Manual 04 - Section 07







Solar Pool Heating Installation Manual
SECTION 7: Installation Of Collector Array

7.1 BEFORE COMMENCING INSTALLATION

Before commencing installation check the system design and component quantities. Make sure you understand the design and have the necessary components to complete the project.

Pay particular attention to the roof condition and do not proceed if the roof is unsafe or in need of repair. If there is any existing damage or breakages to the roof material the owner must be notified prior to commencement.

7.2 INSTALLATION OF HYDROMAX ABSORBER STRIP AND HEADERS

A length of Absorber Strip ( Part No 109601) should be placed on the roof in the proposed position and cut to length. Allow a minimum of 750 mm from the roof edge, this is to provide sufficient space for the Header Assemblies.

This length of Absorber Strip can then be used as a template to cut the remainder of the Absorber Strips to the correct length. All individual Absorber Strips must be exactly the same length. The end of the Absorber Strips must be cut neatly and square so that a good connection to the Header Section or Strip Joiner can be made.

The Supply and Return Headers should be formed by gluing the Header Sections (Part No 109701) together to form the desired length of Header.

Once the Supply and Return Headers have been assembled they can be placed in their correct position on the roof. On tiled roofs the Supply and Return Headers should be positioned such that the Collector Array is as far away from the ridge capping as possible. This reduces the risk of subsequent roof leakage due to the ridge cap being disturbed during the installation.

Using the Header as a positioning guide each Absorber Strip should be run from the Supply Header before looping back on itself and returning to the Return Header. Once all of the Absorber Strips are in position and all roof obstacles avoided the Collector Array is ready for fixing to the roof.

Black Silicone Sealant (Part No 193014) should be used at not greater than 500 mm centres to secure the Absorber Strips to the roof. It is important to use liberal quantities of the sealant at each gluing location and to have the first application points not more than 200 mm from each end of the Black Silicon Sealant.

First check that the end of each Absorber Strip is cut square then, using the brush supplied with the Strip Adhesive (Part No 109707), apply the Strip Adhesive to the outside of the eight Terminator Pins. Brush the Strip Adhesive on to the pins from their base to their tip. Brushing in this direction helps prevent Strip Adhesive entering the pin openings. Ensure that the outside of all eight pins is coated with Strip Adhesive and that no Strip Adhesive has entered inside the pins.

Apply only a very thin coat to the inside walls of the Absorber Strip. Use an almost dry brush with all excess Strip Adhesive removed.

Wipe excess Strip Adhesive from the brush and apply a very thin coating of Strip Adhesive to the inside surfaces of each Absorber Strip tube. Now push the Absorber Strip evenly all of the way over the eight Terminator Pins.

The most important points to remember when using the Strip Adhesive are:

A Terminator Plug (Part No 109704) is to be fitted to every unused set of Terminator Pins on the Header Assembly. The connecting procedure described above is to be used again to fix the Terminator Plugs to the Header Terminator Pins.

The Air Vent (Part No 109648) is connected to the Supply Header at the highest point of the array. The Air Vent is screwed into a 40 mm PVC to 20 mm BSP Thread Adaptor and glued into a 90 Bend (Part No 109679). This combination is then glued, with the addition of a short section of 40 mm pipe, into the end of the Supply Header.

The PVC Cap (Part No 109668) is glued into the open end of the Return Header at the end opposite the return line connection.

The completed Header Assembly can now be secured to the roof with the aid of 40 mm Pipe Saddles fixed to the roof with either Black Silicon Sealant or a mechanical fixing, such as a roofing screw (which ever is appropriate for the roof material on the project).

7.3 INSTALLATION OF THE HELIOCOL ARRAY

Carefully inspect the available roof area to determine the Absorber Panel position that will encounter the least obstructions. Obstructions less than 150 mm in diameter can be circumvented by unclipping the Absorber Panel riser tubes from the Spacer Bar and spreading them around the obstruction.

On tiled roofs the vertical position of the Collector Array should be arranged such that it is as far away from the ridge line as possible. This reduces the risk of subsequent roof leakage due to the ridge cap being disturbed during the installation.

Having determined the best location mark the position of one corner of the outer Absorber Panel top Header. Using a string line from this point, mark a line on the roof which is rising by 5 mm every 2.5 metres toward the return connection end of the Collector Array. This line will be used to align each of the Absorber Panels during the installation.

The Absorber Panels should be fixed to the roof using the Fixing Strap (Part No 109690) and Strap Buckle (Part No 109691). For tile roofs this is achieved by passing the Fixing Strap around the Absorber Panel Header pipe (between the outer two spaces in the riser tube assemblies) then under the roof tile and around a batten before returning to the start position to be secured with a Strap Buckle. Each Absorber Panel should have four fixing points (two top and two bottom). The bottom Straps should be placed under the tiles and around the batten before the Absorber Panel is placed into position. This bottom fixing should only be buckled and tightened once the top fixings have been completed, this will ensure that the array is in the string line position.

On a metal or other sheet roof material the Fixing Strap should be secured by a 3 mm diameter screw (fixed into a timber or steel truss) with a large flat washer (to prevent damage to the strap).

7.3 INSTALLATION OF THE HELIOCOL COLLECTOR ARRAY

The Headers of each Absorber Panel are connected to the Headers of the adjacent Absorber Panels or to the supply and return lines with the Plastic Panel Connector (Part No 109688).

The Air Vent (Part No 109648) is connected to the Return Header at the end opposite to the return pipe connection. The Air Vent is screwed it into a 40 mm PVC to 20 mm BSP Thread Adaptor and glued into a 90 Bend (Part No 109679). This combination is then glued, with the addition of a short section of 40 mm pipe, into a PVC Tube Adaptor (Part No 109689). Using a Plastic Panel Connector (Part No 109688) and following the method described above the complete assembly can now be fitted to the Return Header.

The End Cap (Part No 109686) is screwed into the threaded end of a Threaded Flange (Part No 109687). Using a plastic Panel Connector (Part No 109688) and following the method described above, the threaded flange is fitted to the open end of the Supply Header at the end opposite the supply line connection.