With the growing popularity of solar water heating systems, their installation has become increasingly widespread. The quality of these installations plays a crucial role in determining both the operational efficiency and longevity of the system. Drawing from practical experience, the editor has compiled some common considerations for the construction process, aiming to help minimize potential issues and enhance overall project quality.
### 1. Pre-construction Preparation
A thorough on-site survey is an essential part of the preparatory stage and serves as a critical foundation for refining the design plans. Even if initial surveys were conducted during the design phase, subsequent on-site assessments may reveal changes that require adjustments. Key aspects to focus on during this survey include:
1. Assessing the orientation and structural layout of the building to be installed, along with the actual dimensions of the roof.
2. Verifying the space available for large equipment like water tanks and recalculating the roof's load-bearing capacity. Reliable wind protection measures may be necessary if required.
3. Identifying the location of water sources and assessing water pressure levels.
4. Determining the power supply position and its load requirements.
5. Considering the actual site conditions to optimize pipeline directions and refine design blueprints.
6. Planning the delivery routes for materials and the hoisting of large equipment such as water tanks.
Additionally, it’s important to maintain open communication with the construction team, ensuring they fully understand the project’s specifications, technical requirements, construction methods, safety protocols, and any other relevant details. This ensures a well-organized construction process while minimizing the risk of technical errors.
### 2. Construction Phase
#### 2.1 Installation of Solar Heat Collectors
1. **Collector Orientation**: The solar collector must be installed precisely according to the design specifications, using a compass to verify the orientation. Typically, the tilt angle of a year-round solar water heating system should align with the local latitude, increasing by 10 degrees in winter and decreasing by 10 degrees in summer.
2. **Base Fixation**: To securely connect the collector base to the building structure, embedded parts and fine-grained concrete are commonly used. For steel or concrete bases, applying anti-corrosion treatments is crucial before installing the system. If the collector base compromises the roof’s original waterproofing, additional waterproofing measures must be implemented.
3. **Bracket Assembly**: When assembling the collector bracket on a concrete foundation, cross-reference the design drawings and physical components of the collector to confirm foundation elevations and coordinates. Ensure the bracket is level, stable, and that all connectors exhibit uniform strength. Adhere to guidelines set forth in GB 50212 “Construction and Acceptance Specifications for Construction Anti-corrosion Engineering†and GB 50224 “Quality Inspection and Evaluation Standards for Construction Anti-corrosion Engineering.â€
4. **Collector Placement**: The installation angle error of the collector should not exceed ±3°, and the layout must be orderly and aesthetically pleasing.
#### 2.2 Installation of Key Equipment
1. **Pump Installation**: Follow the manufacturer’s instructions and comply with GB 50275 “Compressor, Fan, and Pump Installation Project Construction and Acceptance Specifications.†Avoid stacking pumps during installation, as this can lead to air accumulation in the pipes, reducing pump performance. Implement vibration and noise reduction strategies, ensuring the pump’s input and output pipelines have independent supports. Outdoor-installed pumps must include weatherproofing measures, with added freeze protection in cold climates.
2. **Insulation Tank Installation**: Securely fix the insulation tank to its base per design specifications. All internal compartments must be grounded, adhering to GB-50169 “Construction and Acceptance Specifications for Grounding Devices for Electrical Device Installation Projects.†Use thermal insulation pads between the tank and bracket to prevent rigid connections and minimize heat loss.
3. **Electrical Control Cabinet**: Ideally, locate the control cabinet indoors, such as in stairwells. If placed outdoors, incorporate features like rain shields, insect guards, and lightning protection, ensuring reliable grounding.
#### 2.3 Pipeline Installation
1. **Ceiling Design**: When constructing a ceiling for pipes, consider the appropriate height and design the support framework accordingly to avoid unnecessary lengths that might necessitate rework.
2. **PPR Pipes**: Transition joints with copper inserts are recommended when connecting PPR pipes to metal components or sanitary fixtures.
3. **Stainless Steel Pipe Protection**: Protect exposed pressurized stainless steel pipe interfaces, wrapping them with transparent tape for added security.
4. **Avoid Plastic Hot Water Pipes**: Do not use plastic hot water pipes in equipment rooms.
5. **Material Compatibility**: When using dissimilar materials, take care to prevent electrochemical corrosion due to differing electromotive forces.
6. **Balcony Wall-Mounted System**: Connect the heat collection circuit using copper coils, ensuring flared pipe ends for optimal slope (≥10°) without reverse inclines.
7. **Antifreeze Solution**: In systems using ethylene glycol-based antifreeze, avoid galvanized steel pipes, as they react adversely with ethylene glycol.
8. **Pressure Testing**: Perform hydrostatic tests on pressurized pipelines and equipment, and water irrigation tests for non-pressurized ones, adhering to the “Technical Specifications for the Application of Solar Water Heating Systems in Civil Buildings.â€
9. **Pipe Insulation**: Conduct insulation after successful system leak detection and trial runs. If using an automated temperature-controlled electric heating belt, install it per manufacturer specifications prior to insulation.
#### 2.4 Additional Considerations
1. **Solenoid Valve Installation**: Install valves horizontally, incorporating fine mesh filters upstream and pressure-regulating shut-off valves downstream.
2. **Circulation Pipelines**: Include a vacuum valve in sections prone to gas blockages. For antifreeze-based systems, use manual exhaust valves.
3. **Solenoid Valve Selection**: Base your choice on diameter, medium temperature, and structural type. Sizes typically match the connected pipe diameter, with temperature resistance meeting operational needs.
4. **Lightning Protection**: Ensure all system components, including pipelines and metal supports, are reliably grounded as per design. Overlapping grounding conductors should be double-sided welded, with corrosion-resistant coatings post-welding. Connect equipment and brackets to the building’s voltage equalization ring via nearby connections. Each collector row should have at least two connection points, with resistance to the voltage equalization ring not exceeding 0.03Ω.
5. **Heat Collector Care**: After installation, avoid prolonged exposure to direct sunlight or complete shading, which accelerates collector aging and reduces lifespan.
6. **Material Handling**: Properly store materials during construction and conduct regular inspections to address and resolve issues promptly.
### 3. Conclusion
The quality of construction reflects a company’s technical expertise and management proficiency. High-quality construction reduces maintenance costs, enhances corporate reputation, and strengthens brand identity. Based on practical experience, this article highlights common construction considerations for solar water heating systems, hoping to assist construction teams and end-users in improving project standards.
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