Loading...
The URL can be used to link to this page
Your browser does not support the video tag.
Home
My WebLink
About
2280 CALLE BARCELONA; ; CB070015; Permit
01-03-2g)0 City of Carlsbad 1635 Faraday Av Carlsbad, CA 92008 Miscellaneous Permit Permit No CB070015 Building Inspection Request Line (760) 602-2725 Job Address Permit Type Parcel No Valuation Reference # Project Title 2280 CALLE BARCELONA CBAD MISC 0000000000 $000 Subtype Lot# OTHER 0 BAUTISTA SOLAR POOL HEATING SYSTEM Applicant NATURAL ENERGY TED MOUNT 147 S VINEWOOD ST 92029 760 743-6400 Status Applied Entered By Plan Approved Issued Inspect Area Owner BAUTISTA LEO ISSUED 01/03/2007 MDP 01/03/2007 01/03/2007 Miscelaneous Fee #1 Miscelaneous Fee #2 Additional Fees TOTAL PERMIT FEES PERMIT ELECTRIC $10000 $2000 $000 $12000 Total Fees $120 00 Total Payments To Date $12000 Balance Due $000 JILDINGP IN STORAGE Inspector FINAL APPROVAL Date Clearance NOTICE Please take NOTICE that approval of your project includes the "Imposition of fees, dedications reservations, or other exactions hereafter collectively referred to as "fees/exactions" You have 90 days from the date this permit was issued to protest imposition of these fees/exactions If you protest them, you must follow the protest procedures set forth in Government Code Section 66020(a) and file the protest and any other required information with the City Manager for processing in accordance with Carlsbad Municipal Code Section 3 32 030 Failure to timely follow that procedure will bar any subsequent legal action to attack, review set aside void, or annul their imposition You are hereby FURTHER NOTIFIED that your right to protest the specified fees/exactions DOES NOT APPLY to water and sewer connection fees and capacity changes, nor planning, zoning, grading or other similar application processing or service fees in connection with this project NOR DOES IT APPLY to any fees/exactions of which vou have previously, been given a NOTICE similar to this, or as to which the statute of limitations has previously otherwise expired PERMIT APPLICATION CITY OF CARLSBAD BUILDING DEPARTMENT 1635xFa'raday Ave , Carlsbad, CA 92008 Address (include Bl3g/Suite #) FOR OFFICE USE ONLY PLAN CHECK EST VAL Plan Ck Deposit Validated By Date Business Name (at this address) Legal Description Lot No Subdivision Name/Number Unit No Phase No Total # of units Assessor's Parcel #Existing Use Proposed Use Description of Work SQ FT #of Stories # of Bedrooms # of Bathrooms Name ueo State/Zip Telephone # Fax # Name Address City State/Zip Telephone Address City State/Zip Telephone # (Sec 7031 5 Business and Professions Code Any City or County which requires a permit to construct, alter, improve, demolish or repair any structure, prior to its issuance, also requires the applicant for such permit to file a signed statement that he is licensed pursuant to the provisions of the Contractor's License Law [Chapter 9, commending with Section 7000 of Division 3 of the Business and Professions Code] or that he is exempt therefrom, and the basis for the alleged exemption Any violation of Section 7031 5 by any applicant tor a permit subjects the applicant to a civil penalty of not more than five hundred dollars [$500]) CA Warns LJ&I VState License # T O i t> U » Address „ T ft -<2I v License Class ,O City State/Zip City Business License # fJ(A. \ Telephone #| — U ' > J- ^( Designer Name State License # Address City State/Zip Telephone Workers' Compensation Declaration I hereby affirm under penalty of perjury one of the following declarations n I have and will maintain a certificate of consent to self-insure for workers' compensation as provided by Section 3700 of the Labor Code, for the performance of the work for which this permit is issued -01 have and will maintain workers' compensation, as required by Section 3700 of the Labor Code, for the performance of the work for which this permit is issued My worker's comjjensation insurance carrier and policy number are Insurance Company C-J *Q \^s "ILSjJQ^ Policy No /*J. ~O O" £• — Z/QQ<7 Expiration Date J "" ' ~~ C- 00 ff' (THIS SECTION NEED NOT BE COMPLETED IF THE PERMIT IS FOR ONE HUNDRED DOLLARS l$100) OR LESS) D CERTIFICATE OF EXEMPTION ( certify that in the performance Of the work for which this permit ts issued, I shall not employ any person in any manner so as to become subject to the Workers' Compensation Laws of California WARNING Failure to secure workers' compensation coverage is unlawful, and shall subject an employer to criminal penalties and civil fines up to one hundred thousand dollara443£Q£00}, in^adtHJJjBFTo the cost of compensation, damages as provided for in Section 3706 of the Labor code, interest and attorney's fees DATE ' | .31 I hereby affirm that I am exempt from the Contractor's License Law for the following reason Q I, as owner of the property or my employees with wages as their sole compensation, will do the work and the structure is not intended or offered for sale (Sec 7044, Business and Professions Code The Contractor's License Law does not apply to an owner of property who builds or improves thereon, and who does such work himself or through his own employees, provided that such improvements are not intended or offered for sale If, however, the building or improvement is sold within one year of completion, the owner-builder will have the burden of proving that he did not build or improve for the purpose of sale) n I, as owner of the property, am exclusively contracting with licensed contractors to construct the project (Sec 7044, Business and Professions Code The Contractor's License Law does not apply to an owner of property who builds or improves thereon, and contracts for such projects with contractor(s) licensed pursuant to the Contractor's License Law) fl I am exempt under Section Business and Professions Code for this reason 1 I personally plan to provide the major labor and materials for construction of the proposed property improvement Q YES QNO 2 I (have / have not) signed an application for a building permit for the proposed work 3 I have contracted with the following person (firm) to provide the proposed construction (include name / address / phone number / contractors license number) 4 I plan to provide portions of the work, but I have hired the following person to coordinate, supervise and provide the major work (include name / address / phone number / contractors license number) _ 5 I will provide some of the work, but I have contracted (hired) the following persons to provide the work indicated (include name / address / phone number / type of work) PROPERTY OWNER SIGNATURE DATE .^oR^^ &T, ''iXiiik/i! r^^ir^li , J , '•&¥$ -;**<» Ci'.ir" \ f^j^S^f^ Is the applicant or future building occupant required to submit a business plan, acutely hazardous materials registration form or risk management and prevention program under Sections 25505, 25533 or 25534 of the Presley-Tanner Hazardous Substance Account Act? Q YES Q NO Is the applicant or future building occupant required to obtain a permit from the air pollution control district or air quality management district? C] YES O NO Is the facility to be constructed within 1 ,000 feet of the outer boundary of a school site? d YES O NO IF ANY OF THE ANSWERS ARE YES, A FINAL CERTIFICATE OF OCCUPANCY MAY NOT BE ISSUED UNLESS THE APPLICANT HAS MET OR IS MEETING THE REQUIREMENTS OF THE OFFICE OF EMERGENCY SERVICES AND THE AIR POLLUTION CONTROL DISTRICT I hereby affirm that there is a construction lending agency for the performance of the work for which this permit is issued (Sec 3097{i) Civil Code) LENDER'S NAME * LENDER S ADDRESS I certify that I have read the application and state that the above information is correct and that the information on the plans is accurate I agree to comply with all City ordinances and State laws relating to building construction I hereby authorize representatives of the CitV of Carlsbad to enter upon the above mentioned property for inspection purposes I ALSO AGREE TO SAVE, INDEMNIFY AND KEEP HARMLESS THE CITY OF CARLSBAD AGAINST ALL LIABILITIES, JUDGMENTS, COSTS AND EXPENSES WHICH MAY IN ANY WAY ACCRUE AGAINST SAID CITY IN CONSEQUENCE OF THE GRANTING OF THIS PERMIT OSHA An OSHA permit is required for excavations over 5'0" deep and demolition or construction of structures over 3 stories in height EXPIRATION Every permit issued by the building Official under the provisions of this Code shall expire by limitation and become null and void if the building or work authorized by such permit is not commenced within 180 days from the date of such permit or if the building or work authorized by such permit is suspended or abandoned at any time after the work is commenced for a periocj ol! 180 days (Section 106 44 Uniform Building Code) APPLICANT'S SIGNATU DATE WHITE File YELLOW Applicant PINK Finance City of Carlsbad Bldg Inspection Request For 02/1^007 Permit* CB070015 Title BAUTISTA Description SOLAR POOL HEATING SYSTEM 2280 CALLE BARCELONA Lot 0 Type MISC Job Address Suite Location APPLICANT NATURAL ENERGY Owner Remarks SOLAR HEATING ? Sub Type OTHER Inspector Assignment TP Phone 7608025596 Inspector Total Time CD Description Act Comment 28 Solar, Domestic Hot Water Requested By LEO Entered By CHRISTINE Comments/Notices/Holds Associated PCRs/CVs Original PC# Inspection History Date Description Act Insp Comments 01/16/2007 21 Underground/Under Floor AP JM 01/12/2007 11 Ftg/Foundation/Piers NR TP PLANS, CARD 01/12/2007 24 Rough/Topout NR TP License Detail Page 1 of2 Wednesday, Janu License Detail Contractor License # 481870 CALIFORNIA CONTRACTORS STATE LICEN DISCLAIMER A license status check provides information taken from the CSLB license data base Before on this information, you should be aware of the following limitations • CSLB complaint disclosure is restricted by law (B&P 7124 6) If this entity is subject tc complaint disclosure, a link for complaint disclosure will appear below Click on the Im button to obtain complaint and/or legal action information • Per B&P 7G71__17, only construction related civil judgments reported to the CSLB are disclosed • Arbitrations are not listed unless the contractor fails to comply with the terms of the arbitration • Due to workload, there may be relevant information that has not yet been entered ont Board's license data base * * * Extract Date 01/03/2007 Business Information TED MOUNT DBA NATURAL ENERGY 147SVINEWOODST ESCONDIDO, CA 92029 Business Phone Number (760) 743-6400 Entity. Sole Ownership Issue Date 10/28/1985 Expire Date 10/31/2007 * * * License Status * * * This license is current and active All information below should be reviewed. * * * Classifications * * * (Class IB IGENERAL BUILDING CONTRACTOR C46 SOLAR Bonding Information * * http //www2 cslb ca gov/CSLB_LIBRARY/License+Detail asp 01/03/2007 License Detail Page 2 of2 CONTRACTOR'S BOND: This license filed Contractor's Bond number 138196 in the arm $10,000 with the bonding company AMERICAN CONTRACTORS INDEMNITY COMPANY. Effective Date 01/01/2004 Contractor's Bonding History Workers Compensation Information* * * This license has workers compensation insurance with the" STATE COMPENSATION INSURANCE FUND Policy Number 1525892 Effective Date 01/01/2000 Expire Date 01/01/2008 Workers Compensation History Personnel listed on this license (current or disassociated) are listed on other licei I i ) 'Personnel List! Salesperson List |Other Licenses • License Number Request H Contractor Name Request | Personnel Name Request • Salesperson Request • Salesperson Name Request ©2006 State of Calrforma Conditions.of.Use Privacy-Policy http //www2 cslb ca gov/CSLB_LIBRARY/License+Detail asp 01/03/2007 r o r* O i -Cx O 1 -C 3C ^ TO SOLAR PANELS BOOSTER PUMP FROM POOL"CHEC< VALVE CIRCULATION PUMP RLTER HEATER PROJECT NATURAL ENERGT SOLAR POOL WEATINCi MODIFIES DRAUN BY CRM CWECKED BT CRM SCALE NONE DATE SK-1 * Ai! work to comply w/2001 CBC, CPC * Truss/Rafters will support weight of Panels * Attachment of PVC Shown on Installation Manual * 1 Panel = 46 Ibs UL Listed Solar Controller UL STD-1563 INSTALLATION TRAINING MANUAL TABLE OF CONTENTS INTRODUCTION Page 3 INSTALLATION CREWS Page 4 SAFETY Page 5 BEFORE LEAVING SHOP Page 6 JOB SITE ARRIVAL Page 7 SYSTEM SIZING Page 8 SIZING ORIENTATION CHART Page 10 MOUNTING COLLECTORS Page 11 ALUMINUM RUNNERS INSTALL Page 12 ALUMINUM RUNNERS CAUTIONS Page 13 ASPHALT SHINGLES Page 14 FLAT ROOFS Page 15 OTHER ROOF TYPES Page 16 BARREL AND CURVED ROOFS . Page 17 EXPOSED BEAM CEILINGS Page 18 SPECIAL CAUTIONS Page 19 SOLAR MANIFOLD PLUMBING Page 20 PIPE RUNS Page 21 GLUING PVC PIPE Page 22 SUPPORTING PVC PIPE Page 23 TRENCHING Page 24 SOLAR CONTROL INSTALLATION Page 25 CONTROLLER TlE-INS Page 27 STANDARD SOLAR SYSTEM Page 28 SENSORS Page 29 STARTUP AND TESTING Page 30 PUMP ADJUSTMENT Page 31 FINISHING UP Page 32 REFERRALS Page 33 INTRODUCTION This manual is designed to enable new installers to be trained in proper methods of installation Experienced installers can use it as a refresher course on a regular basis It can also be used as a reference when installation questions arise The procedures and methoos in this manual are the result of many years of experience from around the country in the installation ana service of Advantage solar swimming pool heaters The information contained in this manua! shoulc not be taKen lightly or treated carelessly This knowledge was gained through years of experience, trial and error, and working with bunding codes and inspectors This document, along with all other company documents, is proprietary in nature and should not be copied or transmitted in any way to any other person or company Any copy violations may result in legal action This manual should be used as a basis for installation, realizing in all cases that the local building codes must be followed If tnere is a conflict between codes and this book, the codes will prevail The number one consideration you should have during any part of the installation is quality As you work on any given .ob, quality should be foremost in your mind, not only in the end product you have created, but also in the interaction with the customer during the installation process The customers are the ones who are ultimately responsible for you having a job They are the ones who musi be pleased with the final product as well as the entire process leading to the final product This manual has been presented so as to standardize our policies, procedures, and installations methods This standardization will eliminate confusion, promote efficiency and ensure quality You need to be familiar with everytning that is contained in this manual and to carry out the policies, procedures, and methods as they are presented and accepted by Natural Energy This manual will act as a basis for improvement in installations Although these policies and procedures act as a standard now, new idess and products will evolve to make the installations even better Improvement is something that we should always strive *o achieve Do not be hesitant to bring up new ideas, they will be evaluated and possibly included in updates to this manual INSTALLATION CREWS The installation crew is usually made up of a crew leader and one technician Safety, job quality, system performance, and customer relations are all part of the job and should be on your mind at all times Remember that you are representing Natural Energy You should arrive at the customers home appearing neat and clean, no holes in the slacks or sloppy t-shirts or tank tops Your truck is a reflection of you and Natural Energy A neat ana clean truck is an indication of a professional workman and it is much easier to locate parts and tools you wiiJ need if the truck is clean and organized While on the job site, remember that you are a guest at the customer's home You must treat his property with respect and care Your attitude and demeanor must be professional, friendly and personable You language and attitude must be above reproach It is the crew leader's responsibility to ensure that the job is completed in a professional manner and the customer is satisfied with the results The crew leader is to make sure the procedures and methods in this manual and the policies of Natural Energy are upheld completely The crewmember's responsibility is to assist in the installation while learning ihe procedures and methods required to one day become a crew leader SAFETY It is the responsibly of everyone to work in a safe manner and to ensure that the working surroundings are safe for others Tools must be maintained in good working order Never use a tool that has a bad electrical cord, a loose handle or is in poor repair *The work area, whetner it is in the truck, on the shop floor or on the customer's roof and property, must be kept clean and neat You shoulo always watch for any conditions that may result in hazards to yourself or to others As you are driving to and from the job remember that you are representing Natural Energy You must drive safely, and courteously, remembering that you need to present a professional appearance and attitude Keeping the shop floor neat and clean at your office will prevent you or your feilow workers from being injured It will also allow you to load up and get out to your jobs in a timely manner with all the parts and equipment that you need to do the installation Remember when you are working in the customer's home you may not be the only ones around Small children and homeowners are curious and may be wandering through the area that you are working in or below the roof you are working on BEFORE YOU LEAVE THE SHOP Prior to the installation of the solar system you will receive a set of plans or an installation directive You must review these documents and be certain that you understand what is required for the job completion If you have any questions about the installation requirements you should ask them now Trying to call back from the job site to learn what is needed or to get more parts or tools is frustrating, both for you and the customer It is also not the sign of a professional UPON ARRIVAL AT THE JOB SITE When you arrive at the job site you should park at the curb, install the yard sign, go to the door and introduce yourself to the customer You should review the installation with them, particularly panel location, pipe run and controller location If there are options, you should discuss them at this time During the installation you should treat the customer's property with respect They are spending a sizeable amount of money on the installation and should receive nothing but your best and neatest work If your truck has any fluid leaks, be sure to put down some type of drip pan so you do not stain the street in front of the customer's home After unioacnng your materials, move your truck out to the street People do not appreciate oil stains on their property, and they are difficult, time consuming and expensive to clean Be careful where you place the panels and your workboxes Turf can be fragile and easily damaged by the panel, especially as it heats up in the sun Above all remember that you are the expert and the professional You must always project that image to the customer If money is due at the completion of the job, or a Completion Certificate is required, inform the customer of the amount of money due, and give them the approximate time of completion There will be times when a customer has a different understanding of the scope of the job than you do from your paperwork If you are unable to politely resolve the differences, you must call your office for instructions You should never get into an argument with the customer If the customer is not home, proceed with the installation unless the directions from your shop state that the customer must be there Be sure not to let any pets out of the yard and to lock the gates when you leave After reviewing the job with the customer, check to see that all the existing equipment and roof information is the same as in your installation paperwork In particular, check that the pump size, pool area, compass heading, roof pitch, and roof type is accurate if there are any discrepancies contact your office Discrepancies in these areas can affect the performance of the system, the cost of the system and the customer's satisfaction with the completed project Check the roof to see that the panels will fit as shown in your paperwork If they do not, call the office to get authorization for any changes in placement When measuring for collectors, remember the formulas for space required is Width = (number of panels) times 49" plus 12" for plumbing Length = (panel length) plus 12" Take a good look at the roof condition before you begin the installation If the roof area is not in good condition, if there are any obvious holes, leaks, rotten areas, or broken tiles, call your office and take pictures If the roof area is deep in pine needles or other debris it will be necessary to sweep it clean prior to the installation Also look to see if the roof is of an open beam construction You do not want to have lag bolts sticking out in the customer's living room ceiling if this is a problem and you cannot avoid penetrating the ceiling, call the office for instructions, as you may need to build a rack for the job Take a good look at the existing pool equipment Write down and take pictures of any water leaks that you find and, if possible, point them out to the customer before you start the installation If there are any major leaks or questions regarding the equipment, call your office Check and write down tne filter pressure before you start the installation It is possible to accidentally drop glue or tools into the pip'ng and cause a problem without realizing it If you know what the readings were before you started and you compare it with ihe readings when you are finished, you will know immediately if you have a problem Check the returns in the pool for small air bubbles This is an indication of a suction leak in front of the filter pump Oider pools nave orass gate valves on the suction lines that sometimes leak past the packing glands on the stems In most cases they jusi need to be tightened The pump strainer basket lid may be loose or have a bad o-ring The vacuum hose could be leaking and causing these bubbles Another cause is low water in the pool, allowing air through the skimmer Once again, note any problems you see and take pictures of them Check the time clocks to ensure that the motor is turning and there are no electrical hazards, burned wires, etc Check the horsepower rating on the pump with that on installation paperwork If the existing pump is an older bronze type, you should check the "dead head" pressure of the pump to verify its strength To do this, cut the pipe between the filter and the heater and remove the section that is to be replaced by your solar manifold Install a 0-60 PSI gauge on the discharge from the filter and turn on the pump Be ready to turn it off instantly if there is a problem As soon as the needle on the gauge passes 30 PSI turn the pump off If you get less than 30 PSI on any pump adjust the impeller forward to get more pressure (See pump adjustment) If you cannot get over 30 PSI, cai! the office SYSTEM SIZING The performance of the system is directly proportional to the number of panefs installed More panels than the minimum required will increase the ability of the system to heat a swimming pool under marginal weather or orientation conditions Remember, minimum coverage equals minimum benefits Always consider increases of panel area on a percentage basis For example 10-panel system plus one panel equals a 9% increase The ideal location for the solar panels is a SOUTH-FACING PITCHED ROOF, near the pool, with enough space for mounting the required number of panels However, an installation on an east or west-facing roof is acceptable, if the panel area is increased Fortunately, the modular nature of the solar panel makes it easy to tailor the system to a specific site Be certain that the location you select, is not shaded by trees or other structures Remember, the effectiveness of a solar system is directly dependent upon the amount of direct sunlight that the panels receive The Advantage solar panels require a mounting space 49" wide for each panel When computing the actual installed dimensions of the entire system, allow an extra 12" around the perimeter of the bank to accommodate mounting apparatus, plumbing fittings and system accessories The panels should be facing true south, for the Northern Hemisphere, with the inclination as follows 1 For year-round heating equal to latitude of installation 2 For summer heating latitude minus 10 to 15 degrees 3 For winter heating equal to latitude plus 10 to 15 degrees The inclination must always exceed 8 degrees to ensure proper drainage This will allow for freeze protection and reduce the possibility of excessively hot water flowing from the panels to the pool when the solar turns on In reality you will often need to work with the customers existing roof pitch and orientation when installing the panels, but you should be aware of the optimum inclination A minimum of 60'- 90% of the pool's surface area in soiar panels is the recommended "rule of thumb" for sizing a swimmtng pool solar heating system (Example 800 sq ft pool needs 480 to 720 sq ft of panel area ) The minimum recommend coverage for pools is as follows SOUTH FACING Collector surface area equal to 60% of pool surface area WEST FACING Collector surface area equal to 90% of pool surface area EAST FACING Collector surface area equal to 90% of pool surface area Revision 06/19/2006 Orientation Coverage Chart Based upon industry standards* NORTH Summer System Only 100% Coverage WEST -4- 270° 90% Coverage SOUTHWEST 225° 80% Coverage SOUTH 180° 60 to 70% Coverage EAST 90° 90 to 100% Coverage SOUTHEAST 135° 85% Coverage "Coverage may be increased or decreased up to 10% depending on site conditions MOUNTING THE COLLECTORS Before beginning the collector installation, check the ground directly below me work area for items that could be damaged or broken by failing objects Move such objects to a safe location if possible This includes vehicles parked in driveways Ask customer to move their car to street or park in garage Handle the collectors carefully Avoid banging ihe headers or dragging the collector body across sharp points on the truck rack, ladder or the roof Watch out for nail heaas sticking out of the roof, especially if you rest the collectors over the roof peak Do not walk on the collectors while installing them Besides potentially damaging them, it leaves unsightly footprints on them Always mount and plumb the collectors so they will dram The inclination must always exceed 8 degrees to ensure the drainage of the panels Determine where the feed and return pipes will be penetrating the roof, or coming over the edge of tne roof, prior to mounting the collectors A little care spent in the location of the feed and return will save many headaches later It is usually easiest, if the day is noi too windy, to drape the panels over the peak of the roof as you begin the installation ALUMINUM RUNNER INSTALLATION Aluminum runners will be used on the installation of the collectors The following roofs will use this method of installation, shake shingles, cement tile (S and Flat) and clay tile Make a layout of the roof to make sure that all panels will fit, take in consideration and leave plenty of room for the plumbing The aluminum runners should be 1 foot longer ;han ihe span of the pane! array, this will leave 6" on each side of the panels to attach the strap Example 5 pane!s=20'5", runners should be at 21'5" All size panels will get an aluminum runner for the header bracket to be installed on 8-foot panels will get 2 additional runners for the body of the panel and 10 and 12-foot panels will get 3 additional runners for the body of the panel Use the chart below to determine the proper location of the runners Distance from top aluminum runner to other runners on body of pane! LENGTH UPPER STRAP MIDDLE STRAP LOWER STRAP 8' 3'2" N/A 6'8" 10' 2'8" 6'4" 9'4" 12' 3'8" 7'8" 11'4" After selecting the location of the panels, install aluminum runners by following these steps Step 1 Using a 5/16 masonry drill bit pre-dnll a hole through the aluminum runner and the shake or tiles {pre-dnll} Step 2 Clean surface of shake or tile and inject Henry 208 sealant into hole, on top of shake or tile leave a 1 1/2" dollop of Henry 208 ( dollop 208) Step 3 Using %" lag screw and washer, dip lag into sealant and drill into roof by going through the aluminum runner and tile {drilling in/dip lag) Step 4 The neader runner and lower runner on the body of the pane! has to be attached to the roof every 49" to make sure that it will be properly secured The middle and upper runner can be attached to the roof every 5' Lag screws should be placed no more than 4" away from end of aluminum runner ALUMINUM RUNNER COMPLETION Now thai aluminum runners are in place, it is time to attach the EZ mount brackets to top of pane! and the hold down strap Each panel will get 2 EZ mount brackets on its header, slide the bracket onto the header and using self tapping screw and washer, attach to the aluminum runner For the hold down strap, start at one end of the panel array, leaving one foot of extra strap, attach the strap to the aluminum runner For the opposite side of the panel array leave another foot of extra strap and attach it to the aluminum runner using the same size screw To make sure that the strap is tightened up properly insert the screw at an ancle away from the panel array This will pull the strap as it goes in Repeat this procedure to each row of aluminum runners, then come back at every gap of the panels and attach the same size self-drilling screw to the strap and aluminum runner To complete the installation of the hold down strap, install a strap bracket at each end of the panel array Install a strap bracket with screw through the strap then pull it through the strap bracket Make a loop then re-insert the strap to the strap bracket with screw and tighten it up ALUMINUM RUNNER INSTALLATION SPECIAL CAUTIONS Please take into consideration that each roof type has its own special needs 1 Shake roofs - Shake roofs for the most part have skip sheeting It is necessary to pre-dnll the shake shingles to prevent splitting Skip sheeting has for the most part 1 x 6 wood runners, so if you happen to miss the runner when attaching to ihe roof, go up or down 6" and you will be able to drill into wood 2 S Cement tile - Make sure to only pre-dnl! on the top of the tile and NOT on the valley This is very important *o orevent any leaks into the home Use caution when tightening up the lags screws to prevent breaking the tiles 3 Flat Cement tile - Runners will be used but to prevent water from damming up due to the runner we will need to install 3" pieces of aluminum runner to lift up the runner and allow water to dram properly 4 Clay tile - Same orecautions as for S cement tile The only difference is that clay tile is very fragile, and you must use special caution when walking and drilling into roof 5 Metal tile - Extremely fragile, use extra care and only walk in the valley part of the tile ASPHALT SHINGLES Measure roof for psnei fit Measure 4S" in width for each panel Once you know that ail panels will fit, slide panels inio location and insiaii top EZ mouni brackets to headers of collectors Apply dollop of mastic to area of roof that will be penetrated and by using a %" lag screw attach bracket to roof All panels will get two EZ mount brackets on headers To install body strapping to panels you will need two size washers V" x 1" and %" x 5/8" Install strap bracket with screw first, leaving one foot of extra strap, attach the strap to the roof by drilling a Y*" hole through the strao, put lag firsi tnrougn sirao, then through strap bracket Apply dollop of mastic to area that will be penetrated and screw into roof Make sure you have a good area of mastic around strap bracket so there will not be future leaks Do the same 10 the opposite side of panel array, making sure that the screw gets put in at an angle away from panel array To attach strapping in between the panels, pre-dnll a !4" hole through the strap and using both wasne^s, run the lag screw first through the %" x 5/8" washer, then through the strap, followed by the V«" x 1" washer and apply a dollop of mastic and drill into roof Follow these steps until all points of strapping have been completed FLAT ROOFS Installation of collectors in flat roofs is very critical Leaks can occur very easily if these steps are not followed properly The goal during installation is to prevent any blockage of water that will in time find its way into the house This method will be used on the following roof types composite, mop, and rock roof 1" x 3" x 6" redwood blocks treated with asphalt emulsion along with aluminum runners will be used in installation The first step is to figure out where the panels will be placed It is important to mark this location so the blocks are installed in the right location The panels will need blocks and runners in the same location as mentioned in the aluminum section of this manual Step 1 Clean surface of roof completely A composite roof won't require as much attention as mop and rock roofs Take time to scrape away all rocks until you reach a smooth surface This smooth surface should be at least a 5" x 9" section Step 2 Apply Henry's 208 mastic to surface and place the block on top Be sure you have a gooa bead of mastic all the way arouna the block Also apply a dollop of mastic on top of the block, where the lag will be penetrating it Step 3 Pre-dnll runner and then using a VS lag screw, drill through the runner into the blocK and finally, through the roof Step 4 Follow the above steps until all blocks and runners have been installed for the body straps Step 5 Install strap on the aluminum runners using the same procedure previously mentioned "For header brackets we stilt need blocks Instead of using the runner, drill through the bracket, then block, and finally to roof "On a torch down neoprene roof, it is very important NOT to use Henry 208 mastic Use white silicone instead The use of rnastic will damage this type of roof OTHER ROOF TYPES . The previous section descrbes the basics for installation The following section discusses the specific differences in installation for different roof types BARREL OR CURVED TILE ROOFS Before starting work on a tile roof you must check the entire roof for broken or cracked tiles Inform the customer of any existing damage to the roof prior to going on the roof yourself If there are an excessive number of broken tiles, you should inform your office and make note of it on your work sheets Do not walk on the roof where solar collectors or pipe will not be located In other words, do not walk over the roof from the front of the house if the collectors are to be mounted on the back of the house Be especially careful of damp slippery roofs in the early morning Use caution when walking on the tiles, stepping only where they can support your weight Be especially careful around tiles that have been cut by the roofer, these will be very difficult to replace if it becomes necessary Some of the newer tiles, and tiles that have not fully cured, are very fragile If you step on the roof and every tile is cracking, get off immediately and call your office Most cement tiles are installed in a similar fashion When walking on a tile roof, walk where the tile is supported by the by the 1" x 4" underneath, not in the middle of the tile Also note the overlap on the sides of the tile Walk on the under-lapping side of the tile, not the over-lapping side or you will start breaking off the corners Stay clear of valleys and ridges, tiles break easier in these areas EXPOSED BEAM CEILINGS Some homes have been built with exposed beam ceilings They have nothing between the roof sheathing and the interior of the home You can look up and see the underside of the roof sheathing from the inside of the home There is no attic or air space The roof sheathing is usually a 2" by 6" tongue and groove stock Some open oeam roofs will have 2"-4" of rigid insulation between the sheathing and the roof membrane Pre-dnll to determine the tnickness of insulation and the lag length needed These roofs are more susceptible to damage from heavy facing objects such as tools and lumber Be careful when working on these roofs to avoid damage to the insulation and the integrity of the roof Always check the installation to determine if it JS an exposed beam ceiling If you do not see any attic vents under the eaves you should become suspicious and make a closer inspection It is very embarrassing to have to explain to the customer why there are numerous lag bolts sticking through their ceiling Determine the lag size to be used depending on the roofing materials used Make sure to not penetrate into the house If we can't use any Size lag then we will need to install blocks and runners (See flat roof installs ) Blocks of 1"x3" will be attached to main beam of the house SPECIAL CAUTIONS When draining a bank of or back-flushing them, do not allow the water to exit the header in a forceful manner Some tile roofs do not have felt paper underneath them and water could be forced uncer the tiles and into the attic causing damage to the customer's home After the job is completed, take a few minutes to survey the roof for any broken tiles It is better to find them now than later when n rains and you get the bill for water damage If you do not have replacement tiles, swap the broken ones out with tiles from another area of the roof that will not be damaged by water, like the eaves Mark and count these tiles for later replacement SOLAR MANIFOLD PLUMBING The solar manifold is installed between the outlet of the filter and the inlet to the heater, if there is one The reason for this location is so that filtered water flows through the collectors Solar pool heating collectors have small holes that can be plugged by dirt and debris On the outlet pipe from the filter, the first component in the line is a check valve (1) When the pool pump shuts off for the day, water from the solar collectors drains back down the pipes and to the pool The purpose of the check valve is to prevent this water from draining backwards through the filter and back flushing the dirt and debris from the filter back into the pool and possibly spinning the pump impeller off or loosening it When installing the check valve, always try to leave room for it to be cut out and replaced should it ever break or become stuck Next in line comes the feed line tee (2) Water wtl! flow through this tee either to the solar collectors or on to the poo! The next component in line is the solar diverter valve (3) The diverter valve causes the water to flow either through the solar collectors or directly to the pool Most valves of this type can be adjusted to bypass some of the water to the pool instead of the panels if the pump is large or the system is very small Isolation valves should be installed in both the feed and return lines so that the solar can be isolated for service or in freezing conditions (4 & 5) Be sure to allow sufficient time for the panels to completely drain before closing the isolation valves In some situations, such as extremely long pipe runs or high lifts to the panels, a booster pump may be required for the system to work properly In these instances, the diverter valve is replaced with a tee The plumbing order from the filter is check valve, then a tee, no more than 6" of space and then another tee and then the heater There should be isolation valves on both the feed line (before the booster pump) and the return lines to isolate both the panels and the booster pump for service or in freezing conditions The booster pump must pump less GPM than the main pool pump does In most cases the booster will be no larger than % HP This avoids the inefficiencies of pulling water back from the solar return to satisfy the pump needs and sending preheated water to the solar It must be electrically connected so that it cannot run without the main pump running This prevents the potential for filter implosions and damage to the pump from running dry PIPE RUNS The pipe run is a very important aspeci of the installation, both functionally and aesthetically A poorly installed pipe run can rim ooth the looks and the performance of an entire job It is good practice *o review the JOD ano plan your piping prior to making any cuts into the existing system A few minutes spent doing this can oreveni many headaches later 1 Be absolutely certain that all the collectors return from a common high point This assures even flow and performance from all the collectors 2 Be sure that the collector banks are fed so as to not "short circuit" a collector bank Be certain that all collector banks will have water fed to them before converging at the common high point 3 Be sure the plumoing to the individual collectors will flow identically to all the others This means you must feea the water in one end and return the water out of the opposite end You cannot have an individual collector bank longer than 17 panels 4 Be certain the feed pipe run allows the panels to drain for freeze protection Aesthetically, ail plumbing must be straight and level Care must be taken to ensure that the plumbing is installed in the least obtrusive manner available Plumbing that is not plumb and neai will stand out like a sore thumb Any jumping over of the feed and return should be made near the equipment pad and not on the roof Plan your installation to reduce the number of 90-degree turns the water must make Two 45-degree turns cause much less backpressure than one 90-degree turn Proper planning will reduce excess backpressure on the system Anytime the pipes penetrate the roof you must install roof jacks Two of the most common types are the large (18" x 18") for shake roofs and the smaller (9" x 12") for composition roofs When installing the roof jack on a shake roof it is imperative that it be slid up underneath the existing felt paper On a composition roof, the top of the jack must slide under the row of shingles directly above it Improperly installed roof jacks can cause major damage On most other roof types, the pipes are plumbed around the eaves making a roof jack unnecessary For cement tile roofs and clay tile roofs, you must remove the tiles where the pipes are going to go through Once this is done, punch the holes through the roof, remembering to also run the sensor wire After punching the holes, run the plumbing through and have the pipes stick straight up at this time Apply Mastic around pipes in order to cover the entire hole After this you will need to cut the tile so it fits around the pipes Last, mix mortar and apply to area If the vertical drop of tne water from the roof to the pool surface is 2 stones, or more, the return line may need to have a section of 1-1/2 inch pipe in it or possibly even be completely composed of 1-1/2 inch pipe The 1-1/2 inch pipe will act to keep the water from falling down the wall faster than it can be pumped up the wall It is good practice to paint the PVC pipe, especially the white pipe, to match the house or roof color As well as looking better, the paint will protect the pipe from the ultraviolet rays of the sun This will increase the pipe life and keep it from becoming brittle As much as possible you should paint the pipe prior to installing on the wall or roof to avoid getting over-spray on the structure In desert communities you must always paint the pipes that are going up the wall If customer has paint that they want us to use, we can use it If not, always paint it "Almond" For places other than desert communities, we only paint pipes when includea in contract Most installations will involve some specific routing of the pipe Always check your installation paperwork for notes and reouests involving the pipe run GLUING PVC PIPE Proper pipe joints are essential to orevent future leaks and to keep the system operational A starved joint or one that is not securely bottomed out will result in leaks over time These leaks can cause considerable damage as well as customer dissatisfaction The proper gluing of PVC pipe is as follows 1 Be sure to cut ihe pipe square and remove any burrs from the end, both inside and out 2 Apply primer to the fitting and the pipe end 3 Generously apply the glue in direct relation to the pipe size, first to the fitting and then to the pipe 4 Press the pipe into the fitting, making sure to bottom out the pipe into the fitting 5 Give the fitting a quarter turn and hold for a few seconas to help assure a solid we!d 6 Wipe of any excess glue Glue outside the joint will not make the weid stronger Do not skip or scrimp on the primer It is designed to clean and soften the pipe and ensure good fittings Do be careful not to spill glue or primer onto the equipment or pad Keep your glue and primer fresh and clean Avoiding bad joints will result in no returns for leaks and a neater job overall SUPPORTING PVC PIPE All horizontal 'UPS of PVC oipe must be supported every 4 feet All vertical runs of PVC pipe must be supported once every story or once every 10 feet When you are attaching piping to a fence where the posts are on 8-foot centers, it may be necessary to add blocks between the posts to have a place for the pipe attachment Always run the pipes as low as possible for aesthetic reasons If it is required to run PVC under an eave, then it should be strapped every 16" or 24" depending on how the rafters on the house are situated TRENCHING By code PVC water lines must have a minimum of 12" of cover The trench for the piping should be 15" to 16" deep to ensure proper coverage Be aware of the area in which you are digging the trench Always look for possible water, gas, sprinkler, drain, or electric lines running through the area When trenching through a lawn, always put down cardboard or something similar to pile the dirt on Old pane! body material works well for this purpose Cut the sod in an orderly fashion so it will be easy to reset Similarly, when trenching through gravel or tan bark, carefully move the gravel or bark aside, cut the plastic sheet underneath and fold it out of the way Shovel dirt onto some cardboard or similar barrier When you are finished, replace the clastic and seal with tape to avoid weeds growing through the gravel or bark Pressure test ail piping connections before you fill the trench By testing the piping, you can avoid returning to the job to dig up the wet spot to investigate a possible leak When filling the trench, pack it down well Wet it if necessary or it will sink during the rainy season and look bad When you are working with a pool builder, you may be installing the solar pipes before the deck is poured In these cases work with him to determine the depth of the trench under the deck but in any case, outside the deck area, the piping must be a foot below grade If the pipe stubs for the solar lines come up through concrete, they must be wrapped with foam tape so that the concrete does not directly contact the PVC Any stubs for solar hook up must be pressure tested before the decks are poured to make sure all the fittings are secure The stubs are to be left under pressure until it is time to hook up the rest of the solar plumbing SOLAR CONTROL INSTALLATION When determining the location of the soiar control you need to keep in mjnd the following requirements 1 It must be located where it can be easily accessed 2 It is required by code to have 36" clearance in front of the control 3 It must be installed where it can be securely attached - usually code requires it to be installed to a permanent structure Always use a level to ensure the control is installed neatly on the wall Follow carefully the instructions from the manufacturer of the control you are using and also ensure that you are meeting ail code requirements The comments in the rest of this section are general guidelines for control installation Building codes and manufacturers' directions should always take precedence over these general instructions if there are conflicts Power to control should come from the line side of the filter pump time clock for motorized valve systems For booster pump systems, the power should come from the load side of the filter pump, after the last switch in line to the main pump This ensures that the solar booster pump will not start unless the filter pump is running This is very important when installing a booster pump system, because the booster pump must be supplied with water by the main pump If the booster pump runs dry, it can cause extensive and expensive damage to itself and to the surrounding plumbing There are two ways to run the power for a booster pump control use a tap circuit or by installing a separate breaker A tao circuit takes the booster pump power from the same circuit that supplies the main pump Because of the extra current draw, the breaker supplying the main pump must be 20 amps at 220 VAC and the wire must be 12 gauge The combined amperage of the main pump and the booster pump must not be higher than 80% of the breaker rating, i e 16 amps on a 20 amp breaker The amperage ratings can be found on the label on the pump motors If at ail possible, the power for the booster pump should be done as a tap circuit Then if the relay should fail (stuck contacts) the booster pump will not be damaged If it can be wired this way you should wire the control hot all of the time Minimum wire sized for various breakers is as follows Breaker Wire Gauge 15 amp #14 20 amp #12 30 amp #10 50 amp # 8 60 amp #6 70 amp # 4 In many areas the largest pump you can use on a tap circuit is Yz HP The largest main pump to tape from is usually 1-1/2 HP If the mam is 2, the amperage will probably be borderline and you should use an amp meter to check the actual amperage to ensure that you do not exceed the 16-amp figure The other method of wiring the booster pump is to put the pump on its own breaker The control power still comes from the main pump time clock, but the power for the booster pump comes from the load center on its own breaker From the breaker the power runs through the relay in the solar control and then to the booster pump In most jurisdictions the breaker, if it is in visual range of the pump, suffices as a pump disconnect If the breaker is not visible, or if in a remote location, fuse disconnect must be installed that kills both legs of power to the pump When making connections to the time dock, you can double up the wires only if it is a new style clock with a square ciamp plate if 't is an ola style unit with just the screw posts, you must cut the wire and use a wire nut When winng the controls, you must always run a #12 green ground wire This wire must connect the grounds from the motor soiar control, disconnect, time clock and any other device in the wiring array, to the ground wire from the sub-panel There are restrictions when running conduit to a controller or pump These restrictions are to ensure the long-term protection of the wire inside the conduit EMT or thin wall conduit can only be used above 36" from the floor because n is very susceptible to rust Below 36", running across floors, must be made in rigid steel conduit When running across floors you must use iron spacers to keep the conduit Y*" off the floor This helps prevent rust The last section of conduit before the pump must be flexible liquid tignt conduit not more than 36" long Conduit must be supported every 10" and within 3' of any coupling or termination When bending conduit, any run must have a junction box after not more than four 90 degree bends When installing conduit underground you can use only two types rigid or PVC Unless they are under Concrete, rigid must be buried 6" deep ana PVC must be buried 18" deep AUTO CONTROL TIE-INS Compoo! - See installation manual for detailed instructions Aqualink - See installation manual for detailed instructions Intellaiouch - See installation manual for detailed instructions Aquaiogic - See installation manual for detailed instructions Innovative - See installation manual for detailed instructions STANDARD SOLAR SYSTEM WITH BOOSTER PUMP The space between the tees in a booster pump situation should be as short as possible and not more than 6" to reduce the pressure drop in this section of the pipe and allow the system to work correctly After the pump you will need to instai! a check valve and a crossover (3/4" to 1" pipe) between the feed and return lines on the roof The check valve is to prevent damage to the pump as the panels dram down The crossover is to allow the panels to dram When plumbing the soiar manifold there are some basic rules to keep in mind The following is a list of these 1 Plumb the isolation valves where they are easily reached 2 Leave room for the check valve to be cut out and replaced 3 Leave room between fittings for repair if at all possible 4 Do not have more than 6" between feed and return tees 5 Plumb the booster pump or diverter valve where they can be easily serviced 6 Do not block access to the rest of the pool equipment so it can be serviced as necessary 7 When adapting from copper to PVC always use the male adapter for the copper and the female adapter for the PVC 8 Leave as much copper before the heater as possible so it can act as a heat sink Use a minimum of 12" if possible SENSORS Solar pool heating systems require two sensors One is located at the pool equipment to sense the water temperature in the pool and the other is located at the collector array sensing the available solar energy The water sensor MUST be installed before the solar feed line so it can sense the pool temperature before any solar heat is acded Try not to install the sensor on the suction side of the main pump unless it is the only possible place to install a sensor Installing the sensor before the pump increases the chance of suction side air leaks, which can affect the performance of the pump and filter as well as causing bubbles in the pool The sun sensor should be placed in the center of the solar array so it will get the same exposure as the soiar panels It should not be strapped to the piping or in the middle of the collector The sensor must not stick straight up in the air, as this will detrimentally affect its performance The sensor wire should be neatly wire tied to the pipes in such a way as to protect it from damage Do not leave the wires hanging loose Any place where the wire has been spliced should have a strain relief/service loop All sensor wire run under concrete or underground should be in PVC conduit, with radius bends (not more than 4 benas at 90 degrees) Do not use PVC fittings for bends Use only electrical sweeps STARTUP AND TESTING Prior to starting up the system, you shouid verify that the solar valve is working and in the correct position, that the isolation valves are open, and you should visually check the plumoing and clamps to ensure that the job is ready to start Turn on the filter pump with the solar control in the off position Let the system run for about 3 to 5 minutes Bleed off any trapped air from the filter and record the filter pressure Note if there is any air coming into the pool If there is air coming into the pool at this time, check all plumbing to ensure that there are no suction leaks in the system Turn on the solar control and, after all the air has purged out of the system, record the same readings again When you are on the roof, use a ratchet or similar tool with a 5/16" socket to tighten all the clamps while the system is running The cool pool water will shrink the collectors and allow the clamps to be tightened further If the pool has a spa, adjust the valves so that the spa is filtering and the solar is stili on Record the pressures as before For proper efficiency, the flow through an Advantage solar poo! heating system should be a minimum of 3 gallons per minute per collector, and a maximum of 8 gallons per minute The ideal flow is 4 gallons per minute If the flow is too fast you will need to bypass some water from the solar array This can be done with most automatic valves by adjusting the internal cams so that the valve does not close off the pool line completely This adjustment can also be done by installing a bypass loop with an adjusting valve in the feed and return lines to the solar After making the adjustments, recheck the pressure difference to ensure that you have the proper flow If the flow is too low, you will need to check the filter to see if it is clean If it is, you will need to adjust the pump if possible, or possibly upgrade the pump The last thing to record is the pool temperature This should be recorded any time you are at the pool site for service or installation Having these temperatures will allow your service department to know that the system is working PUMP ADJUSTMENT * The two basic types of pumps used are open face impeller and closed face impeller Most bronze pumps are open face Plastic pumps like Starne, Pacfab, American, and Challenger are closed face When you test a system for flow, and do not get the required amount, it may become necessary to adjust the pump The typical open face bronze pump can be easily adjusted with an Allen wrench and a screwdriver Loosen the Allen screws on the shaft coupling between the motor and the volute The coupling will move forward and the impeller will make contact with the inside surface of the volute Use the screwdriver to pry back the coupling just enougn so the impeller does not rub and then tighten the Allen screws Maximum flow is achieved when the clearance between the impeller face and the volute is minimized Purex "A" series pumps are harder to adjust They have shims you can remove by loosening the bolts that mount the motor to the volute Removal of these shims adjusts the impeller, but this usually does not get much of a change What you then have to do is remove the 4 mounting bolts and pull out the entire impeller motor assembly Then loosen the Allen screws on the impeiier itself to move it forward slightly Reassemble the pump, tighten all bolts, and check the clearance by reaching through the pump leaf trap and spin the impeller with your fingers Repeat these steps until maximum adjustment is achieved Closed face impeller-type pumps like Stante, Pacfab, American, and Challenger and some bronze pumps cannot be adjusted What you see is what you get But the impeller can become clogged with pine needles, bandages, small stones, etc or the impeller can be broken If a closed face pump looses efficiency, check the impeller FINISHING UP » Take the time to accurately record ALL information on your job paperwork Pick up your tools and equipment and clean up all your garbage Leave the job site in as good or better condition than when you got there You are the last representative your customer will remember, and he will see what is on the ground, and remember that, long before he will look at the plumbing and panels If the customer is home, give them an explanation of how the system functions, how to adjust the control, how to winterize their solar, what to expect from the system, and any maintenance that is required Be sure to let them know that their owner's manual and warranty will be mailed out to them from the office If there is money due or a completion certificate is needed, now is the time to collect it During the system briefing, the tech should finish the cleanup, load the truck, and double check the area for tools and garbage REFERRALS» . Our business relies on getting new customers either from expensive mailings or referrals from our current customers As you are talking with the customer you should, after the job is completed and he understands the system, ask htm if he knows anyone else who would benefit from, or be interested in our solar system Make note of the name, address and phone numbers and return them to your office Each truck should carry literature, information packets, and door hangers to hand out to other homes with pools in the neighborhood While you are working on the roof you have the perfect vantage point to see where these pools are Keep the literature packets clean and place them carefully at the homes so they will not blow all over the neighborhood You should constantly be looking for people who would benefit from our products and your services This will help ensure continuing employment for all of us