Heliocol HC10.5, Installation Manual

Page 1: ... STRUCTURAL FRAMING MINIMUM 5 16 INCH DIAMETER MINIMUM 3 INCH THREAD EMBEDMENT ON SHINGLE MEMBRANE ROOFS 8 TILE ROOFS REQUIRE THE USE OF A CONTINUOUS Z BAR UNDER EACH HEADER THE Z BARS ARE ATTACHED BY CONCRETE SCREW TO EACH TILE CONTACTED THE GATOR CLAMPS SCREW THRU THE Z BARS REFER TO OEM MANUAL THE TILES AT EACH ANCHOR POINT SHALL BE BONDED TO ROOF COVERING WITH A SOLID FSM FOAM SET METHOD BED O...

Page 2: ...Swimming Pool Solar Heating System Residential Installation Manual Heliocol 2011 Revised 09 11 ...

Page 3: ...ngles or tiles CAUTION Safety comes first It is important to recognize that this manual outlines the recommended installation methods and practices as prescribed by the factory It is designed to aid a seasoned contractor or novice do it yourself individual while providing optimum protection for the products It is not designed to override any local codes or ordinances Also these are the minimal req...

Page 4: ...gh the most efficient way to cor rectly install a Heliocol Solar System By following this step by step guide your system will meet the installation standards recommended by the factory see disclaimer on page 1 In addition because we ve included techniques and tips gathered from experienced Heliocol contractors throughout the country using this installation guide will save you time and effort 2 Int...

Page 5: ...d 5 Familiarize yourself with all of the Heliocol com ponents and plumbing materials that you will need to complete the installation Here is a list of materials most commonly used Pipe Use pressure rated Schedule 40 PVC pipe You may prefer to use black as opposed to white PVC pipe on the roof for aesthetic reasons But because black PVC can be difficult to find some installers have inquired about t...

Page 6: ...t head and Phillips head screwdrivers Power drill with bits 5 16 and 7 16 sockets and drivers Pipe cutter or hacksaw Hammer Level Marking pen Silicone Lubricant Safety belts Lanyards Ropes Hard hats where required Garden hose Tape measure Channel lock pliers Caulking gun Ladder Chalk line Note While this manual explains how to install Heliocol Solar Collectors properly in typi cal situations it ca...

Page 7: ...e collectors to the feed and return lines or collector header RSK Row Spacer Kit One of these kits is required if you need to bypass a vent pipe or obstacle larger than six inches It is also used to connect collectors that are on different roof lev els or that are facing different directions into one row It contains the parts necessary to connect the collectors to the PVC pipe between them Other K...

Page 8: ...LLIGATOR CLAMP 6 106A End Cap 117 Pipe Connector 113 Collector Clamp 113B Bottom 113G Gasket 113T Top 113L Latch 100 Short Gator Clamp 100 Long Gator Clamp 142 Pressure Test T Assembly 140 1 2 Ball Valve 141 Pressure Gauge 133 1 4 Chisel 130 Pin Insert Tool ...

Page 9: ... the Most Common Solar Collector Installations 7 Fig 1 1 Single Row Fig 1 2 Double Row Fig 1 3 Single Row Spit Feed Fig 1 4 Series Feed Note No more than two 2 arrays are allowed in series feed and no more than eight 8 collectors are allowed in each array ...

Page 10: ...e the pump used for filtration is inadequate to generate enough flow GPM Because of the unique design of the Heliocol collector arrays of collectors can be plumbed in series Fig 1 4 Specific rules apply for series feeding regarding the number of collectors in arrays and drain down considerations Please contact a factory repre sentative for assistance with design criteria Pump Horsepower The horsep...

Page 11: ...Your Heliocol representative can also assist with this and explain the use of balancing valves on larger systems If you are installing the solar collectors on a flat roof or flat ground rack the top return header of the collec tor should be a least 3 higher than the bottom feed header to assure equal flow through all of the tubes of all of the collectors See pg 13 To achieve even distri bution of ...

Page 12: ... and contraction For barrel tile roofs each clamp needs to be positioned so that it is centered on the top ridge of a tile still as close to 24 centers as possible 4 Since normal horizontal expansion and contraction of an array of collectors takes place every day as collec tors heat up and cool down it is preferable to lock the center of each array in place so that the expansion and contraction ta...

Page 13: ...two 2 SS screws 6 x to secure clamp top to clamp bottom assembly 10 Attach the bottom headers of the collectors with 113 collector clamps 11 Locate and mount the clamps 2 each along the bottom header aligned with the upper header clamps The bottom clamp should be installed allowing a large gap on the top allowing for contraction 12 Attach feed and return lines following Heliocol s published guidel...

Page 14: ...eader end with the larger flat portion facing the roof 6 Seat both headers together by inserting the gasket into the opposite header groove and placing the ends of both headers into the open space in the plastic collector clamp bottom Fig 8 C 7 Interlock the top half of the plastic collector clamp with the tab on the bottom half Swing top half closed over top of headers Caution Be sure to align to...

Page 15: ...Mounting the Solar Collectors on a Flat Roof 13 Multi Ply Flat Roof Single Ply Flat Roof Asphalt Built Up Flat Roof ...

Page 16: ...nnectors as shown in Fig 9 If the distance between the collectors is over 4 inches a 2 inch pipe clamp should be used on both pipes to prevent sagging Note When gluing the 117 CPVC pipe con nectors it is necessary to use good quality multi purpose cement The spacer bar may need to be cut out of the way if it falls in the obstruction s path Warning This should not be done between the header and the...

Page 17: ...will be using the 113 plastic collector clamp See Fig 12 4 The 117 pipe connector allows a 1 PVC street 90 to be glued directly into the socket or a 2 PVC 90 degree to be glued on the outside All purpose cement should be used when attaching PVC fittings or pipe to the pipe connectors to provide for a durable connec tion A 90 degree PVC fitting and vertical pipe run of at least five feet should alw...

Page 18: ... from the return elbow down to the spot that you want to go across the roof to the point established above Be sure to include the depth of the socket in the elbow in your measurement Cut a piece of PVC pipe to this length Repeat this process for the feed line 4 If you are not experienced at cutting and fitting pipe it is a good idea to assemble all pipe and fittings before cementing them just in c...

Page 19: ...17 End Cap u t Return Line End Cap p Feed Line q Rib p Fig 14 ...

Page 20: ...ow to Connect the Solar Collectors to The Existing Pool Filtration System 18 WIRE TO ROOF SENSOR Fig 15 121 5210 5210 3344 1790 PTK Manual Wire to Optional Motorized Actuator Optional Motorized Actuator ...

Page 21: ...bing to your solar system you should be using 2 valves and piping for all of your new plumbing so you will need two 2 2 x1 1 2 reducer bushings to adapt your new 2 fittings to the existing 1 1 2 pipe 3 As discussed earlier in this manual it is a good idea to assemble all pipe and fittings before cementing them just in case you make an error Install a union check valve on the pipe coming out of the...

Page 22: ...s time to wrap up things and to clean up the job site 2 Wrap the threads of the 142 pressure test T Assem bly 140 ball valve and 141 pressure gauge with Tef lon tape Temporarily replace the 121A vacuum breaker with the 142 pressure test T assembly Thread the 140 ball valve and pressure gauge into the pressure test T assembly 3 Attach a garden hose to the ball valve Make sure the ball valve is in t...

Page 23: ...d so that the pump will run when sun is shining on the solar collectors Usually 10 00 AM to 4 00 PM but this will vary with geographic location time of year and the compass location of the system 6 When the solar system is running you should notice A slightly higher pressure reading on the pressure gauge At midday if the sun is out warmer water should be coming into the pool This water should be 3...

Page 24: ... as it flows by the valve Install Answers Be sure filter is clean Backwash to reduce pressure Locate vacuum breaker on the feed line as shown on page 18 Fig 15 and put a solid end cap at the end of the top header where the vacuum relief was located Using the 5210 ball valve on the return line throttle back the flow to produce more back pressure on the system Some of the Solar Collectors are Warm t...

Page 25: ... rec ommended flow on page 24 Adjust the three way valve to by pass some of the water Diagnosis Seasonal normal operation Answer In the cooler months of the year or on cool windy or partly cloudy days the temperature rise through the collectors may only be 2 or 3 degrees Use the back of your hand to feel the water temperature difference at the pool return inlet Installation Troubleshooting Continu...

Page 26: ... many factors to consider Collector Model 50 40 30 12 5 10 Size Nominal 4 x 12 5 4 x 10 5 4 x 8 1 x 12 5 1 x 10 5 Width 47 120 cm 47 120 cm 47 120 cm 11 75 11 75 Length 152 1 380 cm 127 323 cm 91 231cm 151 5 127 Area sq ft 50 0 4 65 m2 41 6 3 88 m2 30 0 2 77 m2 12 2 10 2 Manifold Diameter 2 5 08 cm 2 5 08 cm 2 5 08 cm 2 2 Weight dry 22 lbs 10 kg 19 lbs 8 5 kg 15 lbs 6 8 kg 5 5 lbs 4 75 lbs Volume ...

Page 27: ...25 Notes ...

Page 28: ...26 Notes ...

Page 29: ... 2008 certification Over the two year process necessary to gain certification their customer service record product failure rate and engineering processes were all carefully scrutinized and found deserving of ISO 9001 2008 certification The solar energy system described in this manual when properly installed and maintained meets or exceeds the minimum standards established by the Solar Rating and ...