. Cut off excess tube with a proper tube-cutter. Use a light feed to minimize burr, work-hardening and
compression of tube. Remove burrs with de-burr or ream tool.
6. Install flare-nuts and flare line-set connections from roof-penetration and additional insulated
sections of tube.
7. Connect middle end from the flare fitting tee to line-set from roof penetration. Connect additional
insulated tube into each side of the flare fitting tees. Connect f
to additional
tube ends. Finally, connect f
to collector tubes.
1. Cut excess length of control-wire and/or of thermistor wire as needed. Strip about 1½ “ (3- 4 cm) of
control-wire sheathing. Do not strip insulation from individual conductor wires.
Thermistor has very large resistance and thus negligible current flow. Only voltage
drop across ther mistor is monitore d by Cont rol ler. No p osit ive or ne g at ive
connections are necessary – either thermistor conductor can be connected to either control wire
conductor.
2. Insert one unstripped conductor of control-wire into one of three open holes of IDC. Insert one
unstripped thermistor conductor into one of remaining holes. Conductors should be inserted
completely. Position should be visible through translucent connector body (Fig. 6.5.1a).
3. To make connection: with slip-joint pliers, squeeze gel-filled blue cap into body of IDC until it clicks
and cap is flush with top edge of connector body (Fig. 6.5.1b).
Thermistor wire gauge is 2x22AWG. Control-wire gauge is typically 2x18AWG. Due to small and
different w ire gauges, pliers must be used to squeeze IDCs closed and make
connections.
lare fitting 90˚ elbows
lare fitting 90˚ elbows
6.5 Control-Wire Connections and Line-Set
Solar Collector
Installation Manual
29
Module 4
Summary of Contents for EWRA1
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