4. Repeat with second IDC (Fig. 6.5.1c). Ensure wires and connectors are not under tension or exposed
to UV light. Excess wire should be taped to fluid line-set to keep it off of roof surface and to limit
exposure to moisture.
5. With a proper tube-cutting tool, cut off excess line-set tube, leaving enough to reach upper copper
connections of collectors. Use a light feed with tube-cutter to limit burr, work hardening and
compression of soft-copper tube. Remove burr with de-burring or ream tool but do not remove
material from original wall thickness. Do not allow removed burr material to enter tube.
6. Install 3/8” flare-nuts and flare line-set.
7. Carefully bend line-set tubes down between collectors such that f
will reach
collector tubes (Fig.6.5.2). A proper tube-bender should be used for tight bends.
8. Connect f
onto
collector tube-
ends
. Ensure fittings are tighten.
Do not insulate fittings and do not install collector
f l a s h i n g o r l e a f - g u a r d s u n t i l a p p l i a n c e
h a s b e e n l e a k - t e s t e d , a n d c h a r g e d a n d
pressurized with heat-transfer fluid. Leave plastic
foil cover in place until appliance is charged and
pressurized with fluid.
7 – Collector Flashing and Leaf-Guard Installation
Collectors must remain covered while charging Appliance with fluid. Uncovered collectors will g e t
very hot. Fluid pumped through uncovered collectors will flash boil, placing installer at risk of
scalding. Boiling will also damage heat-transfer fluid and void warranty.
Collector flashing and leaf-guard should be installed after leak-testing and after fitting insulation
as access to collectors, fittings and thermistor may be necessary if a leak or problem is detected.
Collector flashing and leaf-guard are designed for pitched roof installations only. Flashing and leaf-
guard should not be installed on rack-mounted collectors.
lare fitting 90˚ elbows
lare fitting 90˚ elbows
Solar Collector
Installation Manual
Fig. 6.5.1 – To make thermistor/control-wire connections, insert unstripped conductors
into IDC and squeeze with pliers.
Fig. 6.5.2 –
connects line-set
to collectors (to be insulated after pressurizing
heat-transfer fluid).
Flare fitting 90˚ elbow
Flare fitting 90
˚
elbow
(to be insulated)
Collector uncovered
only after heat-transfer
fluid is pressurized
30
Module 4
Summary of Contents for EWRA1
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