Heatl Panel Fabrication Manual
HAETLE PANEL ASSEMBLE MANUAL ver. 3.3

NPO ESCOT Energy Saving Conference & Organic Technology
NPO ESCOT for Renewable Energy & Environmental Technologies
Zip code 277-0011 4-17 Azumakami-cho,Kashiwa-city Chiba-pref.
ser.kashiwa@gmail.com
https://npo-escot.org
Production support ⇒+81-80-4365-0861

10/19/2023

Copy rights NPO ESCOT all reserved.

1

Heatl Panel Kit Contents

Heat-resistant nozzle x4
1/2 size (13) parallel thread
Carbonate

The heatlle panel is made up of four different parts.

Heat-resistant watertight plate x4 UV-cut 910x90x2mm Polycarbonate

Watertight cap: 1/2 size (13) Stainless steel

Production
ManualHollow polycarbonate side for repair x 1Nipple with nut x2
Hose band x 2*The heat-resistant nozzle is designed to hold an appropriate amount (0.5 mm thick) of silicone.
*A guide (convex part) is provided for easy finding of φ25mm holes when gluing.
*Alcohol type silicone for adhesion must be used.

10/19/2023

Copy rights NPO ESCOT all reserved.

2

Heatl Panel Structure, Heat Collection Principle, and External Dimensions
Two types and eight parts are simply laminated to hollow polycarbonate with the channel cut.

Heat-resistant nozzle

Heat collection principle

Heat-resistant watertight plate

Silicone Waterproofing

upper conduit
Backsidewatertight board

wall

underpipe canal

10/19/2023

Copy rights NPO ESCOT all reserved.

3

Heatl Panel Fabrication Procedures(1) Place the hollow polycarbonate on a flat work surface such as plywood. *Don't forget to remove the film on both sides!
(2) Fill the panel cut surface (hamonica structure) with silicone material to waterproof it.

(3) After the silicone has dried, cut the channel section from the panel.
(4) Stretch the heat-resistant watertight board on the "surface" of the panel. *Do not forget to remove the film from both sides of the panel!
(5) After the silicone has dried, invert the panel and open the four nozzle openings.
(7) After the silicone has dried, invert the panel again and put up the heat-resistant watertight board on the back side.
(8) After the silicone has dried, install the four heat-resistant nozzles on the surface.
(9)Wait 4 to 7 days (depending on the season) for complete drying. Wait 4 to 7 days (depending on the season) for complete drying.
(10)Before use, discard water to flush out internal debris, etc.

*The degree of drying of silicone depends on the temperature, location of use, and other factors.
(Approximate time required is 1 to 2 days in summer and 4 to 7 days in winter.)*When applying heat-resistant watertight plates and nozzles, remove any oil with alcohol or the like.

10/19/2023

Copy rights NPO ESCOT all reserved.

4Important!

Hollow polycarbonate andadhesive silicone products
listed on page 6.
Please use it.
This may cause leakage, peeling,or damage after completion.

10/19/2023

Copy rights NPO ESCOT all reserved.

5

Parts, components, tools, jigs, working environment

work environment

Workbench: Composite board
Line drawing over 1 m: El-type angle, etc.
vacuum cleaner

Required Parts and Components(1) Hollow polycarbonate board: 1820x910x4.5mm UV cut
Product name: Twin Carbo, Color: Bronze, Distributed by: Acrisunday Co.
(2) Heat-resistant nozzle: ESCOT Original(3) Heat-resistant watertight plate: 905 x 2.0 mm UV-cut(4) Watertight cap

Tools & Jigs
Required tools → indicated in red
Recommended tools and jigs → indicated in black

Alcohol Mold Silicone*Recommended: Cemedine 8051N*Note: Inexpensive oxime types are notacceptable.
(Rubber-like properties weakly peel off.)
Application: Hollow polycarbonate section
sealed waterproofing
Adhesion of heat-resistant watertightplate
Heat-resistant nozzle bonding

Silicone Injection Guns
*Recommended pressure reducing type: TAJIMA CONVOY LIGHT
Applications: Silicone extrusion

waste (cloth)
Application: Removal of dirt, oil film, etc.

electric drill
Applications: Water supply inlet, water intake
Air vent and drain openings
Drilling holes for installation upon completioncutter
Applications: Waterway, edge cutting, etc.
*Screw-fixed type*1.5 blade tips out for use.
*Caution: Dangerous as it may break if taken out too far.

safety goggles
Holesaw 25mm dia.
Applications: Openings for water supply, waterintake, air vent, drainage, etc.
*Note: Fine type
*Recommended: 454 BOSCH 25mm

safety gloves

ice pick
Application: Positioning of hole saws
Centering jig
Purpose: Centering of 25 mm hole.
*Inoac hose caps are converted

10/19/2023

Fuel alcohol
Application: Cleaning dirt and oil film on adhesive surfaces*Recommended: Takasugi Pharmaceutical Co. 30% ethanol
Methanol 70*Precaution: Use in a fire-free environment.

Copy rights NPO ESCOT all reserved.

clamp
Resin holding part is recommended.

6

Waterproofing and reinforcing of cut surfaces

Inject about 1.5 cm of silicone into the ribs (elongated space) on the upper and lower cut surfaces.
Place silicone up to about 4 cm in the center 5 ribs and 3 ribs on the left and right sides.
This area is for waterproofing and reinforcement, with the possibility of driving in screw nails, etc. for fixation.

Tools: silicone injector, plastic clamps, tip-machined nozzles
Explanation of terminology: A rib is an elongated space surrounded by a polycarbonate plane on the top,bottom, left, and right sides.
Note: Allow to dry for a while after injection. The time required for drying depends on the temperature.
*Usually, allow to dry for half a day to a full day.

Silicone nozzle tip processed for easy entry
Pre-mark the 5 ribs in the center.

10/19/2023

Copy rights NPO ESCOT all reserved.

7

2. cutting out the water flow pathCrepaths.
(1) Mark the bottom position with an ice pick or similar tool (A-F).

A Pump: 5cm from the top cross section, "7" rib from the left
B Water intake: 5 cm from the top cross section, 39" rib from the right.
C Air vent: 5 cm from top cross section, "7" rib from right
D Drain: 5cm from bottom section, "7" ribs from left
*E,F are auxiliary holes to facilitate cutting with a cutter.
E. Machining aid hole: 5 cm from the top cross section, "12" rib from the left.
F Machining aid hole: 5cm from lower section, "7" rib from the right(2) Use a 25 mm dia. hole saw to open 6 anas on the hollow polycarbonate.

(iii) Cut a water passage path approximately 2 cm wide with a cutter.
Create an upper water passage path approximately 2 cm wide between E and C.
ate a water supply inlet, intake, drain, air vent, and lateral water passage Create a lower waterpassage path approximately 2 cm wide between D-F.

Tool: Cutter (screw-fastening type)
Cutter guide（Aluminum unequal angle, etc.)
Clamp = Guide fixation
Ice pick (or a stapler)
25mm dia. hole saw

The cutter is lightly flushed at first, then moves to the cutting motion.
CAUTION: Protect hands with gloves, etc.

10/19/2023

Copy rights NPO ESCOT all reserved.

8

3. installation of heat-resistant watertight plate on the surface
Stretch heat-resistant watertight panels in the upper and lower two places on the surface.
(1) Remove shavings by suction, and wipe off oil, dirt, and moisture on the laminated surfaces with alcohol, etc.
*Do not forget to remove the vinyl from the surface of the heat-resistant watertight board.
(2) Apply silicone in a linear pattern about 5 mm away from the edge of each hole and water passage path.
Furthermore, silicone is applied to the outside of it.
(3) Place the heat-resistant watertight plate on the inside of 5 mm from the top and bottom cut edges of the hollow polycarbonate.
(4) Press your finger on top of the heat-resistant watertight plate to lightly spread the silicone.
After spreading to a certain extent, fix the heat-resistant watertight plate at two points on either side with clamps or the like to prevent itfrom shifting, and then push it further apart.
(5) After the laminating process is completed, let dry for about half a day to one day.
(6) After drying, cut off the top and bottom edges leaving 5mm with a cutter. This work is optional, as it makes the top and bottom edges look clean.

*Silicone is just at the waterway line.
The trick is to extend it to10/19/2023

Remove the oil film with alcohol, etc., and thenremove the oil film from both sides.
Press the corner with a clamp or other fixed object.
The tension can be stretched well without any slippage.

Copy rights NPO ESCOT all reserved.

9

4. drilling nozzle holes for the "front" heat-resistant watertight plate, and installing the "back" heat-resistant watertight plate
Turn the heat-resistant watertight plate over and drill holes for nozzles at A, B, C, and D.
(1)Turn over the hollow polycarbonate. The position of the holes on the hollow polycarbonate is opposite to the left and right.
(2) Mark the center of circles A, B, C, and D on the heat-resistant watertight plate with an ice pick or similar tool to prevent thetip of the drill from shifting.
The heat-resistant watertight plate does not open an anatomical hole in E and F.
To determine the center axis of the hole saw, it is recommended to prepare a piece of cardboard or similar material witha diameter of ø25 mm and a hole drilled in the center.
(3) Drill four holes for nozzles with a 25 mm dia. hole saw and remove burrs from the surrounding area.

(4) Vacuum shavings and thoroughly remove oil, dirt, and moisture with alcohol, etc.
Stretch the heat-resistant watertight board on the back side.
(5) Stretch the heat-resistant watertight board on the back side of the hollow polycarbonate in the same manner as for the surface.

Do not drill holes in E and F!

Remove shavings with a vacuum cleaner, etc.

10/19/2023

Copy rights NPO ESCOT all reserved.

10

5. nozzle installation
Attach the four nozzles to the heat-resistant watertight plate on the surface.
(1) Turn the hollow polycarbonate over again, surface side up.
(2) Remove oil, dirt, and moisture from the laminated surfaces of the nozzle and heat-resistant watertight plate with alcohol, etc.
(3) Apply silicone to the back of the nozzle.
(4) Move the nozzle to fit the convex guide on the nozzle to the anna on the heat-resistant water stop plate.
(5) Once the position is determined, press the center of the nozzle directly down while pressing with the other finger.
Press the outer edge of the nozzle.
(6) Adhesion is complete when the silicone slightly protrudes from the outer edge of the nozzle.
(vii) Allow to dry for 1 to 3 days.
(8) After drying, run water to rinse off internal debris before use.
Completion. Thank you for your hard work!

ConvexGuide

10/19/2023

Remove large burrs.

Copy rights NPO ESCOT all reserved.

Attach silicone.

Press until it
protrudes a little.

11

Precautions and recommendations for use
Do not open or close on the water intake side.

(1) Precautions for pumping water*Open and close the water supply side.
If water is supplied with the intake side closed, the inside of the panel will be damaged.
Pressure buildup may result in damage.
(2) Precautions for installation
When drilling holes in the light-receiving panel, limit them to 3 ribs from the edge.
The holes on the heat-resistant watertight panel should be about 5 mm in diameter,
Fix with stainless steel screws of φ4mm.

Panel fixing holes
Hole for fixing plastic sheet
Cap on the air vent.
Please keep it that way.

(3) Recommendations for improving heat collection efficiency
Use 4mm-thick black plastand in order to reduce heat dissipation to the backside.
*A food coloring agent is added to the circulating water to improve the absorption rate of sunlight.
Blue food coloring can be purchased at supermarkets for about 200 yen.
*4 mm thick hollow polycarbonate (product name: HAMONICARBO) is stretched on
the light-receiving side and double-layered.
(4) Recommendations for freezing*Dispose of the water inside the panel and do not use it during the freezing period.
* 1 or 2 liters of glycerin (safe) is added.
*Use antifreeze, etc. (Safety?) *Collect heat inside greenhouses, etc.
*Collect heat inside a house, etc.
*Use an anti-freeze heater.

Pradan should be used for the reverse side.
Screws should be limited to 3 ribs.

Recommended hoseSuper Water Hose SW-12(Available for purchase on the Internet)⑤Recommended pumpHeat-resistant, solar cell-driven pump manufactured by US SOLAR PUMP Co.
Important! Withstands high temperatures and can be used for long periods of time with onlya small amount of solar cell power.
No compatible products were found for domestic or Chinese products.

Keep the drain capped.

10/19/2023

Copy rights NPO ESCOT all reserved.

12