ASHRAEDesignManualSec4DesignConstr PDF

SECTION 4
DESIGN AND CONSTRUCTION PACKAGE
Solar Design Manual

SECTION 4
DESIGN AND CONSTRUCTION PACKAGE
CONTENTS
Page
OVERVIEW ............................................................................................................
-4-1
DESIGN PACKAGE ...............................................................................................

4-2
CONSTRUCTION PACKAGE ............................................................................

4-2
Design and Installation Drawings ......................................................................4 - 2

Construction Specifications .................................................................................4 - 3
.
Component Spec~fcations............................ .... .......................................................4-4
Installation. Operation and Maintenance Procedures ................... .... .................4 - 6
Component Specification Worksheets -- Liquid Collector Systems .......................4-7
Component Specification Worksheets --.Air Collector Systems ............................4.7
TABLES
Page
4-1 List of Component Specification Worksheets -- Liquid Collector systems .............4.5
4-2 List of Component Specification Worksheets -- Air Collector Systems ..................4-6
APPENDlXES
Page
4A Installation Checkout Procedure (Sample) ............................................................

4A-1
4B Example of Construction Specification....................................................................4B-1
Solar Design Manual

4.1 OVERVIEW
SECTION 1 SECTION 2 SECTION 3 SECTION 4
Prepare Perform Complete

Conceptual + Feasibility Detailed
Analysis Study Design
\ # \ J \
h Design
Package
kL-Ty'ntradOr
Construction
Package
installation
~K)M) Procedures
This section describes the preparation of design and construction packages. The design
package summarizes various analyses conducted by the A/E during feasibility and detail
design phases. This package can be used by owners or reviewers to follow the rationale
for certain design decisions and for checking accuracy of analysis methods used to make
design decisions. The construction package combines the output of Section 3, Detailed
Design. This output is in the form of design and installation drawings; construction specifi-
cations; component specifications; and installation, operation and maintenance (IOM)
procedures. The construction package is the basis for contractors to bid on the construc-
tion of the project and to actually construct the solar energy system.
Solar Design Manual

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Section 4 Design and Construction Package Constmction Package- Page 4-2
4.2 DESIGN PACKAGE
The design package summarizes analyses completed during feasibility

and detail design phases. The basic analyses which should be included
in the design package are:
System thermal load analysis
System thermal performanceanalysis
Collector array and storage tank sizing analysis
Pipelduct and pumpflan sizing analysis
Array shading calculation
Results of any significant t radeoff studies

Construction cost estimate
Economic evaluation of as-designed system.
In addition, an updated system design description (SDD), all detail draw-

ings, and an installation checkout procedure should be included in the
design package. A sample installation checkout procedure is included in
Appendix 4A.
4.3 CONSTRUCTION PACKAGE

The construction package consists of design and installation drawings,
construction and component specifications, and the installation, opera-
tion and maintenance (IOM) procedures.
4.3.1 Design and Installation Design and installation drawings for large solar energy system construe-
Drawings tion projects are divided into five categories -general, mechanical,
architectural/civil, structural, and electrical. Size and complexity of the
project determine the number of drawings in each category. Drawings
that should be included in each category include:
- Legend of symbols and abbreviations

- Site plan and location.
Mechanical
I
- Interface requirements with conventional service hot
waterlheating, ventilating and air conditioning (SHWI
HVAC) systems
- Collector and piping schematics and details
I
Solar Design Manual
- Storage tank and piping schematics and details
- Plumbing schematics and schedules
- Piping routing plans
- Installation of all mechanical components.
- Interface requirements with conventional SHWI

HVAC systems
- Grading and site preparation
- Plot plan and floor plan
- Roof plan
- Sectional elevations
- Mechanical equipment location plan.
i
Structural
- Interface requirements with conventional SHWI
HVAC systems
- Collector structure-to-building attachment details
- Structural collector support and details
- Structural framing plan.
Electrical
- Interface requirements with conventional SHWI '
HVAC systems
- Operational mode matrix
- Electrical and control wire routing plans, wiring
diagrams, or schematics
- Control logic diagram.
Informationto be included on drawings is discussed in Section 3, De-

tailed Design.
4.3.2 ConstructIan Speclflca- Informationfrom Section 3, Detailed Design, which cannot be easily or
tlons explicitly included on design and installationdrawings must be described
in the construction specification. This information is usually divided into
various categorical subsections, such as mechanical, electrical, concrete,
painting, etc. The Construction Specfication Institute has developed a
format for construction specifications. Typical information which can be
described in the various subsections includes:
Part 1 -General
- Scope
- Standard tests and performances
- Related work
- Submittals
- Definition
Part 2 - Pmduct
- Overall description
- Physical description
Section 4 - Design and Construction Puckage Construction Paekage- Page 4-4
- Material requirements and firnitations
- Environmentalconditions
- Operational conditions
- Operational performance
- Special requirements (codes, standards, tests, etc.)
- Warranty
Part 3 - Execution
- General requirements
- Special conditions
- Handling and storage
- Applicable codes and standards
- Workmanship
- Inspection and tests
- Finishing
The A/E should use the construction specification to document all infor-
mation which may be pertinent to the proper procurement of the compo-
nents, fabrication of the structures, installation of equipment, interface
connection between the subsystems and also the main heating system,
identification of the components, installation checkout, system startup,
and any other information and requirements not explicit in other docu-
ments.
Appendix 4A contains a sample installation checkout procedure that may

be used by the owner or owner's representative to assure a satisfactory
checkout.
Appendix 48 contains a sample construction specification for a typical

solar energy system that can be used as a model to prepare the con-
struction specificationfor the particular system. The NE should select
those sections or clauses appropriate to that solar energy system and
add or substitute standard "boilerplates" to cover that system's require-
ments.
Many of the general clauses included here are common to all good
construction practice; their use here emphasizes their importance to
solar energy systems.
4.3.3 Component Speciflca- Components identified in Detailed Design, Section 3, must be specified
t ions by the A/E in sufficient detail to assure that the construction contractor
will procure the components best fitted to the specific requirements of the
system.
Sample specification worksheets for various liquid collector system

components discussed in Sections 3.3, 3.4, and 3.5 are listed in Table
4-1 and for various air collector system components discussed in Sec-
tions 3.6, 3.7, and 3.8, in Table 4-2.
The sample worksheets list physical parameters and performance data

required of each major component in solar energy systems. They should
be completed when detail design of each c o w n e n t is finished in
Section 3 and used for requests for quotation by the construction con-
tractor to initiate procurements.
Solar Design Manual

Section 4 - Design and Construction Package Construction Package- Page 4-5
The worksheets provide a concise summary of component design efforts
and, after procurement and system installation, may be included as
marked-up, as-built records in the operations and maintenance manual
for use by system operators.
Careful review of this list of worksheets will also assure that NEs have
specified all of the important components.
Table 4-1. Llst of Component SpecificationWorksheets -

Llquld Collector Systems
Flat plate liquid collectors

Evacuated tube collectors
Heat exchangers ,
Heat transfer fluids
Pumps
Pump starter boxes
Expansiontanks
Thermal storage tanks
Piping
Isolation valves
Pressure relief valves
Pressure temperature relief valves
Pressure reducing valves
Backflow preventers
Check valves
Automatic flow control valves
Flow balancing valves
Air separator valve
Air vent
Tempering valve
Pressureltemperature ports
Flex couplings
Insulation
Differentialtemperature controller
Temperature sensor
Temperature switches
Flowmeters
Visual flow indicators
Pressure gauges
Thermometers
Btu meters
Solar Design Manual

Table 4-2. Llst of Component Speclflcation Worksheets -
Alr Collector Systems
Flat plate air collectors

Heat exchangers
Fans
Filters
Manual dampers
Motorized dampers
Backdraft dampers
Ducting
Flexible connections
Insulation
Differential temperature controllers
Temperature sensors
Temperature switches
Two-stage thermostats
Time delay relays
Pump/fan starter boxes
Air flowmeters (anemometers)
Pressure gauges (manometers)
Thermometers
Btu meters
A companion volume to this design manual, the Installation, Operation,

and Malntenance Procedures and Maintenance (IOM) Manual, i s a compilation of industry recom-
mended practices and procedures for installation, operation and mainte-
nance of solar energy systems. This IOM Manual should be referenced
for the preparation of the system !OM procedures. These procedures
are intended to save time and costs during construction and to ensure
more reliable, efficient operations. A summary of the system IOM proce-
dures is discussed as follows.
lnstaflatlon The installation section describes preconstruction activities such as site

survey, permits, material ordering and change control; installation proce-
dures; and checkout, startup, and acceptance tests to confirm and record
that the system was built to specification.
A sample Installation Checkout Procedure, included in this design

manual as Appendix 4A, is intended as general checkout procedure that
is applicable to any of the solar energy systems discussed in this man-
ual.
The A/E should review Appendix 4A, select only those actions pertinent
to the specific system, and prepare a complete installation checkout
procedure for the construction package. The A/€ should, at this time,
make a final review of the system's instrumentation to assure all control
and monitoring components required for system checkout were included
in the design.
Solar Design Manual

Section 4 - Design and Construction Package ConstructionPackage- Page 4-7
I
Operation The operation section describes typical operating procedures (startup,
steady-state, shutdown) for active solar energy systems designed with
this manual. A complete procedure for the construction package should
be prepared by the NE for each specific system for operating procedures
such as normal startup, shutdown and emergency shutdown. Specific
valve numbers and component identificationsshould be used. Mode
matrix tables should be used as applicable to describe the operation of
controls. Emergency procedures should specify specific shutdown and
recovery steps to be followed by system operators.
Maintenance The maintenance section describes typical maintenance procedures to

assure reliable operation of solar energy systems. This section provides
tmubleshooting procedures and solutions related to typical solar energy
system problems and includes pertinent literature from manufacturers of
components used in the system.
The NE should prepare a complete checklist for the constwction pack-

age for periodic maintenance of the specific solar energy system, using
checklists (such as Appendix 4A) and manufacturer's recommendations.
(The construction contractor should provide the specific manufacturer's
data sheets for the components actually used in the system.)
4.3.5 Component Speciflca- Sample component specification worksheets for liquid collector systems
tion Worksheets (Liquid Cob are illustrated on the pages that follow.
lector Systems)
/
4.3.6 Component Speclflca- Sample component specification worksheets for air collector systems are
tion Worksheets (Air Collector illustrated on the pages starting with page 4-48.
Systems)
Solar Design Manual

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Section 4 Design and Construction Puckage Specification W o r k s h e e t s o- Page 4-6
F
SPECIFICATION WORKSHEET
Flat Plate Liquid Collectors

Designer Owner Date
Project Page 1 of 4
Item
General Data
Applicatian: (La, DHW heating, space heating, etc.)
Fluid Type:
System Type: (La,

draindown, recirculation, etc.)
Quantity:
Nominal Size: is.,4 x 8 ft, 4 x 10 ft (12i9 x 2438 mm,

1219 x 3048 mm)
Gross Area:
Net Area:
Filled Weight: (Max., based on structural estimates)
Wind Loading Capability:
Design Life:
Warranty:
Absorber Plate
Material:
Flow Pattern: (i.e., series, parallel)
Manifold: (i-e., internal or external size)
Maximum Operating Pressure:
Coating Type:
Absorptivity: (Min.)
Ernissivity: (Max.)
ExpansionCapability: (fixed or floating within frame)
Degradation:
-- - - -
Solar Design Manual

Designer Owner Date
Project Page 2 of 4
Item Requirement
Cover Glazlng
Glazing Material:
Glazing Fasteners: (easy field replacements)
Number of Covers:
Impact Resistance:
Collector Caslng
Casing Fastener:
Frame Material:
Weep Hole Locations:
Finish:
Inlet/Outlet Connection Locations:
Mounting Method: (integral flange, etc.)
Cover Gaskets and Outlet Grommets
Temperature Limits: (operation)
Temperature Limits: (installation)
Insulation
Material and Type:
Back Thickness:
Side Thickness:
R-Value for Back:
Solar Design Manual

Project Page 3 of 4
Requirement
Fluids and Flows
Fluid Type:
Operating Temperature Range:
FIow Rate Range:
Allowable Pressure Drop at Design Fbw Rate:
ASHRAE PerformanceTest Data
F,(m): (Min.)
F,U,: Max.)
Test Fluid:
Test FIow Rate:
Incident Angle Modifiers:
Certifications:
SRCC Approvals:
Solar Design Manual

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Section 4 Design and Construction Package
L
.Specification Wotkdteets(L/C)- Page 4-1 I
SPECIFICATIDN WORKSHEET
Designer Owner Date
Project Page 4 of 4
/
Item Requirement
Mounting Requirements
installation Orientation: (vertical or horizontal)
Drainability Requirement:
Maximum Collector-to-Callector Lateral Space:
Manufacturer'sTypelModel (or equivalent)
Solar Design Manual

Evacuated Tube Collectors
Designer Owner Date
Project Page 1 of 3
Requirement
General Data
Application: (i.e., DHW heating, space heating, etc.)
Type: (i.e.. liquid evacuated tube)

(See Appendix 3A for several ETC designs)
System Type: (i.e., draindown, recirculation, etc.)
Quantity:
Nominal Size:
Gross Area:
Net Area:
Number of Tubes/Module:
Centerline Distance Between Tubes:
Reflector Type:
Tube Type: (Dewar, fin-in-tube, heat pipe, flow through)
Tube Length:
Tube Diameter:
Filled Weight: (based on structural design estimates)
Design Life:
Warranty:
Absorber
Solar Absorptance: (Min.)
Infrared Emittance: (Max.)
Solar Design Manual

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Section 4 Design and Construction Package Specification Worksheets(L/C)- Page 4-13
SPEClFlCATlON WORKSHEET
Evacuated Tube Collectors

Designer Owner Date
Project Page 2 of 3
Requirement
Tube(@
(For Dewar-type tubes, describe both inner and
outer tubes separately)
Glass Type:
Transmittance at Normal Incidence:
U.V. Stability:
Impact Resistance:
Gaskets and Seals
Temperature Limits: (polymer types)
Fluids and Flows
Fluid Type:
Flow Rate Range:
Allowable Pressure Drop: (at flow)
Flow Passage Material:
Flow Pattern: (i.e., series or parallel)
Reflector Description: (if applicable)
ASHRAE PerformanceTest Data
F,(m) : (Min.)
F,U,: (Max., a + b AT; a, b obtained from tests)
Incident Angle Modifiers: (perpendicular and parallel

to tube axis)
SRCC Certifications:
Solar Design Manual

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Section 4 Deskn and ConstmctionPackape Specification Worksheets(WC)- Page 4-14
\
Evacuated Tube Cotlectors
I Designer
Project
Owner Date
Page 3 of 3
Requirement
'InstallationOrientation: e.g., north-south, east-west)
Mounting Options: (e.g., slope angle, horizontal, vertical)
Drainability:
Space Requirements:
Manufacturer's TypeModel (or equlvrlent)
Solar Design Manual

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L
Specification Worksheets(LIC)- Page 4-15
Heat Exchangers
Designer Owner Date
Project Page 1 of 2
Item Requ'lrement
pplication: (i.e., liquid-to-liquid, liquid-to-air, etc.)
ype: (i.e., shell and tube, mukiplate, etc.)
lumber of Units:
Iverall Envelope:
,imitations:
:ode Requirements:
Zonnection Sizes and Types: i.e., 2-in. (51 mm) flanged
System Interface Material: (i.e., copper tubing, etc.)
Service Life: (casing materials)
Mounting Requirements: (i.e., floor, wall, etc.)
Cleaning Requirements:
Number of Walls: (i.e., single wall, double wall, etc.)
Venting: (for double-wall designs)
Operating Effectiveness: (nominal conditions)
Hot Side Cold Side
Fluid Type:
Fluid pH:
Dissolved Solids:
Nominal Met Temperature:
Nominal Outlet Temperature:
Minimum Operating Temperature:
Nominal Flow Rate:
Energy Transfer Rate:
Solar Design Manual

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Section 4 Design and Construction Package Specification Worksheets(L/C)- Page 4-1c
f
I
Heat Exchangers
Designer Owner Date
Project Page 2 of 2
Requirement
Hot Side Cold Side
Face Velocity: (for liquid-to-air systems only)

Specific Heat:
Specific Gravity of Fluid:
Thermal Conductivity of Fluid:
Viscosity of Fluid at Min. Temperature:
Viscosity of Fluid at Operating Temperature:
Maximum Allowable Pressure:
Operating Pressure:
Maximum Allowable Pressure Drops at Nominal Flow Rate:
Fouling Factor:
Warranty:
Manufacturer's TypelModel: (or equivalent)
Solar Design Manual

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Section 4 Design and Construction Package Specifrution Worksheets(LIC)- Page 4-1 7
Heat Transfer Fluids

Designer Owner Date
Project Page.tof1
~tem Requirement
Application:
Type: (i.e., glycol, water, etc.)
Operating Temperature Range: 1

Mixture Ratio: 1
Maximum Viscosity
Minimum Viscosity
Toxicity Rating:
a '
Vapor Pressure: (at max. temperature)
Maintenance Requirements:
Available Container Sizes:
Material Compatibility:
Special Additives:
GuaranteeNVarranty:
Manufacturer's Type/Model: (or equivalent)
Comrnents/Remarks:
Solar Design Manual

Pumps
Designer , Owner Date
Project Page 1 of 2
/
Item Requirement 1
Application:
Pump Type:
Pumped Fluid:
Pumping Temperature Range:
Fluid Specific Gravity @ Temperature:
Fluid Viscosity @ Temperature:
Design Flow:
Developed Head:
Shutoff:
Design Flow:
Loop Max. Operating Pressure:
Available NPSH:
Pump Speed:
Pump Seals Compatibility with Fluid:
Mator Impeller Connection:
System Connection Sizes and Types:
Mounting Orientation:
Pump Support Requirements:
Available Electrical Service (V, 1, 0, Hz)
Pump Code Requirements:
Pump Material:
Pump Operating Environment:

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Section 4 Design and Construction Package Specification Worksheets(L/C)-Page 4-19
SPECIFlCAT1ON WORKSHEET
Pumps
Designer Owner Date
Project Page 2 of 2
Item Requirement
Ambient Temperature:
Motor Code Requirements:
Space Requirements:
Drainback Operation Capability: (if applicable)

(Note: For some drainback systems, fluid must be
able to flow backward through pump.)
Warranty:
Manufacturer's TypeIMadel: (or equivalent)
Solar Design Manual

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Section 4 Design and Conshuction Package Specification Worksheets(L/C)- Page 4-2
h
SPECIFCATION WORKSHEET
Pump Starter Boxes

I
Designer Owner Date
Project Page 1 of 1
Item Requirement \
Application:
Input Signal(s):
If Multiple (OR, AND):
Output Power: (volt and amp)
Manual Switch Position:
Operating Environment:
Code/Agancy Approval:
Warranty:
Manufacturer's Type/Model (or equivalent)
Solar Design Manual

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Section 4 Design and Construction Pockage Specification Worksheets(L/C)- Page 4-21
Expansion Tanks
Designer Owner Date
I
Project Page 1 of 1
Requirement
Application:
Type: (bladder or free surface)
Bladder replaceablehonreplaceable:
Total Volume:
Type of Fluid:
Fluid Expansion: (over temperature range)
Overall Envelope Limits:
Connection Type and Size:
Warranty:
Solar Design Manual

Item Requirement
Application:
Volume:
Dimensions: (refer to tank drawing)
Material:
Code Requirements:
Maximum Allowable Temperature:
Mounting Supports:
Connection Types and Sizes:
Connection Locations:
Manhole:
Baffles:
Lining:
Corrosion Protection:
Level Gage Requirements:
Solar Design Manual

1 Thermal Storage Tanks 1

/ Designer Owner Date
I
Project P a g e 2 o f 2
Insulation Requirements: (ifactory installed)
Warranty:
Auxiliary Heating Type:
Warranty:
Manufacturer'sTypelModel: (or equivalent)
Comrnents/Rematks:
Solar Design Manual

Requirement
.Application:
Minimurn/Maximum Temperature Range:
Fluid Compatibility:
Fluid Velocity: (Maximum)
Material:
Size and Type or Schedule:
ASTM Specification Requirements:
Dissimilar Material Connections:
Manufacturer'sTypefModel: (or equivalent)

Item Requlrement
Application:
Valve Type: (ball, gate, globe)
End Connections: (type and size)
Material:
Pressure Rating:
Code Requirement:
Working Temperature Range: (minimum to maximum)
Working Pressure Range: (minimum to maximum)
Fluid:
Maintenance Requirements: (i.e., ease of changeout)
Space Requirements:
Maximum Allowable Pressure Drop at Design Fbw:
Actuator Assembly: (power or manual)
Actuator Service lnput Requirements:

(pneumatic - psi or electric - voltage)
lnput Signal:
Position Indicator:
Insulation Requirements:
Warranty:
Commentsf Remarks:
Pressure Relief Valves
Application:
End Connections:
Material:
Set Pressure Limit: (setting)
Working Pressure:
Code Requirements:
Steam Rating or Relief Capacity:
Minimum/Maximum Working Temperature:
Lifting Lever:
Set Pressure Adjustability:
Warranty:
Manufacturer's TypeModel: (or equivalent)
Solar Design Manual

Application:
End Connections:
Material:
Sat Pressure:
Working Pressure:
Set Temperature:
Code Requirements:
Fluid:
Steam Rating or Relief Capacity:
Minimum Temperature Element Length:
Lift Lever:
ltem Requirement
Application:
End Connections:
Material:
Maximum Working Pressure:
Reduced Pressure Adjustable Range:
Code Requirements:
Fluid:
Space Requirements:
Mounting Requirements:
Warranty:
Manufacturer's TypeModei: (or equivalent)
Solar Design Manual

Backflow Preventers
Designer Owner Date
Project Page A o f . 1 .
Item Reauirement
Application:
End Connections:
Material:
Minirnum/Maximum Working Temperature:
Code Requirements:
Relief Requirements:
Detection Requirements:
Warranty:
Manufacturer'sTypeModel: (or equivalent)
CommentslRemarks:
Solar Design Manual

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Section 4 Design and Constmclion Package Specmation Worksheets(L/C)-Page 4#
Check Valves
Designer Owner Date
Project Page 1 of 1
Item Requirement
Application:
Type: (i.e.. spring-loaded or swing check)
End Connections: (type and size)
Material:
Pressure Rating:
Code Requirements:
Minimurn/Maximurn Temperature:
Minirnum/Maxirnurn Pressure:
Minimum/Maxirnum Pressure Differential

(i.6.. across flapper/plug):
Required Opening Pressure:
Warranty:
Solar Design Manual

$&on -
4 Design and Construction Package Specificatbn Worksheets(WC)- Page 4-31
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SPECiFlCATlON WORKSHEET
1 Automatic Flow Control Valves I
Designer Owner Date
Project Page 1 of 1
Item Requirement
Application:
Design Flow Rate: (and range of control)
Size and Type of End Fitting:
Fluid Viscosity:
Specific Gravity:
Temperature:
Accessories: (pressure taps, PIT taps, etc.
Minimum/Maximum Operating Temperature:
Warranty:
Solar Design Manual

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Section 4 Design and Consimction Package Specificution Worksheets(L/C)-Page 4..
Flow Balancing Valves

I Designer Owner Date
Page 1 of 1
Item Requirement
Application:
Size and Type of End Fbings:
Material Cornpatibility:
Range of Control: (Min. to Max. %)
Shutoff Capability:
Accessories: (i.8.. P K plugs to read AP)
Memory Set:(i.e., capable to set balance point and

return to that point after valve is used for shutoff)
Operating Temperature and Pressure:
Warranty:
Solar Design Manual

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section 4 Design and Construction Package
Irr
- - -
Specification Worksheets(WC)- Page 4-33
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Air Separator Valve

Designer Owner Date
Project Page 1 of 1 1
ltem
Application:
Size and Type of End Connections:
Vent Connection Size and Type:
Warranty:
Manufacturer'sTypeModet: (or equivalent)
Solar Design Manual

?$
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Section 4 Design and Construction Package Specflcatimt Worksheets(L1C)- Page 4-34
Air Vent
I .
Item Requirement
Application:
Type: (i.e., automatic, float, and manual, etc.)
Minimum/Maximum Operating Pressure:
Minimum/Maximum Temperature Range:
Size and Type of End Connection:
Environmental Conditions: (i-e.,freezing, dirt, rain, etc.)
Warranty:

f SPECIFICATION WORKSHEET
Tempertng Valve
Designer Owner Date
Project Page 1 of 1
Application:
End Connections:
Operating Pressure:
Output Temperature Adjustment Range:
Code Requirements:
Output Temperature Indicator:
Response Time:
Warranty:
Manufacturer's TypeNodel: (or equivalent)
Solar Design Manual

ltem Requirement
Application:
Material: (body and gasket)
Connection Size and Type:
MinimumlMaximum Operating Temperature:
Test Probe Diameter Requirements:
Manufacturer's TypefModel: (or equivalent)

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Section 4 Design and Consmtction Package Specification Worksheets(LIC)-Page 4-37
\
>
Flex Couplings
Designer Owner Date
Project Page 1 of 1
Item
Application: (torsion, lateral, sound)
Material:
Compatibility:
Connection Size and Type:
Geometry:
Nominal Length:
Maximum Expansion:
Maximum Contraction:
Minirnum/Maximum Temperature:
Insulation Requirements:
Cycles to Failure:
Warranty:
Solar Design Manual

Insulation
Item Requirement
Application:
Type:
Material:
Thermal Conductivity:
Ozone Resistance:
U.V. Resistance:
Odor/Outgassing:
Flame and Smoke Characteristics:
Code Requirements:
Weat herproofing/Jacketing:
Water Absorption:
Mildew Resistance:
Wall Thickness: (i-e., overall R-value requirement)
Warranty:
Manufacturer's Ty pe/Model: (or equivalent)
Solar D a s i ~ nManual
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C
Specification Worksheets(L/C)- Page 4-39
Differential Temperature Controller
Designer Owner Date
Project Page 1 of 1
[tern Requirement
Application:
Number of Outputs:
Sensor Type
On/Off Thresholds/Range:
Storage High Temperature Shutoff:
Freeze Protection:
Operating Environment:
Input Power:
Output Relay Capacity: (Volt, amp)
Power Backup:
Set Point Adjustability:
Control Accuracy:
Display Capability:
ManuaVAuto Capability:
Mounting Dimensions:
UL Requirements:
Warranty:
Manufacturer's TypeModel (or equivalent)
Solar Design Manuel

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Section 4 Design and Construction Package Specification Worksheets(LIC)-Page 4
Temperature Sensor
Designer Owner Date
Project Page hf1
Item Requirement
Application:
Type: (thermister, RTD, IC)
ResistanceflemperatureCharacteristics:
Accuracy:
Leads:
Casing Material:
Interchangeability:
Matching:
Attachment:
Response Time:
Warranty:

~amncrratureSwitches I
Requirement 1
Application:
Type: (NC, NO, DP,ST, DT)
Temperature Set Point Range:
Switch Contact Rating:
Number of Contacts:
Construction:
Warranty:
CommentslRemarks:
Speci~cntimWorksheets(L/C)-P
Flowmeters
Item
Application:
Type:
Minimum/MaximumTemperature:
Flow Rate Range:
Fluid Specific Gravlty:
Fluid Viscosity:
Readout Requirements: (mechanical, electrical)
End Connection Types and Sizes:
Accuracy:
Warranty:
Mounting Requirements: (vertical pipe, horizontal pipe)
Maximum Allowable Pressure Drop:
Drainability: (Note: In drainback systems, the flowmeter

may have to run backward during draining.)
Warranty:
Solar Design Manual

Application:
Type:
Operating Pressure:
End Connections: (size and type)
Visibility Requirements: (i.8.. color of fluid,

closeup or distant observation) k
Flow lndication Range:
Reversible Flow Capability:
Flow lndication Accuracy:
Warranty:
Manufacturer'sTypeModel: (or equivalent)
Cornments/Remarks:
Solar Design Manual

-
Section 4 Design and Construction Package Specifration Worksheefs(L/C)-Page 4-44:!
"1
Pressure Gauges
Designer Owner Date
Project Page 1 of 1
item
Application:
Pressure Range: (max.)
Operating Pressure Range:
Operating Temperature Rang
Dial Size:
Pressure Indication Range:
Accuracy:
lndication Increment:
Warranty:
Manufacturer's TypeIModel: (or equivalent)
Solar Design Manual

Thermometers
Designer Owner Date
Project Page 1 of 1
Requirement
Application:
Type:
Temperature Indication Range:
Dry Well or Immersion:
Size of Readout:
Accuracy:
Stem Length:
Warranty:
Manufacturer's Type/Model: [or equivalent)
Solar Design Manual

SPECiFlCATlON WORKSHEET 7
Btu Meters
Item Requirement
Application:
Type:
Average Continuous Flow:
Peak Flaw:
Minimum Flow:
Temperature Sensor Type:
Temperature Sensor Matching:
Temperature Sensor Attachment:
Flowmeter Type:
Flowmeter Connection Sizes and Types:
Maximum Allowable Pressure Drop A~ross~Flowmeter:
Integrator Readout Requirements:
Fluid:
Fluid Specific Gravity:
Fluid Specific Heat:
Sensor (Temp and Flow) Mounting Requirements:
Input Power Requirement:
Warranty:
-
.~cction4 Desian and Construction Package Specification Worksheets(L/C)- Page 4-47
Btu Meters
Designer Owner Date
I Project Page 2 of 2 I
Item Requfrement
Site Adjustment Capability:
Tamper Resistance:
Power Backup:
Environmental Conditions of Integration:
Solar Design Manual

Type: (i.e., flat plate air)
System Type:
Quantity:
Nominal Size: i.e., 4 x 8 ft, 4 x 10 ft (1219 x 2438 mm,

1218 x 3 M 2 mm)
Gross Area:
Net Area:
Weight: (based on structural design estimates)
Design Lie:
Warranty:
Absorber Plate
Material:
Coating:
Absorptivity:
Emissivity:
Outgassing:
Degradation:
-
C
Specifcah'on Worksheets(A/C)- Page 4-49
--.
Flat Plate Air Collectors

Owner Date
Project Page 2 of 3
Item Requirement
Cover Glazing
Glazing Material:
Glazing Fasteners: (easy field replacements)
Number of Covers:
Impact Resistance:
Collector Casing
Casing Fastener:
Frame Material:
Weep Hole Locations:
Finish:
InletIOutlet Connection Locations:
Mounting Method: (integral flange, etc.)
Cover Gaskets and Outlet Grommets
U.V. Resistability:
Temperature Limits: (operation)
Temperature Limits: (installation)
insulation
Type:
Back Thickness:
Side Thickness:
R-Value:
Outgassing:
Solar Design Manual

-
Section 4 Design and Construction Package Specificatioion Worksheets(A/C)- Page .44
*:
Flat Plate ATr Collectors

Designer Owner Date
Project Page 3 of 3
/
item Requirement
Fluids and Flows
Flow Rate:
Allowable Pressure Drop:
flow Passage: (e.g., front and/or back of absorber)
Performance Testing
F,(.rot):
F,U,:
Incident Angle Modifiers:
Certifications:
Code Approvals:
Installation Orientation: (i.e., horizontal risers, etc.)
Space Requirements:
Wind loading: (of manufacturer-supplied hardware)
Manufacturer'sTypeModel (or equivalent)
Solar Design Manual

Heat Exchangers
Hot Side Cold Slde
Viscosity:
Operating Pressure:
Maximum Allowable Pressure Drop:
Fouling Factor:
Operating Effectiveness:
Warranty:

Application:
Type:
Air Flow Rate at 70°F (21OC):
Design Discharge Head:
End Connection Size and Types:
lmpeller Type: (e.g ",f omard curved)
Drive Type: (e.g., direct, V-belt) I
Motor Location: (induct, external)
Ambient Condition For Motor:
Motor Code Requirement:
Power Requirements:
Space Requirements:
Efficiency:
Support Requirements:
Warranty:
CornmentsJRemarks:
Solar Design Manual

-
Section 4 Design and Construction Package Specifcuttion Worksheets(A/C)- Page
f SPECIFICATION WORKSHEET
Filters
Item Requirement
Application:
Type:
Face Velocity:
Minimum Efficiency:
Filter Enclosure Dimensions:
Warranty:

Item
Application:
Duct Size:
Blade Edge Seals:
Number of Blades:
Multiblade Operation: (parallel, opposed)
Minimurn/Maximum Operating Temperature:
Maximum Operating Pressure: (or differential pressure)
Mounting Requirements: (end fitting type and size)
Type of Manual Lock:
Design Flow Rate:
Pressure Drop at Design Flow Rate: (fully open)
Warranty:
Manufacturer's TypeModel: (or equivalent)
Solar Design Manual

Motorized Dampers
Item
Application:
Duct Site:
Blade Edge Seals:
Number of Blades:
Muhiblade Operation: (parallel, opposed)
Minimurn/Maximum Operating Temperature:
Maximum Operating Pressure: (or differential pressure)
Design Flow Rate:
Pressure Drop When Open at Design Flow:
Type of Operator:
Operator Power:
Damper Return Power: (spring, weight)
Code Requirements:
Warranty:
Manufacturer'sType/Model: (or equivalent)
Solar Design Manual

Item
Application:
Duct Size:
Blade Edge Seals:
Number of Blades:
Multiblade Operation: (parallel, opposed)
Maximum Operating Differential Pressure:
Design Flow Rate:
Pressure Orop at Design Flow Rate: (fully open)
Warranty :
Manufacturer'sType/Model (or equivalent)
CommentslRemarks:
Application:
Material Requirements:
Size Requirements:
Code Requirements:
Insulation: (if integral)
-
Solar Design Manual
SECTION 2: VISUAL INSPECTION CHECKLISTS
GENERAL ADMINISTRATIVE
Yes/No
Operation and Maintenance Manual is available on site. -/-
As-built drawings are available on site. --
I
Manufacturer's lierature on major components is available on site. --

I
The installationcheckout procedure is complete and is available on

site. --
1
All required building permits are available on site. --

/
Items Requlring AttentlonlComments:
Initial: Date:
COLLECTORS
Type of collectors is as specified ( >-

Number of collectors is as specified ( rows, collectors per row,
"totat).
Location of collectors is as specified ( axis orientation,

ft spacing between collector rows).
Orientation of coliectors: Specified ( ).
Measured:
Collector magnetic orientation: O
Site magnetic deviation: O W
Collector deviation from true south: O W
Solar Design Manual

Collector tilt from horizontal: Specified ( 1
Solar collectors have an unobstructed view in a southerly direction
between 9:00 a.m. and 3:00 p.m.
There is safe and easy access to collectors, gutters, downspouts,

flashing, and caulked joints to allow minor repairs and preventive
maintenance.
Leakage from collectors is evident.
Leakage from connections between collectors is evident.
Coifectors are sloped for draining in accordance with the installation

drawing.
Glazings and absorber plates are free of dirt and degradation.

Collectors are not damaged.
Collectors are free of outgassing or condensation.
Items Requlrlng AttentlonlComments:
Initial: Date:
Solar Design Manual

BuNQ
3.1 Identification
All piping lines and components are installed in the locations specified by the system
schematic and are clearly identified and labeled with name or identlication number
from system schematic, appropriate flow direction, fillweight, pressure, temperature,
and other information useful for servicing or routine maintenance. -- I
A copy of the system schematic should be marked up during the pipewalk to confirm
proper component location. Major component identificationsshould be confirmed by
recording the manufacturer and model number of each installed component in Table
4A-1 and comparing with the construction package.
Table 4A-1. Major Component ldentiflcatlon

--
Component
Designation Name ManufactuterlModelNo.
C-1 Solar coHectors (40)
T-I Solar storage tank; 1150 gallon

(4359 L)
T-2 Drainback tank; 120 gallon

(455L)
HX Solar loop-to-solar storage

loop heat exchanger
P-1 Solar loop pump
P-2 Solar storage loop pump
DTC Differentialcontroller
A1 Aquastat
Btu HX to storage
meter4
Btu Storage to load

meter-2
Solar Design Man unl

MECHANICAL (Continued)
.bsu!Q
Liquid Systems
Components are set, aligned, and bolted down in accordance with

installation drawings. --
/
Adequate space is available around components for operation,

maintenance, inspection, and servicing. , --
/
Piping runs are routed and sloped in accordance with installation

drawings. --
I
Piping and components can be completely filled and drained. --

I
Piping runs provide for thermal expansion. --

/
Piping is supported in accordance with installation drawings. --

I
Piping connections are tight, and no leakage is evident (must be

checked before insulation is installed, see 3.2.16). --
I
Corrosion protection has been applied in accordance with drawings
and specifications (i.e., dielectric unions have been installed between
dissimilar metals). --
/
Check valves have been installed with proper flow direction

and orientation. -1-
Valves are of correct type and have been installed with proper flow
direction and with handles horizontal or above. --
/
Three-way valves are piped properly. --

I
Caps are loosened on automatic vent valves. -I-

Drain valves have been installed at low points and are accessible. --
I
Air vent valves have been provided at high points in the system so
that air can be removed from the liquid circulation loop during both
filling and normal operation. --
I
Suitable connections have been supplied for filling, flushing, and

draining both the collector loop and the other water piping of the system. /
Piping has been successfully leak tested (prior to installation of

insulation) to 1 112 times system design pressure or as otherwise
specified for at least 2 hours at constant temperature (with
collectors covered). --
/
Solar Design Manual

-
Section 4 Design and Construction Pockage Appendix #A- Page 4A-9
3. MECHANICAL (Continued)
3.2 Liquid Systems (Continued)
3.2.17 Tanks are installed with adequate access to nozzles, gauge glasses,
and instruments.
3.2.18 Tank supports have been thermally isolated from the tank.
3.2.19 Tanks have been mounted in accordance with installation drawings,

and inlet and outlet connections are in accordance with installation
drawings.
3.2.20 Heat exchanger has been mounted in accordance with installation

drawings, and inlet and outlet piping has been correctly plumbed.
Pumps have been plumbed in proper direction.
Pump-to-motor coupling is properly aligned.
Water treatment is installed and placed in service for heating water

systems, and sofar collection systems.
Piping and components are insulated and weather protected;

insulation jacketing is lapped to shed water, all joints are sealed,
and insulation is undamaged.
All exposed insulation is protected from weather damage. . --

/
Insulation is continuous through sleeves or openings in walls and floors. /
Pipe hangers, supports, and expansion devices are installed in

accordance with installationdrawings. --
/
In ground-mounted systems, insulated pipes to and from collectors

are buried below the frost lines. --
1
Air Systems
Rocks are uniformly distributed in the pebble bed. --

/
Rock bed rocks have been thoroughly washed. --

/
Condensation is not evident in rock box. --

/
Insulation in rock box is not damaged. --

/
Ducting runs provide for thermal expansion. -/-

Dudim is supported in accordance with installation drawings. Hangers
and anchors are secured. -I-
- Solar Design Manual

MECHANICAL (Continued)
Air Systems (Continued)
Ducting connections are tight, and no leakage is evident.
Ducting and components are insulated and weather protected.

Insulation jacketing is lapped to shed water, and all joints are sealed.
No damage is evident.
Dampers do not show signs of excessive leakage or degradation.
Automatic dampers have proper flow direction and freedom of

movement.
Dampers are of correct type and have been properly located.
Fans run smoothly and quietly; flow is in proper direction.
Items Requiring AttentlonlComments:
Initial: Date:
Solar Design Manual

-
Section 4 Design and Conshuction Package Appendix 4A - Page #A-I1
STRUCTURAL AND CIVIL
Structural materials and sizes are as specified in the installation

drawings.
Structural assembly bob are secured in accordance with installation

drawingslspecific;ations.
Structural welds are in accordance with installation drawings1

specifications.
Structural members are painted in accordance with installation

drawings/specifications. --
/
Collector support structure is attached to the building in accordance with

installation drawings/specifications.
Collectors and their supwrt structure are grounded for lightning
protection in accordance with installation drawings/specifications.
Concrete pads and paved work areas are sloped to drain.
Areas required to be paved are paved to thickness.
Excavated areas are backfilled and compacted in accordance with

installation drawings/specifications.
Base plates are level, bolted, and grouted.
Roof and wall penetrations are flashed and sealed in accordance with
installationdrawings/specifications. No leakage is evident.
Floor drains are installed where specified.
Items RequirlngAttention/Comments:
Initial: Date:
Solar Design Manual

-
- - -
Appendix 4A- Page 4A-12
?
:
ELECTRICAL
Electrical equipment is tagged and identified.
Electrical connections are securely fastened.
Controllers are grounded with protected power outlets for the system
controls.
Instrumentation and control wiring is shielded and grounded.
Power wiring is in conduits.
Control circuit wiring has been color coded or otherwise labeled so that
wires are readily traceable.
Utility power outlets are readily available and identified.
Emergency and auxiliary power requirements are as specified, and

systems are operational. Batteries are charged.
Power source corresponds with motor ratings.
Items Requiring AttentionlComments:
Initial: Date:
Cninr Dmim Manual

-
Section 4 Design and Construction Package Appendix #A- Page 4A-13
INSTRUMENTATIONAND CONTROLS
w
instrumentation and control sensors are as specified in installation
drawings (make and model) and are properly tagged. --
/
Control and instrumentation sensors are installed and located in

accordance with installation drawings and are accessible for repair
or replacement (see Table 4A-2 and 4A-3). --
I
Instrumentation and control sensor wiring is separate from power

wiring. -/-
Outdoor instrumentation and control sensor wiring and connections are -
weatherproofed. 1-
All instrumentation has been calibrated. --

I
Data acquisition system (DAS) output parameters agree with actual
measured system parameters (i.e., DAS temperature and pressure
readings match thermometer and pressure gauge measurements,
all zero offsets are incorporated in the DAS). --
/
Flowmeters are in their correct location and orientation. --

/
Btu meter components are installed in accordance with installation

drawings. --
/
Sensor lines are not kinked or damaged. --

I
Thermometers (in thermawells) and pressure gauges are in place in
accordance with installation drawings. --
1
PTT fittings (Pete's plugs) are in place in accordance with installation

drawings. --
I
Thermal shock sensors have been iocated in each isolatable row of

evacuated tube collectors. --
I
The collector temperature sensor is located in a collector or near outlet

from collector array. --
/
Items Requiring Attention/Comments:
Initial: Date:
Solar Design Manual

Table 4A-2. Sensor Locatlans
(Refer to Schematic)
Sensor Sensor Type Location Yes/No
Thermistor Solar collector absorber plate on row 3
Thermistor Bottom of solar storage tank
Thermistor Top of storage tank
Thermistor Heat exchanger outlet - storage loop
Thermistor Bottom of drainback tank
Thermistor -
Heat exchanger outlet collector loop
Aquastat tem- Drainback tank

perature switch
NO flow switch Collector loop piping
NO flow switch Storage loop piping
Temperature Storage loop

sensors, fiowrneter
Temperature Storage to load loop

sensors, flowmeter
Table 4A-3. Thermistor Connections to

Differential Temperature Controller
Sensor Location at Controller
S1 Collector
Storage
Aux 1
S4 Aux 2
S5 Aux 3
S6 Aux 4
Solar Design Manual

Section 4 - Design and ConstructionPackage Appendix 4A-Page 4A-15
7. HEAT TRANSFER FLUID (Propylene glycol systems)
YsLM
7.1 If a system containing propylene glycol is used, threaded joints have
been sealed with tightly drawn TeflonRtape. --
/
7.2 If a system using propylene glycol is used, a manual fili valve and a drain
(for sampling) have been provided in the collector loop. -/-
7.3 Automatic filling apparatus is not used on propylene glycol loops. --
/
7.4 If a system using propylene glycol is used, relief valve discharges are
directed into an unpressurized container. --
1
Items Requiring Attention/Comments:
Initial: Date:
Solar Design M ~ n ~ a l
-
Section 4 Design and ConstructionPackage Appendix 4A- Page 4A-I 6
SAFETY
All surfaces with temperatures at 120°F (49%) or higher are labeled

and isolated from pedestrian traffic in order to prevent burns.
Relief valve discharging piping is directed safely away from operating

areas and personnel and is adequately secured for the relief
forces involved.
When glycol is used in the system, fluids overflow or discharge into

storage. The end of the pipe draining the glycol is cut at an angle to
prevent any type of hose hookups.
If supplied water pressure is in excess of working pressure rating of

any system components, an approved pressure regulator has been
installed, preceded by a strainer.
A backflow preventer is installed at cold water supply inlet.
A double-walled heat exchanger is installed in the system, or another

approved method is used for separating nonpotable heat transfer fluids
from potable water. --
1
All outlets and faucets on the nonpotable water lines of the system have
been marked "DANGER -WATER NOT DRINKABLE or "GLYCOL"
when glycol is used in the system. --
1
Fire protection systems/devices (e.g., dry chemicals) are available and

prominently displayed. --
/
Safety welding glasses are available for personnel in collector area

when the system is in operation. --
/
Lines containing glycol are labeled "TOXIC." --

I
Guards and covers around rotating equipment are installed as required. /
A temperature limiting device (e.g., tempering valve) has been installed

to limit domestic hot water temperature to 130°F (54°C) or less. --
I
High voltage sources are marked with warning labels. --

/
Items Requirlng AttentlonIComments:
Inif ial: Date:

-
Section 4 Design and Construction Package Appendix 4A -Page 4A-17
SECTION 3: PREOPERATIONALTESTING AND

PROCEDURE VERIFICATION
The following items shall be verified prior to operational testing of the system:
System has been flushed until all foreign material has been removed,
and all strainers have been cleaned.
System has been pressure tested (prior to installation of insulation) in

accordance with the installation drawings.
Collector loop has been filled with the heat transfer fluid specified in the
installation drawings.
Type:
Glycol solution has been tested; concentration meets specification.

Concentration / glycol
OO
Entrapped air has been vented from the system.
Collector array has been flow balanced.
Pressure relief valves have been set in accordance with the installation
drawings.
Pumps and moton have been tested for proper operation.
All appropriate components have been lubricated as necessary.
All controller set points have been set.
Motors have been test run uncoupled to check the motor and control
circuitry; correct rotation direction has been verified before connections
were made.
Pumps have been run in accordance with the manufacturer's specific

recommendations.
Tanks are filled to proper levels.
Collectors and collector loop piping drain back properly.
lsolation valves are open or closed, in accordance with installation

drawings.
hems Requiring AttentlonlComments:
Initial: Date:
Solar Design Manual

-
Section 4 Design and Construction Package Appendix 4A- Page #A-1 8
SECTION 4: OPERATIONAL TESTING
The purpose of operationaltesting is to verify that the system performs as designed in all operating modes.
Operational testing consists of two parts: (1) Operational Mode Checkout and (2) Performance Testing.
The operational mode checkout will verify that the system will function under startup, normal operation,
transitional, and shutdown conditkns. The checkout will also verify proper system response in protective1
emergency modes of operation.
Performance testing will quantify system performance and verify individual component performance. These
procedures may be used by the owner at his discretion to estimate system efficiencies.
1. OPERATIONAL MODE CHECKOUT
The intent of the operational mode checkout is to verify that all modes function as designed. Controller
operation and system response shall be tested for the modes listed in Table 4A-4.
This table is specific to a drainback system and must be adapted to each systenl's control matrix, e.g., add
freeze protection mode.
The mode checkout forms that follow describe the tests to be conducted. The startup and shutdown tests
may be made under either actual conditions (system running) or simulated conditions; checkout forms are
provided for both. All data on the mode checkout forms should be recoded in a short period in order to
"freeze" the system at a given time. This will ensure an accurate representation of the system at that time
and a valid interpretation of recorded data.
Deviations from test procedures that might be necessary during the test should be documented in detail in the
comments/concerns section of the mode checkout forms.
Table 4A-4. Operational Mode Matrlx
(Refer to System Schematic)
Operating Mode Pump P-I Pump P-2 Conditions
Normal system startup ON ON
Normal system shutdown OFF OFF
Primary overtemperature OFF OFF

shutdown
Backup overtemperature OFF OFF

shutdown
Solar Design Manual

-
Section 4 Design and Construction Package Appendix 4A- Page 4A-19
OPERATIONAL MODE CHECKOUT
MODE: NORMAL SYSTEM STARTUP
1. MODE DESCRIPTION
The differential controller starts the solar collector loop pump and the solar storage loop pump when the
collector temperature sensor (S1) detects a temperature 20°F (1I0C)greater than that from the bottom solar
storage tank sensor (S2). Pump operation is initiated by closure of a relay inside the differential controller.
2. TEST PROCEDURE: ACTUAL CONDlTlONS
System startup should be observed under actual conditions and requires acceptance test personnel to be
onsite prior to startup. The controller must be set on "automatic" and main power to the controller turned on.
Drainback tank water level must be measured prior to system startup and then after the system is operating if
possible.
3. CHECKOFFIDATA SHEET: ACTUAL CONDITIONS
Controller "power on" indicator light is on,Yes No
Drainback tank level prior to startup, inches
Solar collector loop pump starts, Yes No
Solar storage loop pump starts, Yes No
Controller "Output 1" indicator light is on, Yes No
Time when pumps start,
Number of times pumps cycle ONIOFF,
System continues to operate normally, Yes No
Collector temperature at startup (controller "collector" readout),
Bottom solar storage tank temperature at startup (controller "storage" readout),
Top solar storage tank temperature at startup (controller "Aux 1" readout),
Solar collector inlet temperature at startup (controller "Aux 4" readout),
Solar collector loop drainback tank temperature at startup (controller "Aux 3"
readout),
Solar storage loop heat exchanger outlet temperature at startup

(controller "Aux 2" readout),
Flow switch checkout
Pumps P1 and P2 shut off when one lead from FS1 is

disconnected momentarily, Yes No
Solar Design Manual

-
MODE: NORMAL SYSTEM STARTUP (Continued)
Pumps P I and P2 shut off when one lead from FS2 is

Note: Each step of the flow switch checkout must be conducted after the time delay relay
(OFF after ON) has opened. The differential temperature controller must be shut off mornen-
tarily to restart the system after each step.
Items Requiring AttentiontComments:
Initial: Date:
TEST PROCEDURE: SIMULATED CONDITIONS
Measure drainback tank water level.
Remove "collector" and "storage" sensor wires from the differential

controller. Be certain to identify and tag each wire and terminal before removal.
Attach dual potentiometer leads to controller "collector" and "storage" terminals.
Set "storage" resistance setting to 9.3 kn at 80°F (27OC)or equivalent and "collector" resistance
setting to about 10 kn. Note: This temperature-resistance reading must be obtained from the
I
sensor calibration chart rom the controller manufacturer.)
Decrease "co~lector"resistance setting until pumps start. Note the resistance.
After system has operated 30 min, measure resistances of the "collector"

and "storage" sensor circuits with a dual potentiometer to verify proper sensor operation (i.e., appro-
priate resistance for sensor temperature; a temperature-resistance calibration chart should be ob-
tained from the controller manufacturer).
If possible, measure collector temperature near sensor S1 and the

bottom solar storage tank temperature near sensor S2 using a hand-held temperature probe. Do this
immediately after the potentiometer measurements.
Measure drainback tank water level.
Proceed to simulated shutdown checkout.
Solar Design Manual

-
Section 4 Design and Consbuction Package Appendix 4A- Page 4A-21
MODE: NORMAL SYSTEM STARTUP (Continued)

5. CHECKOFF/DATA SHEET: SIMULATED CONDITIONS
Drainback tank water level prior to system startup, inch (mm).
Drainback tank water level during operation inch (mrn).
Collector resistance setting when pumps start, m;

equivalent temperature; ,should be 100°F (380C)
Resistance of collector sensor circuit S1, kR; equivalent temperature,
Resistance of storage sensor circuit S2. kS2; equivalent temperature,
Measured bottom solar storage tank temperature adjacent to S2,
Flow switch checkout
Pumps P I and P2 shut off when one lead from FS1 is

Pumps ~1 and P2 shut off when one lead from FS2 is

Note: Each step of the flow switch checkout must be conducted after the time delay relay
(OFF after ON) has opened. The differential temperature controller must be shut off momen-
tarily to restart the system after each step.
Solar Design Manual

-
MODE: NORMAL SYSTEM SHUTDOWN
1. MODE DESCRIPTION
The differential controller stops the solar collector loop pump and the solar storage loop pump when the
collector temperature sensor (S1) indicates a temperature 5°F (3°C)or less greater than that from the bottom
solar storage tank sensor (S2). When pumps are off, the water in the collectors and collector loop piping
drains back to the drainback tank.
2. TEST PROCEDURE: ACTUAL CONDITIONS
System shutdown and drainback should be observed under actual conditions. Drainback tank level should be
measured after sufficient time has elapsed to ensure complete drainback; note elapsed time from pumps stop
to completion of drainback.
3. CHECKOFFIDATA SHEET: ACTUAL CONDITIONS
Solar collector loop pump stops, Yes No
Solar storage loop pump stops, Yes No
Controller "Output 1" indicator light is on, Yes No
Time when pumps stop,
Collector temperature at shutdown (controller "collector" readout),
Bottom solar storage tank temperature at shutdown (controller "storage" readout),
Top solar storage tank temperature at shutdown (controller "Aux 1" readout),
Solar collector inlet temperature at shutdown (controller "Aux 4" readout),
Solar loop drainback tank temperature at shutdown (controller "Aux 3" readout),
Solar storage loop heat exchanger outlet temperature at shutdown

(controller "Aux 2" readout),
Drainback tank level after shutdown, inch (mm).
Approximate elapsed time to completely drain collectors and collector

loop piping, minutes.
Solar Design Manual

-
Section 4 Design and Construction Package Appendix 4A- Page #A-23
MODE: NORMAL SYSTEM SHUTDOWN (Continued)
Flow switch checkout after pumps stop:
Open circuit between leads of FS1,Yes No
Open circuit between leads of FS2, Yes No
TEST PROCEDURE: SIMULATED CONDITIQNS
Follow procedure given for normal system startup mode for simulated conditions to check out
collector and storage sensor resistances.
Increase "collector" resistance setting until pumps stop; note the resistance. "Storage" resistance
setting should be 9.3 k 0 at 80°F (27°C).(Refer to temperaturelresistance sensor calibration chart.)
Measure the drainback tank water level after drainback is complete; note time to complete draining.
Reattach sensor wires to controller.
CHECKOFF/DATA SHEET: SIMULATED CONDITIONS
Collector resistance setting when pumps stop, m;

equivalent temperature; ,should be 85°F (27°C)
Drainback tank water level after complete loop drain, inch (mm). .
Approximate elapsed time to completely drain collectors and collector loop piping,
minutes.
Flow switch checkout after pumps stop:
Open circuit between leads of FSt , Yes No
Open circuit between leads of FS2, Yes No
Initial: Date:
Solar Design Manual

-
Section 4 Design ond Construction Package Appendix 4A- Page #A-24
MODE: PRIMARY OVERTEMPERATURE SHUTDOWN
1. MODE DESCRIPTION
Primary overtemperature protection is provided by a high temperature limit circuit in the differential controller.
When the solar storage tank sensor (S2) indicates a temperature of 185°F (85*C), the controller stops both
pumps.
2. TEST PROCEDURE: SIMULATED CONDITIONS
Perform this test after completing the system shutdown simulation.
Connect 0-10 kW potentiometer leads to "storage" terminals and set resistance to about 9.3 kW at
80°F (27°C) equivalent. (Refer to temperaturelresistance sensor calibration chart.)
Short circuit ''collector" terminals to simulate a high temperature, >21Z°F (I

00°C).
Decrease "storage" resistance setting until pumps stop.
Disconnect potentiometer and unshort collector terminals.
Reattach sensor wires to controller.
CHECKOFFIDATA SHEET
Storage high temperature set point on controller; should be set at 185°F (85°C).
Storage potentiometer resistance setting when pumps stop, kW;

equivalent temperature,
Verify wires properly reattached, Yes No
Initial: Date:
Solar Design Manual

-
Section 4 Design and Construction Package Appendix 4A -Page 4A-25
MODE: BACKUP OVERTEMPERATURE SHUTDOWN
1. MODE DESCRIPTION
Backup overtemperature protection is provided by use of an aquastat mounted at the drainback tank. When
water temperature in the drainback tank reaches 200°F (93%), the aquastat contact opens, deactivating
collector and storage loop pumps. The action of the backup protection is independent of the differential
temperature controller.
2. TEST PROCEDURE: SIMULATED CONDITIONS
2.1 Lower aquastat (A-1) set point until pumps stop: set point range,l30 to 240°F (54 to 116°C).
2.2 Return aquastat set point to 200°F (93%).
3. CHECKOFFIDATA SHEETS
Aquastat set point when pumps stop,
Drainback tank temperature when pumps stop; controller "Aux 3 readout,
Initial: Date:
Solar Design Manual

-
Sectioa 4 Design and Consiruction Package Appendix 4A- Page 4A-26
SECTION 5: PERFORMANCE TESTING
A system thermal performance test may be conducted to complete operational testing of the system. During
this test, data are recorded at periodic intervals (typically, every 15 minutes) so that energy flows and efficien-
cies may be calculated. Testing should be performed on a clear, mild day over a 4-hour (minimum) period
with at least 2 hours on each side of solar noon, with the solar energy system isolated from the load.
The instrumentation and procedures needed to perform the performance test are described below; equivalent
instruments or methods may be used where available. Sample Performance Data Sheets are included, listing
parameters to be measured and calculations to be made. The time for each data point should be recorded at
the top of each column. All measurements for one data-taking period should be recorded in a short elapsed
time span to improve validity of instantaneous energy flow calculations. Definitions of terms and equations
are provided after the Performance Data Sheets.
An equipment list is provided to indicate instruments required to perform aH operational checkouts.
Temperatures:
The system should be equipped with Pete's plugs at locations where test data will be obtained. Caution
should be used during removal of Pete's plugs safety caps and insertion of instrumentation probes (i.e.,
protect hands, eyes). Instrumentation probes should be coated with a silicone grease before insertion. To
obtain temperatures at locations where there are no Pete's plugs, insert temperature probes (end section
coated with heat-conductinggrease) under pipe insulation and make physical contact with pipe surfaces.
Insolation:
A solar sensor to measure instantaneous insolation and a solar integrator to measure accumulated insolation
should be used for monitoring solar insolation. The sensor should be mounted on collectors to measure total
solar insolation incident on the collector plane.
Flow Rates:
Liquid flow rates of collector and storage loops may be measuredwith a clamp-on-type electronic flowmeter
or be determined from flow signals generated by the Btu meter flowmeter. Fiow rates determined from either
of these methods can be checked by comparisonwith the following:
1. Collector flow balancing data
2. Flow estimated from pump headlflow performance data by use of

measured differential pressures across the pump
3. Flow estimated by use of heat exchanger flow/pressure drop

characteristics and measured differential pressure
4. Flow indicated by an installed visual flowmeter.
Solar Design Manual

-
Section 4 Design and ConsfructionPatrkaae Appendix 4A- Page 4A-27
SECTION 5: PERFORMANCE TESTING

(Continued)
Performance Evaluation:
The method to use for calculation of system performance is described in "Performance Data Sheet Notes."
Acceptable instantaneous collector efficiency (Item 23 on the data sheets) should be within the 75 to 100%
range of the efficiency determined in the collector's ASHRAE Standard 93 test when compared at equivalent
-
operating conditions [(T, TJI]. Efficiencies determined during the performance test should be plotted
against the collector test curve, which is available from the collector manufacturer.
The integrated overall system efficiency (Item 28) is a measure of the solar energy system's capability to
convert incident solar energy into net usable thermal energy. A test value exceeding 35OA indicates "accept-
able" performance for the system. The 1d a y test should not be extrapolated to predict all-year performance
but does give a general indication that system performance will approach design goals.
During this performance test or from records prepared during the test, the data sheet below should be filled
out and placed in the Operations and Maintenance Manual as an example of typical operating data. Data
recorded around solar noon should be used. Questions about system performance in subsequent operations
may be answered by comparing the data for the same parameters listed here with the data from this opera-
tions checkout and its known efficiency.
Date Time Weather
Differentialtemperature across each collector bank, 4
3)
Differentialtemperature across coilector side of heat exchanger,
Differentialtemperature across storage side of heat exchanger,
Inlet temperature of storage tank,
Outlet temperature of storage tank,
Collector loop flow rate,
Storage loop flow rate,
Differential pressure across collector loop pump
Differential pressure across storage loop pump
Items Requiring AttentionlComments:
Initial: Date:
Sunrise:
Solar Noon: Performance Data Sheet
(Sheet 1 of 2)
Sunset:
Parameter MeasuredfCalculated Values (at Specified Time of Day)

Measuredl
Calculated
1. Instantaneous
solar insolation
2. Integrated solar
insolation
3. Ambient
temperature
4. Collector array
inlet temperature
5. Collector array
outlet temperature
6. Collector loop
flow rate
7. Rate of solar
energy collection
8. Instantaneous col-
lector array efficienq
9. Collector loop pump
current
voltage
power
2. Storage inlet
temperature
-
Section 4 Design and Construction Package Appendix 4A - Page 4A-29
Solar Design Manual

Performance Data Sheet Notes (I-P Units)
ltem 1 - As measured in the plane of the collectors
ltem 7 - As determined by the following equation:
8.021 x p, x c, x ltem 6 x (Item 5 - Item 4)
where: PC = collector loop fluid density, I b W

C
, = collector loop fluid specific heat, Btullb-OF*
8.021 = conversion factor
ltem 8 - As determined from the following equation:
100 x ltem 7 t (Item 1 x A,)
where: A. = gross collector area, f t 2

100 = conversion factor
Item 11 - As determined from the following equation:
3.41 4 x ltem 9 x ltem 10 x PF
where: PF = collector loop pump power factort

3.41 4 = conversion factor
ltem 15 - As determined from the following equation?
-
8.021 x p, x c, x Hem 14 x (ltem 12 ltem 13)
where: Ps = storage loop fluid density, lb/ft3*

cw = storage loop fluid specific heat, Btullb-OF*
--
'Evaluated at average temperature of fluid

twill generally range from 0.8 to 0.9 for motor under load; multiply by 43 for
3-phase motors
§Equationdoes not account for auxiliary energy input or energy supplied to
load
Solar Design Manual

-
Section 4 Design and Consttuction Package Appendix 4A- Page 4A-31
Performance Data Sheet Notes- I-P Units(Continued)
ltem 18 As determined from the following equation:
3.414 x ltem 16 x ltem l i ' x PF
where: PF = storage loop pump power factoft

100 x (Item 15 - ltem 18 - ltem 11) + (ltem 1 x A,)
where: 100 = conversion factor
ltem 21 - As determined from the following equation:§
p, x c, x V, x [(ltem 20), - (ltem 20),,] + 7.48
where: v, = storage tank liquid volume, gal

ti = beginning of test period
t2 = end of test period
Add to energy from previous period to get integrated up to that

time.
0.0569 x Item 9 x Item 10 x PF x At
where: PF = collector loop pump power factor+

At = duration of test period, min
*Evaluated at average temperature of fluid

3-phase motors
load
Solar Design Manual

-
Performance Data Sheet Notes I-P Units (Continued)
0.0569 x ltem 16 x ltem 17 x PF x At

where: PF = storage loop pump power factort
I00 x (Item 21 - Item 22 - ltem 23) t (Item 2 x AJ

3-phase motors
load
Comments from Performance Test
Solar Design Manual

Performance Data Sheet Notes (SI Units)
ltem I - As measured in the plane of the collectors
ltem 7 - As determined by the following equation:
0.001 x p, x c, x ltem 6 x (Item 5 - ltem 4)
where: PC = collector loop fluid density, kg/m3*

c,,P = collector loop fluid specific heat, kJlkg*OC*
ltem 7 + (Item 1 x Ac) x 1O5
where: A, = gross coilector area, m2

10 5 = conversion factor
Item 9 x ltem 10 x PF x 1O*=
where: PF = collector loop pump power fact0l.t

10" = conversion factor
ltem 15 - As determined from the following equation:o
0.001 x p. x c, x ltem 14 x (ltem 12 - ltem 13)
where: Ps = storage loop fluid density, kg/rn3*

c, = storage loop fluid specific heat, kJ/kg*OC*
0?1l = conversion factor
*Evaluated at average temperature of fluid

3-phase motors
SEquation does not account for auxiliary energy input or energy supplied to
load
Solar Design Manual

Performance Data Sheet Notes-SI Units (Continued)
ltem 16 x ltem 17 x PF x I 0-3
where: PF = storage loop pump power factop

10-3 = conversion factor
(Item 15 - ltem 18 - ltem I 1) + (Item 1 x A,) x 1 Q5
where: 1 O5 = conversion factor
ltem 21 - As determined from the following equation?
p. x c, x V8 x [(ltem 20),, - (ltem 20),,] + 1000
where: "8
= storage tank liquid volume, L
tl = beginning of test period
tz = end of test period
1000 = conversion factor
0.06 x ltem 9 x Item 10 x PF x At

where: PF = collector loop pump power factup
0.06 x ltem 16 x Item 17 x PF x At
where: PF = storage loop pump power factorr

At = duration of test period

3-phase motors
load
Solar Design Manual

-
Section 4 Design and Construction Package Appendix 4A - Page #A -37
Performance Data Sheet Notes-SI Units (Continued)
I00 x (Item 21 - Item 22 - Item 23)+ (Rem 2 x A=)
%valuated at average temperature of fluid

twill generally range from 0.8to 0.9for motor under load; multiply by 43 for
3-phase motors
PEquation does not account for auxiliary energy input or energy supplied to
load
Comments from Performance Test
Solar Design ManlcaE

-
Section 4 Design and Construction Package Appendix 4B- Page 4B-1
APPENDIX 4 8
EXAMPLE OF CONSTRUCTION SPECIFICATION
Solar Design Manual

Section 4 - Design and Construction Package Appendix 4B- Page 4B-2
Sample
Construction Specification
for Solar Domestic Hot Water System Retrofit

Project No.
at the
prepared by
Contract No.
(Date)
-
Table of Contents
Dlvlslon Sectlon Page
1 General Requirements
01000 General Requirements
Work Summary
Reference Drawings
Applicable Publications
Submittals
Supervision
Workmanship
Hours of Work
Interruption of Existing Utilities
Site Access
Vefification of Dimensions
Coordination of Trades
Delivery and Storage
Fire Protection
3 concrete
03300 Cast-in-Place Concrete

1.0 General
2.0 Materials
3.0 Execution
Metals
Structural Metal framing
1.0 General
2.0 Materials
3.0 Execution
Thermal and Moisture Protection
Thermal and Moisture Protection

1.0 General
2.0 Materials
3.0 Execution
Special Construction
Solar Energy System

1.0 Description
2.0 Operation
3.0 Warranty
Solar Design Manual

-
Table of Contents
Section Page
Mechanicaf
Basic Materials and Methods

I.O General
2.0 Materials/Products
3.0 Execution
I.nsulation
1.0 General
2.0 Products '
3.0 Execution
Electrical
Basic Materials and Methods

1.0 General
2.0 Wiring
3.0 Differential Temperature Controllers
4.0 Temperature Monitoring System
5.0 Btu Monitoring System
6.0 Lightning Protection
7.0 Panel Boards
Solar Design Manual

-
DIVISION 1 GENERAL REQUIREMENTS
SECTION 01000
GENERAL REQU!REMENTS
Work Summary
The scope of this project consists of furnishing all materials, labor, equipment, etc., required for the
installation of a solar domestic hot water system retrofit at
The building is located at
Reference Drawings
Project Title: Solar Domestic Hot Water System Retrofit
(address)
Date:
Project Number:
Drawing Title Sheet No.
Title, Index, and Key Plan

StructuraVRoofing/Penetration Details
Piping Schematic, Schedules, and Control Matrix
Solar System Layout
Elevations and Sections
Electrical Schematic and Details
Note: The contract drawings are diagrammatic and indicate the general arrangement of systems
and work included in the contract. Do not scale the drawlngs.
Applicable Publications
The publications listed below form a part of this spedication to the extent referenced. The publications are
referred to in the text by the basic designation only. The latest edition in effect at date of invitation to bid shall
apply
3.1 American Concrete Institute Standard
318 Building Code Requirements for Reinforced Concrete
3.2 American National Standards Institute, Inc. (ANSI), Standards
A13.1-1981 Scheme for the Identification of Piping Systems
B1.20.1-1983 Pipe Threads, General Purpose (Inch or mm)
BI 6.15-1978 Cast Bronze Threaded Fittings, Class 125 and 250 (PN 20 and PN 42)
I316.18-1978 Cast Copper Alloy Solder-Joint Pressure Fittings
BI 6.21-1978 Nonmetallic Flat Gaskets for Pipe Flanges
Solar Design Manual

-
Section 4 Design and Construction Package Appendix 43- Page 4B
Bl6.22-1980 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
816.24-1979 Bronze Pipe Flanges and Flanged Fittings, Class 150 and 300 (PN 20 and PN 50)
816.26-1983 Cast Copper Alloy Fittings for Flared Copper Tubes
American Society of Heating, Refrigerating and Air-conditioning Engineers, Inc. (ASHRAE),

Standards
93-86 Methods of Testing to Determine the Thermal Performance of Solar Collectors
94-77 Methods of Testing Thermal Storage Devices Based on Thermal Performance
American Society of Mechanical Engineers (ASME) Codes
Boiler and Pressure Vessel Code and Interpretations
Section Viil Pressure Vessels, Division 1 (1983; Addenda:

Summer & Winter 1983; Summer & Winter 1984;
Summer & Winter 1985)
Section IX Welding and Brazing Qualifications 1983; Addenda:

Summer & Winter 1983; Summer 8 Winter 1984;
Errata; Summer 8 Winter 1985)
American Society for Testing and Materials (ASTM) Publications
Structural Steel
High-Strength Bolts for Structural Steel Joints
Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and
Shapes
Carbon and Alloy Steel Nuts
Solder Metal
Seamless Copper Water Tube
Salt Spray (Fog) Testing
Copper Sheet, Strip, Plate, and Rolled Bar
Aluminum and Aluminum-Alloy Sheet and Plate
Ready-MixedConcrete
Insulating Board
Asphalt Primer Used in Roofing and Waterproofing
Mineral Aggregate Used on Built-up Roofs
Solar Design Manual

-
Section 4 Design and Conshuctiun Package Appendix 4B- Page 4B-7
American Welding Society, Inc. (AWS), Publications
01.l-85 Structural Welding Code - Steel

Expansion Joint Manufacturers Association, Inc. (EJMA), Standard
Standards (5th Edition, 1980)
InternationalAssociation of Plumbing and Mechanical Officials (IAPMO), Publication
Uniform Solar Energy Code (1985 Edition)
InternationalConference of Building Officials (ICBO) Publication
Unform Building Code (1982 Edition; 1st Printing; Errata)
Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS),
Standards
SP-38 Pipe Hangers and Supports - Materials, Design and Manufacture (1983)
SP-69 Pipe Hangers and Supports - Selection and Application (1983)
SP-73 Silver Brazing Joints for Wrought Copper and Copper Alloy and Cast Copper Alloy
Solder Joint Pressure Fittings (1982)
SP-80 Bronze Gate, Globe, Angle and Check Valves (1979)
Subrntttals
Materials List
Within 15 days after award of the contract, the contractor shall submit for approval a list of
manufacturer's names of material and equipment he proposes to provide. (The component specifica-
tion worksheets in Section 4 of this design manual} may be used for this purpose. In the event any
items of material or equipment contained in the list fail to comply with the specification requirements,
such items will be rejected. Rejected items shall be resubmitted within 15 days. If, prior to the expi-
ration of the 15-day period or any duly authorized extension thereof, the contractor fails to submit a
schedule of acceptable material or items, selection will be made by the A/E, and such selection will
be final and binding upon the contractor as a condition of the contract.
Proof of Compliance -Where materials or equipment are specified to comply with requirements of a
national code or standard, proof of such compliance shall be submitted. The label or listing of the
specified agency will be acceptable evidence. In lieu of the label or listing, a written certification may
be submitted from an approved, nationally recognized testing organization equipped to perform such
services, stating that the items have been tested and conform to the requirements and testing meth-
ods of the specified agency. Where equipment is specified to conform to requirements of the ASME
Boiler and Pressure Vessel Code, the design, fabrication, and installation shall conform to the code.
Certificates of compliance for each individual component shall be submitted by the contractor prior to
installationof the component.
-
Shop Drawings Shop drawings shall consist of illustrations, schedules, performance charts,
instructions, brochures, diagrams, and drawings necessary for the installation of solar equipment and
associated equipment and for piping, wiring, and related foundations. Shop drawings for each
component will be submitted prior to installation of that component in the solar energy system.
Solar Design Manual

-
Section 4 Design and Construction Packaae Appendix 4B- Page 4B-8
If material or equipment is installed prior to receipt by the contractor of pertinent shop drawings from
the NE marked "No Exceptions Taken" or "Comments as Noted," the contractor shall be liable for its
removal and replacement at no extra charge to the owner.
Solar collector submittal will include ASHRAE 93-86 performance data certifiedby a nationally
recognized testing laboratory, manufacturer's model number and warranty, manufacturer's
installation recommendations, replacement parts sources, and replacement parts cost schedule.
Also included will be details of the coflector/support frame-mounting system showing materials
and tolerances, the headerkasing gasketing system, the glazing replacement system, and
collector manufacturing methods (i.e., stainless steel bolts, welds).
Storage tank submittals will include warranty, dimensions, materials, weight, pressure limits,
replacement gaskets, installation instructions, and service restrictions.
TanWheat exchanger piping insulation submittals will include catalog cuts, warranty, performance
data, and installation requirements.
Heat exchanger submittals will include shop drawings or catalog cuts indicating dimensions,
materials, heat exchanger surface area, flow rates, pressure drops, warranty, replacement parts
availability, and replacement parts cost schedule. Cleaning and maintenance procedures will be
included.
Pump submittals will include catalog cuts, performance curves, wiring diagrams, manufacturer's
warranty, replacement parts availability, installation procedures, service requirements, and
troubleshooting guidelines.
Expansion tank submittals will include warranty, dimensions, materials, total and acceptance test
volume, weight, pressure limits, replacement gaskets, installation instructions, and service
restrictions.
Control and instrumentation component submittal will include catalog cuts, manufacturer's model
number and warranty, recommended installation procedure and performance data, and replace-
ment parts availability.
Record Drawings -Contractor shall keep accurate records of all deviations in work as actually
installedfrom work indicated by marking up the approved design drawings. When work is complete,
contractor will furnish two complete "Record" sets of marked prints no fewer than working days
prior to the final inspection. Contractor will certify the accuracy of each print by endorsing and signing
each marked print.
Acceptance Test Reports - Upon acceptance of the solar energy system, the results of tests con-
ducted during the final acceptance inspection shall be submitted in booklet form.
Operation and Maintenance Manual - Contractor will furnish complete sets of operation and
maintenance manual, as described in Section 4.3.4, with the results of final acceptance inspection.
Supervision
The contractor shall furnish the services of an experienced superintendent who constantly shall be in charge
of the installation work.
Solar Design Manual

Section 4 - Design and Construction Package Appendix 4B- Puge 4B-9
6.0 Workmanship i~
I
The quality of workmanship provided by each trade in the execution of its work shall be the finest and highest
obtainable in that trade working with the materials specified. Workmanship shall be satisfactory to the AIE,
and his decision as to acceptable quality is final.
7.0 Hours of Work
Work shall normally be performed between and with no work on Saturdays, Sundays, or federal I
holidays without specific approval. For utility changeovers and other critical items of work that might incon-
venience normal operations if the work were done during normal hours, permission for night, Saturday,
Sunday, and holiday work will be granted subject to certain specified limitations.
8.0 Interruption of Existing Facilities
Utility outages shall be coordinated with a minimum of days prior to the desired outage. Out-
ages shall be limited to 2 hours maximum at any one time. If such outages must be scheduled for a time
other than the normal workday, they shall be accomplished at no additional cost.
9.0 Site Access
The contractor shall avoid any extended blockage of driveways required for access to the building. The
contractor shall notify the owner at least 24 hours in advance of any access interference and shall obtain ap-
proval fro m before proceeding with said interruption.
1
10.0 Verification of Dlmenslons
The contractor shall become thoroughly familiar with all details of the work and working conditions and verify
all dimensions in the field and shall advise of any discrepancy before performing any work.
11.0 Coordination of Trades
The contractor shall be specifically responsible for the coordination and proper relation of the work to the
building structure and to the work of all trades.
t 2.0 Delivery and Storage
Contractor shall ensure that sufficient lead time is given to prevent late delivery of equipment and materials
and installation delay problems. All equipment delivered to the jobsite, including owner-furnished, shall be
stored under roof or other approved covering on pedestals above the ground. Particular care shall be taken
to keep solar collector glazings clean and undamaged. All enclosures for equipment shall be weatherproof.
Any motors involved in the work that are not totally enclosed shall be stored in a heated area with a minimum
temperature of 50°F (10°C). All valves shall be stored under a roof on wood pedestals above ground. The
contractor shall have complete responsibility for the storage and care of equipment and materials.
If any materials and/or equipment are found to be in poor condition when being installed, the contractor shall
furnish and install new undamaged equipment at no cost to the owner.
13.0 Fire Protection
Contractor shall provide as a minimum, one 5-lb (2.3-kg) extinguisher rated for Types A, B, and C fires with
each work crew at all times when working within the building or on the roof of the building.
Solar Design Manual

DIVISION 3 CONCRETE
SECTION 03300
CAST-IN-PLACE CONCRETE
General
A concrete pad will be placed near the east wall of the mechanical room as shown. The purpose of
the pad and piers is to distribute the weight of the storage tank and solar collectors uniformly over the
roof area.
The AC1318 building code requirements for reinforced concrete shall govern the work.
Materials
Concrete shall be Class A and have a minimum compressive strength of 3000 psi in accordance with
ASTM specification for Portland Cement and shall conform to ASTM C94.
Reinforcing steel is to be provided as shown by drawings and shall be deformed, Grade 60 biller,
axle, or rail steel.
Execution
Built-up roofing will be removed as shown.
Forms will be constructed of dressed lumber sufficiently strong to maintain lines required and prevent
leakage of mortar.
Exposed edges will be constructed with a 314-inch (19-mm) chamfer.
Mat shall be finished to a true plane with no deviation exceeding 118-inch (3-mm) when tested with a
straightedge.
Roofing around pad will be repaired as shown and according to Sect ion 07100.
Solar Design Manual

-
Section 4 Design and Constmction Package Appendir 4B- Page 4B-I1
orvrsml 5 METALS
SECTION 05100
STRUCTURAL METAL FRAMING
General
The collector support structure shall be fabricated and installed as shown.
The structure will have a horizontal clearance of 20 in., and the roof underneath will be accessible
"thmugh" the back of the structure.
The AlSC Specificationfor the Design, Fabrication and Erection of Structural Steel for Buildings shall
govern the work.
Welding shall be in accordance with AWS Code D l .l.
Materials
Structural Steel - Structural steel shall conform to ASTM A 36.

Steel Pipe - Steel pipe shall conform to ASTM A 500, Grade B.
Paint -- Primer shall conform to Fed. Spec. TT-P-86, Type I;oil base paint shall conform to
Fed. Spec. 77-P-105.
b
-High strength bolts, including nuts and washers, shall conform to ASTM A 325.
High Strength Bolts
Carban Steel Nuts -Carbon steel nuts shall conform to ASTM A 563, Grade A, hex style.
Execution
Fabrication shall be in accordance with the applicable provisions of the referenced AlSC specifica-
tions.
To the greatest extent possible, fabrication and assembly shall be done in the shop.
All exposed steel shall be prepared for painting in accordance with the referenced AlSC specifications
and primed and coated with paint materials listed before. Final color shall be selected by the
contracting officer.
Erection of structural steel shall be in accordance with the applicable provisions of the referenced
AlSC specifications.
The structural pipe posts shall be anchored to the penthouse roof structure as shown using
112 x 3 314-inch (13 x 95-mm) anchor bolts with a minimum of IZ13OO-lb(5584-kg) pullout and
10,200-lb (4631-kg) shear ratings.
Solar Design Manual

-
Section 4 Desian and Construction Package Appendix 4B- Page 4B-12
DlVlSlON 7 THERMAL AND MOISTURE PROTECTlON
SECTION 07000
THERMAL AND MOISTURE PROTECTION
General
Existing built-up roofing will be locally removed as shown for installation of roof stub-ups (collector
structure supports), tank support pad, and piers.
Ail areas where roofing must be removed will be insulated, waterproofed (sealed), and fully flashed
for weathertightness.
Walk pads will be installedfor protecting the roof against traffic.
Materials
Asphalt primer shall conform to ASTM D 41.
Bitumen cement shatl conform to Fed. Spec. SS-C-153, Type I.
Roof insulating board shall be fiberboard conforming to ASTM C 208 and treated for moisture
resistance.
Cants shall be fiberboard conforming to ASTM C 208 and treated for moisture resistance.
Felt shall be bituminous-saturatedtype.
Crushed stone shall conform to ASTM D 1863.
Execution
The entire roofing system, including aggregate surfacing, shall be finished in one operation at each
location to be reroofed.
Asphalt primer shall be applied at the rate of 1 gallon per 100 ft2 (3.79 L per 9.3 rrf) over the entire
surface to be reroofed.
Insulation shall be cut to fit neatly against adjoining surfaces and applied to concrete deck.
Each course of roofing felt shall be mopped in hot bitumen and shall be lapped with existing layers as
specified by the drawing.
Cants shall be laid in a solid coat of bituminous cement just prior to laying the roofing plies.
Flashing shall be installed as shown.
Roof flanges or sheet metal flashings shall be stripped with two layers of roofing felt set in plastic
cement as shown to form a waterproof joint between roofing and flashings.
Solar Design Manual

Section 4 - Design and Construction Package Appendix 43- Page dB-13
3.8 After roofing felts have been laid and flashings installed, the roof surface (or repair area) shall be
flood-coated uniformly with 60 lb (27.2 kg) of hot asphalt per 100 ft2 (9.3 m2). While bitumen is still
hot, 400 Ib per 100 V(181.6kg per 9.3 m2) of roofing gravel shall be embedded therein. Aggregate
shall be placed in the manner and quantity required to form a compact embedded overlay. Roof
surface shall be swept and all loose aggregate removed.
3.9 Walk pads shall be installed per manufacturer's recommendations.
Solar Design Manual

-
Section 4 Design and Construction Package Avvendix 4B- Pam 4B-14
DIVISION 13 SPECIAL CONSTRUCTION
SECTION 13980
SOLAR ENERGY SYSTEM
(This section should provide a brief description of the solar system and its operating mode.)
The system is designed to preheat domestic water and interconnects directly with the existing conventional
domestic hot water and electrical systems of the building. The system consists of collectors, hot water
storage tanks, a heat exchanger, pumps, automatic controls, monitoring instrumentation, interconnecting
piping, and all accessories required for the operation of the system. The system features flat plate, black
chrome-coated, single-glazed collectors. The system uses pure water as the heat transfer medium.
As shown by the drawings, storage water is pumped directly through the collectors via a drainback return
piping arrangement. The collectors are interconnected in parallel with a reverse return.
Energy is transferred from the storage tank to the domestic water by pumping storage water through a heat
exchanger between the "preheat" tank and storage tank.
The system is designed to be fail-safe from freezing. When the collector loop pump stops, water in the
collector bop drains back into the storage tank automatically. The bottom supply header and lines from the
bottom headers are installed with a positive slope back to the collector loop pump, and the return lines from
the top (return) headers to the storage tank are continuously sloped downward. he design allows air to enter
the main return line when the collector loop pump stops via a small vent line connected to an air space in the
storage tank.
There are no vents to the atmosphere; the system is sealed and will self-pressurize during operation. The
storage tank is not completely filled with water, leaving an air space at the top of the tank to allow for expan-
sion of the water.
2.0 Operation
The collector loop pump is activated when the collector loop controller senses that the collector temperature is
15OF (8°C) higher than the water temperature in the bottom of the storage tank. The pump draws water from
the bottom of the storage tank and overcomes the lift head and piping losses to completely fill the collector
array. Water is forced out the top of the collectors and down the return line and back into the top of the
storage tank.
The collector loop pump will continue to circulate until the collector temperature is within 3OF (2OC) of the
storage water temperature. When the collector loop pump stops for any reason, air enters the return line via
a small tube vented to the air space in the storage tank. This allows water to drain back from the collector
loop.
TRe heat exchanger loop pumps are activated when the heat exchanger loop controller senses that the water
temperature in the top of the storage tank is 8OF (4°C) higher than the water temperature in the bottom of the
preheat tank. One pump draws water from the top of the storage tank and circulates it through the heat
exchanger and back into the bottom of the storage tank. The other pump draws water from the bottom of the
preheat tank and circulates it through the heat exchanger and back to the top of the preheat tank. The heat
exchanger loop pump will continue to circulate until the preheat tank temperature is within 3°F (3°C)of the
storage tank temperature or until the preheat tank temperature reaches 250°F (121O C ) . An aquastat placed
inside the preheat tank serves to limit the operational temperature and, thereby, protect the tank lining.
Solar Design Manual

-
Warranty
The contractor shall warrant for a period of 2 years from the date of final system acceptance that the
svstem will be free from defects in workmanship and materials (except solar collectors, which shall
&rry their own warranty).
This warranty covers faulty materials andlor workmanship only. All other causes for system malfunc-
tions and/or failures, including, but not limited to, those caused by misuse, abuse, neglect, accident,
riot, fire, vandalism; acts of nature such as floods, storms, earthquakes, or tornados; or other causes
beyond the control of the contractor, are excluded from this warranty.
This warranty is invalid if the system is modified in any way without the consent of the contractor.
Any defects in workmanship or materials that appear within the guarantee period shall be corrected
by the contractor without cost to the owner within a reasonable time to be specified in notice from the
owner. In default thereof, owner may have such work done and charge cost to contractor.
Contractor shall provide all service work required for equipment during the guarantee period.
Contractor shall note that the guarantee for certain items of equipment such as pumps, etc., which
may be installed early and utilized during construction, shall not begin until final completion and
acceptance of all work.
Solar Design Manual

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DIVISION 15 MECHANICAL
SECTION 15050
BASIC MATERIALS AND METHODS
1.0 General
This section covers the furnishing and installation of all pipe fittings, piping specialties, valves, pumps, tanks,
heat exchangers, solar collectors, etc., as required for the solar heating system described and as shown.
-
Identical ltems ltems of the same classification shall be identical, including equipment, assemblies,
parts, and components.
-
Standard Products Material and equipment other than existing shall be new (that has been in
satisfactory use at least 1 year) and shall be the standard products of a manufacturer regularly
engaged in their manufacture.
-
Specifications The description, characteristics, and requirements of products and materials to be
used shall be in accordance with qualifying conditions established in the specificationworksheets in
Section 4.3.3.
-
Alternate Materials/Products Only those materials and equipment named in the specifications,
worksheets, and drawings shall be used as a basis for the preparation of the base proposal and,
unless otherwise permitted herein, only those materials shall be furnished under the contract. Where
the catalog numbers of one manufacturer are given and reference is made to similar equipment of
alternate manufacturers, equal equipment by any of those manufacturers may be used. Other
materials or equipment may be offered in substitution, provided the substitute manufacturer's name
and catalog numbers are stated in the Form of Proposal, together with amounts of savings. Any such
changes in work under this or other sections must be approved by the AIE before implementation;
any changes made necessary by such alternate or substitute equipment shall be made by the
contractor at his own expense.
Nameplates -All component parts of each item of equipment or device shall bear the
manufacturer's nameplate, giving the name of manufacturer, description, size, type, serial or model
number, electrical characteristics, etc., in order to facilitate maintenance or replacement. The name
plate of a subcontractor or distributor will not be acceptable. Where Underwriter's Laboratories
standards apply, material and equipment shall be approved by them and shall bear the UL label.
Nameplates shall be provided for:
Expansion tanks
Heat exchangers
Hot water storage tank
Hot water heater
Pumps
Motors
Starters
Solar collectors
Relief valves
Power-operatedvalves
Solar Design Manual

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Section 4 Design and Construction Package Appendix 4B- Page #B-17
-
Equipment Guards [and Access] Belts, pulleys, chains, gears, couplings, projecting set screws,
keys, and other rotating parts so located that any person coming in close proximity thereto shall be
enclosed or guarded. High temperature equipment and piping so located as to endanger personnel
or create a fire hazard shall be guarded or covered with insulation of type specified for service.
-
Motors Contractor shall provide motors of a size adequate to drive the equipment, but in no case
less than the size shown or specified. If a motor larger than that specified is used, the contractor
shall bear the expense of changes in supports, wire and conduit connections, circuit protective
devices controls, or other affected elements of the system. Each motor shall have sufficient capacity
to start and operate the machine it drives without exceeding the motor nameplate rating at the speed
specified or at the load that may be obtained by the drive actually provided. Rate motor for continu-
ous duty at 100% of rated capacity; base the temperature rise on the ambient temperature of 104°F
(40°C).
The contractor shall assume responsibility for the correct direction of rotation required by the equip-
ment drives. In the event of damage caused by reverse rotation, the equipment shall be repaired or
replaced at no charge.
Motor controllers will be provided under Division 16 -- Electrical.
Execotion
The general contractor shall be responsible for ail work included in the divisions, and the
delegation of work to subcontractors shall not relieve him of this responsibility. Subcontractors who I
perform work under these sections shall be responsible to the general contractor.
Contractor shall not deviate from the equipment and piping routing, location, configuration, or
arrangement specified on the design drawings without the specific approval of the NE.
Roof Protection- Contractor shall lay down temporary wooden walkways on the roof to protect the
existing roof surface until more permanent protection is installed.
Equipment Support - Contractor shall provide equipment supports consisting of concrete pads,
platforms, gratings, structural mernbers, hangers, rods, and related materials as required for the
mechanical and electrical work.
Collector Array - Each collector shall be individually removable for maintenance, repair, or replace-
ment.
Piping -- Pipe and fittings installation shall conform to the requirements of ANSI 831.l. All piping/
tubing and pipe fittings shall be of sweat solder configuration unless the fitting joint is specifically
designed to withstand a minimum design pressure of 150 psig (1034 kPa) at normal room tempera-
ture.
Tubing shall be Type L seamless hard drawn copper; tube fittings shall be brass.
Silver bearing solder (9614) will be used on all sweat joints. Only water-soluble binder flux will be
used to solder pipe joints.
Pipe Hangers - Pipe hangers, inserts, and supports shall conform to MSS SP-58 and -69.
Hangers and supports for pipe shall be spaced not over 10 ft (3048 mm) on centers for 1 1/4 inch (32
mm) and larger, with additional supports at valves, fittings, and accessories. Hangers and supports
for other pipe shall not placed more than 8 tt (2438 rnm) on centers.
Solar Design Manual

-
Hangers used to support piping 2 inch (51 mm) and larger shall be fabricated to permit adequate
adjustment after erection while still supporting the load.
Horizontal pipe supports shall be spaced as specified in MSS SP-69, and a support shall be installed
not over 1 ft (305 mm) from the pipe fitting joint at each change in,directionof the piping. Pipe
supports shall be spaced not over 5 ft (1524 mm) apart at valves.
Vertical pipe shall be supported at each floor, except at slab-on-grade, and at intervals of not more
than 15 ft (4572 mm), not more than 8 ft (2438 mm) from end of risers, and at vent terminations.
Guides using steel, reinforced polytetrafluoroethylene (PTFE) or graphite slides shall be provided
where required to allow longitudinal pipe movement. Lateral restraints shall be provided as required.
Slide materials shall be suitable for the system operating temperatures, atmospheric conditions, and
bearing loads encountered.
Pipe hangers/supports on insulated pipe shall be the size of the outside diameter of the insulation. A
protection saddle shall be installed between support and insulation.
Piping and attached valves shall be supported and braced to resist seismic loads in accordance with
the Uniform Building Code for lateral force resisting system utilizing a Cp factor of 0.3 and an I factor
of 1.5.
Valves V a l v e s shall be installed in accessible locations with stems horizontal or above and shall be
of the same size as the lines in which they are installed.
Shutoff valves shall be gate valves rated at 125 psig (862 kPa), bronze body with solder ends. Gate
valves shall have nonrising stem and solid disk.
Strainers - A strainer shall be installed at the inlet of each pump.

Differential Temperature Controller -Automatic control equipment shall be installed at the location
shown in accordance with the manufacturer's instructions. Control wiring will be run through in thin
wall conduit and will not be run with power wiring. Aft sontrol wiring will be color coded and identified
with permanent numeric or alphabetic codes at the sensor location and at the controller.
Identification
-
Control Devices All control devices (i.e., circuit breakers, panels, switches, starters, pushbutton
stations, relays, temperature controls) shall be clearly identified as to their function and the equipment
controlled. All equipment such as pumps, fans, heaters, etc., shall be marked to clearly identify
equipment and space or duty they serve. Marking of electrical equipment is specified under
Division 16. Mechanical equipment shall be identified using engraved laminated black and white
phenolic legend plates. Letters shall be minimum 3/4-inch (19 mm)-highwhite on surrounding black.
Plates shall be mounted by means of sheet metal screws.
-
Piping Piping shall be identifiedwith colored prerolled, semirigid plastic labels. Labels shall be
Seton "Set mark" system and shall be set around pipes with a fieid-installed, high-strength cement
compound applied along their longitudinal edge. Labels shall be placed around the piping or insula-
tion every 25 ft (7620 mm) with one label on each pipe in rooms smaller than 15 ft (4572 mm).
Exception: Solar collector supply and return piping above the roof shall be identified every 100 ft
(30480 mm). A label shall be placed at every major valve and within 6 ft (I 830 mm) from exit and
entrance to an item of equipment.
Solar Design Manual

-
Section 4 Design and Construction Pockage Appendix 4B- Page 4B31
DlVlStON 15 MECHANICAL
SECTION 15250
lNSULATlON
The General Provisions of the contract, including the General and Supplementary Conditions and Division 1,
General Requirements, are hereby made a part of this section as fully as if repeated herein.
General
Scope
1. Work included in this section is the thermal insulating done in the field on the mechanical
systems as specified herein.
2. All pipe fittings, valves, and strainers are to be insulated.
3. Do not insulate heads of pumps.
Standards
I. Except for materials subsequently exempted, all other materials used as part of the thermal
insulation shall have a fire hazard rating not to exceed 25 for flame spread and 50 for fuel
contributed and smoke developed.
2. Test factory-assembled material as assemblies.
3. Determine ratings by the Standard Method of Test for Surface Burning Characteristics of
Building Materials, ASTM E-85 or NFPA No. 255.
4. The following will be required to establish that fire hazard ratings for materials proposed for
use do not exceed those specified:
a. Label or listing by Underwriter's Laboratories, Inc.
b. Certified test report from an approved testing laboratory.
5. The following materials are exempt from the foregoing Fire Resistance Rating:
a. Jackets of canvas, PVC, or nylon
b. Nylon anchors for securing insulation to equipment
c. Factory-premoMed, one-piece PVC fiing and valve covers.
Submittals
Provide shop drawings in accordance with Seclion 15010 and the General Requirements,which shall
include all insulation, jackets, finishes, etc. Shop drawings shall additionally describe each system or
component to be insulated, insulationtype and thickness, and method of insulation.
Solar Design Manual

Definition
1. Thermal resistance "R" values used herein are expressed in units of h**F*it2/Btu[(m2**C)/Wj
on a flat surface at a mean temperature of 75°F (24°C) unless specifically noted.
2. The "K" factor means the number of British thermal units transmitted per h*ft2m0F(temperature
difference) through a material with flat, parallel sides 1 inch apart. The material shall be
tested and rated according to ASTM Test Method C-177.
Note: I BtwinJ(h*ft2*OF)= 0.144 W/(m2*OC)
Products
Materials
1. Type I pipe insulation (outdoor) -premolded rigid insulation with K = 0.1 5 i0.02W/(ma°C)]
maximum and with weatherproof Tedlar, PVC, or aluminum jacketing.
2. -
Type I! pipe insulation (indoor) preformed fiberglass, urethane, or isocyanurate with
K = 0.22 i0.03 W/(rn.OC)] maximum and with laminated aluminum foil, glass reinforcing, and
white Kraft paper or PVC covering.
3. Type 1 -
I1blanket insulation blanket-type fiberglass insulation. The K factor shall not exceed
0.36 i0.05 W/(m*OC)] at 200°F (93°C) mean temperature.
Insulation Schedute
Senrlce
1. All outdoor collector loop piping,
including collector interconnections
2. Indoor collector and storage loop

piping from solar storage tank to
penthouse heat exchangers
Service
3. All hot water piping from solar
storage tank to distribution
system
4. A l new cold water piping and

steam condensate piping
5. All equipment components I11
6. Solar storage tank Ill

-
-
Appendix 4B- Page 4B-23
3.0 Execution
a. General
1. All insulation shall be installed by skilled workmen regularly engaged in this type of work.
2. Insulation shall be continuous at all hangers and openings. Vapor seals shal be provided for
all cold surfaces and shall be continuous. A protective aluminum or stainless steel shield will
be installed between the pipe insulation and all hangers.
3. Arrange to permit expansion and contraction of piping without causing damage to insulation
or surface.
4. Actual insulationthickness must be at least equal to the minimum specified in the schedule.
Where the manufacturer's rated or nominal thickness is less than the minimum specified, a
thicker material or more layers will be required so that the stated minimum thickness will be
attained or exceeded.
5. The application of all insulation materials, accessories, and finishes shall be in accordance
with the manufacturer's published recommendations.
6. Insulation materials shall not be applied until all surfaces to be covered are clean and dry; all
foreign material, such as rust, scale, dirt, etc., has been removed; and, where specified,
surfaces have been painted. lnsulation shall be clean and dry when installed and during
application of any finish. The insulation on pipe fittings, valves, and pipe joints shall not be +
installed before the piping is tested hydrostatically and approved.
b. Pipe Insulation
1. Highdensly pipe saddles shall be provided at all points of support as hereinbefore specified.
2. insulate all valves and strainers. Use prernolded and factory-precut insulation where
applicable. Unions and flanges shall not be insulated.
3. Insulate valves up to and including bonnets.
4. lnsulate strainers in a manner to permit removal of the basket without disturbing the insulation
of the strainer.
5. Application - Type I Insulation
a. Install insulation per manufacturer's recommendation.
b. Insulate all valves and fittings with factory-premolded urethane fittings with one-piece
UV-stabilized PVC or aluminum covers.
c. All piping shall be supported outside of the insulation jacket. Provide high-density
inserts (e.g., calcium silicate) as required.
d. Seal all seams and joints with weatherproof tape.
e. Seal all joints, including interconnections between collectors between insulating
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SECTION 4

DESIGN AND CONSTRUCTION PACKAGE

Solar Design Manual

DESIGN AND CONSTRUCTION PACKAGE

DESIGN PACKAGE ...............................................................................................

CONSTRUCTION PACKAGE ............................................................................

Design and Installation Drawings ......................................................................4 - 2

4-1 List of Component Specification Worksheets -- Liquid Collector systems .............4.5

4-2 List of Component Specification Worksheets -- Air Collector Systems ..................4-6

4A Installation Checkout Procedure (Sample) ............................................................

4B Example of Construction Specification....................................................................4B-1

Solar Design Manual

SECTION 1 SECTION 2 SECTION 3 SECTION 4

Prepare Perform Complete

Solar Design Manual

4.2 DESIGN PACKAGE

The design package summarizes analyses completed during feasibility

System thermal load analysis

System thermal performanceanalysis

Collector array and storage tank sizing analysis

Pipelduct and pumpflan sizing analysis

Array shading calculation

Results of any significant t radeoff studies

Economic evaluation of as-designed system.

In addition, an updated system design description (SDD), all detail draw-

4.3 CONSTRUCTION PACKAGE

- Legend of symbols and abbreviations

- Interface requirements with conventional SHWI

Informationto be included on drawings is discussed in Section 3, De-

Appendix 4A contains a sample installation checkout procedure that may

Appendix 48 contains a sample construction specification for a typical

Sample specification worksheets for various liquid collector system

The sample worksheets list physical parameters and performance data

Solar Design Manual

Table 4-1. Llst of Component SpecificationWorksheets -

Flat plate liquid collectors

Solar Design Manual

Flat plate air collectors

A companion volume to this design manual, the Installation, Operation,

lnstaflatlon The installation section describes preconstruction activities such as site

A sample Installation Checkout Procedure, included in this design

Solar Design Manual

Maintenance The maintenance section describes typical maintenance procedures to

The NE should prepare a complete checklist for the constwction pack-

Solar Design Manual

Flat Plate Liquid Collectors

Applicatian: (La, DHW heating, space heating, etc.)

System Type: (La,

Nominal Size: is.,4 x 8 ft, 4 x 10 ft (12i9 x 2438 mm,

Filled Weight: (Max., based on structural estimates)

Wind Loading Capability:

Flow Pattern: (i.e., series, parallel)

Manifold: (i-e., internal or external size)

Maximum Operating Pressure:

ExpansionCapability: (fixed or floating within frame)

Flat Plate Liquid Collectors

Glazing Fasteners: (easy field replacements)

Weep Hole Locations:

Inlet/Outlet Connection Locations:

Mounting Method: (integral flange, etc.)

Cover Gaskets and Outlet Grommets

Temperature Limits: (operation)

Temperature Limits: (installation)