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The solar energy system described by this manual, when properly installed and maintained meets the
minimum standards established by the Solar Rating and Certification Corporation (SRCC).
certification does not imply endorsement or warranty of this product by SRCC.
Thank you!
You have just purchased the most attractive and easiest to install active solar water heater
made! We have worked on every detail to assure you that SolarRoofs water heater will completely satisfy
you in its very high level of performance and dependability.
SUBJECT
Tools and Materials.................................................................................1.0.
Systems, Components, Options and Diagram ............................................2.0.
Specifications and Schematics..................................................................2.1.
Antifreeze Safety Data:.............................................................................2.1.1
Components included with system............................................................2.1.2
Important Notes.......................................................................................2.2.
Collector Location, Orientation and Tilt......................................................3.0.
Overview of the Basic Installation Steps.....................................................4.0.
Assembling the Collector (Split Kits Only)..................................................5.0.
Collector Installation................................................................................6.0.
Determining the Best Pipe Run..................................................................7.0.
Making Line Connections.........................................................................8.0.
Control Component Details.......................................................................9.0.
Tank Connections..................................................................................10.0.
Charging the Solar Loop.........................................................................11.0
Questions and Answers..........................................................................12.0.
Certifications.........................................................................................12.1.
Toll Free USA Technical Install Help Number: (888) 801-9060
NOTE:
Installation Color Photo Sheets Accompany this Manual for You to Refer to.
Generally drawings or diagrams are at the end of their respective sections.
WE WELCOME YOUR COMMENTS!
and complete. We are always looking to make them better and welcome your comments and suggestions!
Wholly owned by ACR Solar International Corp.
5840 Gibbons Dr. Suite G Carmichael, CA 95608 (916) 481-7200
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INSTALLATION MANUAL
CONGRATULATIONS!
Table of Contents
PLEASE CALL SolarRoofs.com WITH QUESTIONS
We have worked to make SolarRoofs installation instructions easy
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August, 2005
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(Note: SkyLine formerly Fireball)
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Table of Contents
Summary of Contents for Solar Roofs SkyLine 200152C80EX
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Page 1: Table Of Contents
Wholly owned by ACR Solar International Corp. 5840 Gibbons Dr. Suite G Carmichael, CA 95608 (916) 481-7200 ! " #$ ! " # & ! " # ' ( % INSTALLATION MANUAL August, 2005 The solar energy system described by this manual, when properly installed and maintained meets the minimum standards established by the Solar Rating and Certification Corporation (SRCC). -
Page 2: Tools And Materials
PLEASE READ ENTIRE MANUAL BEFORE STARTING INSTALLATION The system 5 can be installed in straightforward SAFETY FIRST!! See section 2.2 situations by two experienced people in less than 6 hours. With no experience, the installation will This Installation Manual assumes good probably take 2 people 8 to 12 hours, with added technical experience and ability. - Page 3 2.0. The following Systems, Components and Options are Wholly or Partly Covered in this Manual Note: This manual covers 20-01 collector installation, we hope the 10-01 collector will soon be OG100 approved for use with this system System 5. Complete 20 Square Foot (1.86 m ), 20”...
- Page 4 SkyLine System 5 ! " $ ! " $ ! " $ Air Vent Pressure Relief Valve SkyLine Collectors: 40, 60, or 80 S/F Domestic cold in Optional Hot Out PV panel Solar Loop Temperature Cold shutoff gauges Pressure Gauge Switch Domestic hot out Mixing...
- Page 5 SkyLine System 5 OG300 2 Tank Installation ! " )( $% )( $ ) ! %) ! Air Vent Pressure Relief Valve Fireball 2001 Collectors Domestic cold in Hot Out PV panel Solar Loop Cold shutoff Temperature Pressure gauges Gauge Solar Domestic hot out Mixing...
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Page 6: Antifreeze Safety Data
2.1. “20-01” OG300 Solar Water Heater Specifications COLLECTOR (Panel) Trim & Frame Materials: Finished 27 mil Aluminum Trim and Frame = Total 54 mil (1.37 mm). Absorber Material: “Black Crystal” coated - all Copper with unions. Glazing: .236” (6.0 mm) Twinwall Polycarbonate UV Treated Dimension / Weight: 200 -144.3”x 20.”x 3”... - Page 7 2.1.2. Components Included with the SolarRoofs Type 5 Please Note: SolarRoofs has improved its system and some pictures will not be visually accurate but show all the components included. Most copper fittings have been replaced with Brass. More visually accurate pictures will be included in their sections. Mixing valve only included with kit, assembly is included in picture to illustrate complete assembly PV Panel...
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Page 8: Important Notes
2.2. IMPORTANT NOTES: CHECK WITH YOUR LOCAL BUILDING DEPARTMENT FOR CODE COMPLIANCE FOR THE INSTALLATION OF YOUR SOLAR WATER HEATING SYSTEM. SAFETY FIRST!! USE CAUTION!!! Do not attempt to self-install without help if you have back or physical limitations!!! GENERAL WARNINGS: This manual assumes that the installer has good mechanical experience and can confidently use simple hand tools, building materials and adhere to safe building practices. -
Page 9: Collector Location, Orientation And Tilt
3.0. COLLECTOR LOCATION, ORIENTATION AND TILT Your solar water system will be providing savings for produced if it were facing directly south. At 90 degrees your family for decades to come. Because the sun rises east to west of south the loss is closer to 20%. in the east, crosses over the horizon on the south and Exceptions include easterly facing systems in areas sets in the west, you want your collector to face as much... -
Page 10: Overview Of The Basic Installation Steps
4.0. 4.Collector cool feed (bottom compression union) and OVERVIEW - THE BASIC hot return lines (top compression union) installed INSTALLATION STEPS: through roof boots to tank area. PV wire connected and run to water heater area. Insulation partly installed before tubing connections are made. PV panel THE BASIC INSTALLATION STEPS (3 to 8... - Page 11 Collector installation Components: Note 10-01 collectors will have 2 sets of collector brackets instead of 3 Roof Kit contains: Mounting Ells and washers, 3.5 or 4” Lags, Center U Brackets for 2 or PV Parts Bag contains PV more collectors, switch Brackets and Color coded Tec Screws for hardware.
- Page 12 Collectors mount horizontally and Collector Mounting Rails go as shown below. Two Collector 20-01 Top View (10-01 collectors use 2 rails about 1’ in from the ends) The Diagram above is a top view of two collectors installed together showing: 1.
- Page 13 2001 Side View The above Diagram shows a side view of the Collector installed on the roof and shows: (Refer to Color Pictures for Details of Ell Brackets) 1. Side view of a Collector. 2C. Roof Rafter. 2. Mounting Rails (3 per 20-01 collector). 3.
- Page 14 Use wisdom, when pulling collectors up onto the roof, have the collector at a good angle to the roof (out at the Mounting bottom). Protecting the gutter with a heavy cloth may be Rail Ell Bracket a good idea. Do not lean over the edge of the roof at all, simply pull and leverage the collector up onto the roof.
- Page 15 A NOTE ON MAKING TUBE CONNECTIONS: The tube connections top and bottom shown in top view as 3 & 5, are made at the top and bottom of ONE end of the collector. The connections can be at either end of the collector simply by placing the collector end left or right.
- Page 16 Two, Three and Four Panel Mounting Rails and Tilt Kit (two collector maximum per tilt kit): For installing two to four collectors or when two collectors are installed on the optional tilt rack, a special Quick Mount clip (6) is used between the collectors to firmly hold them onto the mounting rail.
- Page 17 FLASHING IN UNDER SHINGLES pipe to easily slip through and the small space left can be easily sealed with caulk and further covered with For Tile and other roofs, consult with the Factory. insulation. The base of the flashing can flex and be For Composition and Cedar Shake Installation: moved in different directions.
- Page 18 SC01 Stacked Array Installation Kit Loosely assemble your kit, per the following pictures, to locate the exact location of your roof penetrations and then follow the flashing and roof boot installation instructions. SC01 - Stacked Collector Assembled SC01 Stacked Collector Array Installation Kit Array Pre-soldered adaptor for...
- Page 19 SSC1 Side by Side Collector Installation Kit IMPORTANT SSC1 TIP: Before installing the last Left collector, lift shingle for the flashing to go under See: “Roof Boot” Flashing and Waterproofing Details. The SSC1 is the same as SC01 with addition of a Tee and 2”...
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Page 20: Determining The Best Pipe Run
7.0. DETERMINE THE BEST PIPE RUN COORDINATE THE PIPE RUN WITH THE BEST SOUTH FACING COLLECTOR LOCATION FOR THE SHORTEST RUN. IMPORTANT: SLOPE all lines to DRAIN! It is important that all pipes between the collectors maintain a 1/4" per foot drop to prevent traps and assure that all fluid drains when the drain valves are opened. COMMON RUNS sources of energy loss in a house. - Page 21 D e te r m in in g T h e P ip e R u n (b ir d s e y e v ie w ) * L o o k fo r t h e fo l lo w i n g : N o te : = s o la r p i p e r u n S e c o n d F lo o r...
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Page 22: Making Line Connections
8.0. Making Line Connections Line connections are easily accomplished using the gets inside the tubing. See Section 6. supplied brass compression connectors. Preparing the Collector When using compression connectors, be sure a small Pull the Absorber tubes fully out of the inlet and outlet amount of tubing material is showing on the outside of holes. - Page 23 To prepare for the pipe runs, straighten the copper lines by putting a foot on the end and carefully unroll the tube and keep the line straight. Carefully unroll the tubing through the roof boot into the attic. If available, have a partner guide the tubing to the tank being very careful not to kink the line.
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Page 24: Control Component Details
9.0. CONTROL COMPONENT DETAILS Seal the roof penetrations with a quality sealant. Photovoltaic (PV) panel: Place the PV panel on the same plane as the collector. If you have a tilt kit you Wire nuts are supplied to connect the PV wire to the may need to fabricate a tilt assembly for the PV panel. -
Page 25: Tank Connections
10.0. TANK CONNECTIONS for SYSTEM 5 Rheem / Rudd / Richmond Model Number 81V080HE180 Gallon Heat Exchanger Tank Solar Component Installation If it is desirable to have 80 Gallon Heat Exchanger Storage Tank the expansion tank and pump higher or above Feed Line to collector the tank, this can be ac- complished by making... - Page 26 NOTE: For The Two Tank System 5 Diagram, See Large Diagram In Section 2. IMPORTANT: Be sure floating ball goes inside the ½” x ¾” nipple adaptor as shown and that the tank ¾” brass nipple arrows point towards the tank with the ball block on the outside. Hot Return from Collector Assembly ½’...
- Page 27 Installing the Heat Exchanger Connections Refer to Above For Individual Components. The threaded brass fittings are installed using at least 6 tight turns of Teflon Tape or Teflon pipe dope. Heat Exchanger IN (Hot Return): Starting at the bottom with the ¾” brass nipple, connect and tighten the Hot Return Brass Fittings (with the temperature gauge and check valve) to the TOP Heat Exchanger fitting as shown.
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Page 28: Charging The Solar Loop
11.0. Charging the Solar Loop With Propylene Glycol Items Needed: 2 - 5 gallon buckets, 2 or 3 gallons of glycol, charging pump, 3 laundry hoses. 3. You can use a low cost hand drill pump like the above. Be sure to use it with a high speed drill, usually a 1. - Page 29 Charging the “Fireball 2001” Rheem HE System Non-Toxic Propylene Glycol Solar Loop* NOTE: A CHARGING PUMP IS RECOMMENDED, use the following method if one is not available and only when freezing weather is not a threat. *Use non-toxic Propylene Glycol only, never use or mix with Ethylene Glycol (Antifreeze) NOTE: You will need 2 Laundry hoses (these can be "borrowed"...
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Page 30: Questions And Answers
We Hope Your installation Went Smoothly!! PLEASE CALL WITH QUESTIONS OR COMMENTS: Toll Free USA Install Help Number: (888) 801-9060 Thank You and Now Enjoy the Savings! 12.0. QUESTIONS AND ANSWERS: HOW DO I GET THE MOST EFFICIENCY FROM MY SOLAR WATER HEATER? An easy method to increase storage efficiency is to have a 220-volt timer installed by an electrician.
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