Solar Roofs SkyLine 200152C80EX Installation Manual Download Page 1

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Wholly owned by ACR Solar International Corp.

5840 Gibbons Dr. Suite G Carmichael, CA 95608 (916) 481-7200

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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). This

certification does not imply endorsement or warranty of this product by SRCC.

(Note: SkyLine formerly Fireball)

CONGRATULATIONS!

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.

Table of Contents

SUBJECT

SECTION

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.

PLEASE CALL SolarRoofs.com WITH QUESTIONS

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!

We have worked to make SolarRoofs installation instructions easy

and complete. We are always looking to make them better and

welcome your comments and suggestions!

Summary of Contents for SkyLine 200152C80EX

Page 1: ...ials 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 Cont...

Page 2: ...anual Operation and Maintenance Manual and Stickers TOOLS AND MATERIALS NEEDED Overview Everyday homeowner tools are all that are needed to assemble and install the Skyline solar loop Tools and Materials Needed For Assembling a split kit or Skyline split kit model collector Pop Rivet Gun 2 large adjustable wrenches and or wrench set to secure collector absorber brass unions and compression fitting...

Page 3: ...ied 24 rails with 6 legs and hardware Option Code TK01 Single panel tilt kit Double panels Collector kit 3 4 1 x 1 Aluminum Rails with 12 legs and hardware Option Code TK02 Double panel tilt kit Tripple panels Collector kit 3 6 1 x 2 Alum Rails with 24 legs and hardware Option Code TK03 Double panel tilt kit Standard Color Default Musket Brown C101 Free Optional Color Dove Old Town Medium Gray C10...

Page 4: ...r Vent Pressure Relief Valve PV panel Solar Loop Temperature gauges Domestic cold in Mixing Valve Tank Drain Domestic hot out SkyLine Collectors 40 60 or 80 S F Floating Ball Check valve Tank Pressure Temperature Relief Valves Switch Cold shutoff 12 V PV pump Expansion Tank Solar Loop Pressure Gauge Heat Exchanger Optional Hot Out Temperature gauges ...

Page 5: ...c cold in Mixing Valve Tank Drain Domestic hot out Fireball 2001 Collectors Floating Ball Check valve Tank Pressure Temperature Relief Valves Switch Box Cold shutoff 12 V PV pump Solar Bypass SRCC Required Solar Bypass Valves Normal Solar Operation A and C are Open and B is Closed Solar Tank bypass A and C are Closed and B is Open A C B Expansion Tank Solar Loop Pressure Gauge Heat Exchanger Hot O...

Page 6: ...age tank must be kept in an area above 32 degrees F CONNECTING LINES INSULATION standard Tubing 1 2 12 7 mm OD copper 50 15 24 m Insulation 6 1 83 m supplied 1 2 12 7 mm ID 1 2 12 7 mm or 3 4 19 05 mm wall TUBING CONNECTION METHODS standard Type Brass Union Compression Brass Fittings for Heat Exchanger STORAGE TANK Rheem Rudd Richmond Model Number 81V080HE1 Not Supplied 80 Gallon Tank with In Tank...

Page 7: ...m charging fill valve V2 with cap Cool feed tank to un ion adaptor 3 1 square tube mounting rails 2 collector system shown 6 mounting rail brackets with 6 lags and 6 washers for every system rail set Collector component Assembly Air vent Pressure relief valve Upper comp unions 2 90s and 1 straight Center compression union body Lower compression 90 union Color coded bracket tec screws 2 Color codes...

Page 8: ...ectly associated with the installation of this system Do not install this system alone wwithout someone knowing where you are and what you are doing at all times In all cases where a firewall drywall is penetrated it is important to seal the hole A good general rule is to always fill in and seal around all holes made for solar lines to prevent heat loss and to maintain fire stops Properly support ...

Page 9: ...er sun can help year round performance In most areas with heavy winter overcast a solar collector s orientation on a low pitched roof can face anywhere from 45 degrees east to west of south without losing more than 8 of the energy it would have produced if it were facing directly south At 90 degrees east to west of south the loss is closer to 20 Exceptions include easterly facing systems in areas ...

Page 10: ...pplemental Split Kit Addendum COLLECTOR INSTALLATION 6 0 BE SECURE AND USE CARE Good procedure suggests that you always secure your ladder to the gutter so it does not slip Place blocks in the gutter so the weight of the ladder does not crush the gutter Protect the surface of the gutter with a cloth to prevent marks WALKING ON THE ROOF Use soft sole shoes Walk in the center of the shingle to preve...

Page 11: ...side the compression body before tightening nut Nut Ring Union Body PV Parts Bag contains PV switch Brackets and hardware See 9 0 Control Component Detail Roof Kit contains Mounting Ells and washers 3 5 or 4 Lags Center U Brackets for 2 or more collectors Color coded Tec Screws for securing Ell brackets and U brackets to collector Low profile Roof Boots Plumbing Kit 50 of OD Copper Pressure Relief...

Page 12: ...g from 14 to 2 for collector overhang find and mark Rafters for the Three Collector Rails shown in this picture are 3 rails for 3 collectors Use a chalk line to get the 3 rails even at the bottom Get the center rail as close to center between the end rails as possible Using a hammer to Sound Out the rafters usually finds the rafters If not use a feeler bit long small drill to drill through the roo...

Page 13: ...e Hollow Wall Expanding Anchors If using this method be sure to use the size bolt Drill a hole through the sheathing to allow for the thickness of the anchor Place the anchor in the hole pull the nut end up using the supplied bolt until it is tight but do not over tighten Expanding Anchor Tile Roof Installations be prepared to get longer 20 bolts NOTE Correct placement of the collectors on tile is...

Page 14: ...o boost the collector up to you On two story houses we strongly recommend two people for safety A sling can be made with sturdy rope going all the way around the bottom of the collector with shorter pieces going around the collector to secure the rope in place Be sure to secure it very well and always have a secure safety rope you can grab onto Have the second person push the collector up the ladd...

Page 15: ...oof by three mounting rails and 6 mounting Ell brackets 2 Position the Ell bracket between the trim and frame so it is CENTERED over the Lag hole Install the collector onto the rails with the mounting bracket tab UNDER the trim and BETWEEN the frame The small bend at the bottom of the trim makes inserting the mounting bracket easy Be sure to press the collector all the way down on the mounting rai...

Page 16: ...ount Installations Place the first collector in place with mounting bracket tabs inserted for final assembly Tighten down the lags Place three Quick Mount clips in place over their rail lag hole locations Partially install the lags to hold the clips loosely in place you will need an extension to your lag driver to get between the collectors Slip the next collector under the clips connect the compr...

Page 17: ...o drilling see Section 8 top and bottom connections NOTE sound out your roof to be sure no rafters are under where holes will need to be drilled Preposition the roof boot where it will go when the pipes are connected to the compression 90 in its final out position Mark the center of the hole remove the fitting and place out of the way Using a 1 hole saw or paddle bit drill the hole Carefully pry u...

Page 18: ... soldered adaptor for Pressure Relief Valve and Coin Vent Coin Vent 2 stick of OD copper Assembled SC01 Stacked Collector Array 1 compression Ell for the feed Bottom Roof Boot Top roof Boot 150 Lb pressure relief valve PRV 1 compression TEE to collector 1 compression Ell for the Collector Hot Return One union body is supplied per additional system collector IMPORTANT Be sure the union body is full...

Page 19: ...ctor IMPORTANT SSC1 TIP Before installing the last Left collector lift shingle for the flashing to go under See Roof Boot Flashing and Waterproofing Details SSC1 Side by Side Collector Installation Kit The SSC1 Feed has an additional Ell 2 copper sticks and a Tee for the second collector ...

Page 20: ...y this hole can be made out of sight in a closet After sealing the fire stop it may be desirable to make the remaining drywall removable by putting a simple frame around it and placing it back in place with a few finish nails INFILTRATION AND FIRE STOPS In all situations remember that infiltration is one of the main sources of energy loss in a house In no way should the installation of a solar sys...

Page 21: ...e e d fu r na c e a c re tur n s o la r w a te r ta nk fire p la c e ve nt p ip e c ha s e a c re tur n c ha s e N o te s o la r p ip e r u n N O Y E S D uc t C ha s e S o la r L i ne s C lo s e t S o la r L i ne s ve nt li ne c ha s e b lo c k a nd s e a l ho le s a nd fire s to p s c ha s e c ut ho le to a c c e s s fire s to p s e a l a nd re p la c e ...

Page 22: ... tilt for proper operation Bottom Connection of Collector When the end of the union is flush with the edge of the collector alignment in the collector is correct Put in the 90o compression union at this point and drill a 1 hole directly below it for the roof boot flashing to be installed Cut the shingle as needed and slide the roof boot flashing into place The copper tubing will be installed into ...

Page 23: ... working alone it may be easier to unroll the tube in the attic or first floor and send the tubing up and through the roof boot from the attic Fully insulate all lines Press about of supplied high temperature insulation into grommet hole to fully seal Covering the insulation with aluminum take and painting is recommended Be sure to overlap top over bottom like the shingles for good water shedding ...

Page 24: ...most of the way through it seal with calk lifting a shingle a little before drilling can help and put PV panel in place over it Pump Connections The PV panel wire is simply attached to a 14 to 18 gauge wire supplied with full system using wire nuts It is then attached to the switch which in turn is connected to the 12 Volt pump using wire nuts As mentioned we recommend going through the switch bre...

Page 25: ...ith water for flushing and Propylene Glycol for operation Isolation valve V3 close to charge sys tem open for operation Solar Loop Charging valve V2 used as out line to flush solar loop as out for Siphon Loop charging method or to return Propylene Glycol to charging bucket with preferred pump charging method 80 Gallon Heat Exchanger Storage Tank Cover to 220 Volt Element WARNING Always turn off po...

Page 26: ... tube to 1 2 MPT adaptor Thermometer Tee to Nipple Adaptor Floating Ball goes inside this fitting Floating Ball Hot Return From Collector Nipple with copper ball valve block on Ell end valve block in front Brass Ell Charging Valve Assembly System 5 Mixing Valve Hot Return Assembly Pump and Expansion Tank Feed to Collector Assembly Charging Vale Assembly X brass adaptor to tank nipple Finishes Tank...

Page 27: ...nnect the Collector Hot Return Line to the short Hot Return Tank Fitting 7 Connect the tank hot and cold lines and Mixing Valves per the diagram below 8 Charge the system by following one of the 2 procedures in Section 11 0 below 9 Insulate all water lines including the last 5 of cold water line as accessible with R 2 6 or greater insulation 10 The PV pump is simply connected to the switch which i...

Page 28: ... below is recommended 5 With 3 laundry hoses connect V1 to the pump outlet the second hose from the glycol bucket to the pump inlet and the third hose from V2 into the 2nd bucket as shown Fill the glycol bucket with 4 gallons 50 50 water glycol mixture V3 must be closed Open V1 and let water out to clear all air out of the hoses into the glycol bucket This also primes the pump if needed Turn on th...

Page 29: ...ble Connect a laundry hose to the Tank Drain and connect it to V1 Close V3 and fill the solar loop with water through V1 and allow water to flow out a hose connected to V2 to flush the solar loop Close V2 allow pressure to build to 48 50 pounds close V1 and check the system for leaks Keeping the loop full of water disconnect the V1 hose from the Tank Drain and insert it into the bottom of a 5 gall...

Page 30: ...olar efficiency by not allowing the element to come on during hours of solar gain as well as keeping it off during non use nighttime hours Ideally it is most efficient to completely turn off the electricity in sunny weather WHAT ABOUT FREEZE PROTECTION The SolarRoofs com s closed loop Propylene Glycol Antifreeze heat exchange system s collector as well as feed and return lines will not be damaged ...

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