UMA Solar HC-10.5 Installation Manual Download

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PRESSURE TESTING THE HELIOCOL SOLAR SYSTEM

1.
2.

3.
4.

Pressure testing the entire solar system provides for a trouble-free installation and takes only about fifteen minutes. Any

weak PVC glue joint, fittings or pipe, and any improper panel clamp connections, will be evident while the system is put

under 40 to 50 PSI of pressure.

Allow ample time for all glue joints to dry completely. Use this time to wrap up things and to clean up the job site.

Wrap the threads of the (2-2015-101) pressure test “T” assembly, ½” ball valve and (2-3020-001) pressure gauge with

Teflon tape. Replace temporarily the vacuum breaker with the (2-2015-101) pressure test “T” assembly. Thread the

½” ball valve and pressure gauge into the pressure test “T” assembly.

Attach a garden hose to the ½” ball valve. Make sure the ½” ball valve is in the “OFF” position.

Turn the solar system on to allow the pool pump to completely fill the solar system. (If the pool pump is not operational,

shut off the ball valve on the feed line and use the garden hose to fill the system.)

Once the solar system is completely full of water, turn off the pool pump or turn the 3-way valve to bypass the solar

system. Quickly turn off the ball valves on both the feed and return lines.

Turn on the city water to the garden hose and open the ½” ball valve on the pressure test “T” assembly until the

pressure gauge reads 40 to 50 PSI and then turn off the ½” ball valve. Turn off city water.

With the system under pressure, check the whole system for any leaks. A drop in pressure on the pressure gauge

indicates a leak in the system.

If there are leaks, open the ball valve on the return line to relive the pressure. Repair any leaks. Repeat the pressure

testing procedures as needed.

Return a system to normal when through with the pressure testing. Be sure to open both ball valves and replace the

pressure test “T” assembly with the vacuum breaker.

14. Pressure Testing the Heliocol Solar System.

INSTALLATION MANUAL HELIOCOL

SOLAR POOL HEATER

2014 UMA Solar

Summary of Contents for HC-10.5

Page 1: ...at care has been taken to make this an easy to follow procedure A little time spent understanding the system and its parts will assure a successful trouble free installation CAUTION SAFETY COMES FIRST When working on or around your roof or pool please take care to avoid hazards such as electrical wires and loose shingles If you have any product or installation questions contact your Heliocol repre...

Page 2: ...meet the installation standards recommended by the factory see disclaimer on front page In addition because we ve included techniques and tips gathered from experienced Heliocol contractors throughout the country using this installation will save you time and effort 1 1 Introduction 2 2 Getting Started 3 3 Things to Remember 5 4 Installation Kits Components 6 5 Parts Breakdown 7 6 Solar Panel Layo...

Page 3: ... complete the installation Don t take shortcuts Whenever possible panels should be installed so they are accessible without being walked on Walking on the collectors should only take place when absolutely necessary Depending upon your specific job you will need various plumbing items and materials Be sure to use quality products that will withstand direct sunlight year after year Please take care ...

Page 4: ...mming pool filtration pump must be adequate to supply the solar system with enough water to provide the recommended flow rate necessary for the collectors being installed The recommended rates are Generally a 1 horsepower pump is sufficient for a standard pool solar system unless there is an unusually long pipe run a high roof or a large number of collectors If you are not sure what your pump flow...

Page 5: ...s not possible to achieve complete automatic drain down manual drain down valves should be installed in appropriate places in the plumbing or at the end of the bottom feed header Instead of installing an end cap 2 1410 013 at the end of the header you would place a 2 1410 005 type connector 2 1410 004 1 x 1 THD PVC reducer bushing along with a boiler drain 1 5115 017 These valves should be opened ...

Page 6: ...e the 2 3045 003 row spacer kit is only required for certain installations The 2 3020 022 pressure testing kit is used at the end of the installation to test the system while the 2 3020 025 Repair Tool Kit is used if you ever need to repair a collector MISCELLANEOUS Depending upon your specific job you will need other plumbing items and materials such as PVC valves stainless steel lag bolts polyur...

Page 7: ...NTS 2 1410 023 Vacuum Breaker 2 2015 010 PVC 2 Check Valve 2 2000 015 Pipe Clamp 2 2015 064 Two Way Ball Valve 1 5060 011 Lag Bolt 2 2015 065 Three Way Valve 2 1020 004 Drill Bit 2 1410 017 Gasket for Panel Clamp 2 1120 001 Repair Plugs 1 5060 021 3 8 X 4 Stainless Steel Lag Bolt 2 1060 002 2 1410 005 2 1410 013 2 2015 101 PRESSURE TEST T ASSEMBLY KIT 2 1060 001 2 1410 004 2 1410 008 1 4 CHISEL 1 ...

Page 8: ... 7 Shown below are the 5 most common solar collector installations Fig 6 1 SINGLE ROW Fig 6 2 DOUBLE ROW Fig 6 3 SINGLE ROW SPLIT FEED INSTALLATION MANUAL HELIOCOL SOLAR POOL HEATER 2014 UMA Solar Fig 6 1 SINGLE ROW Fig 6 2 DOUBLE ROW Fig 6 3 SINGLE ROW SPLIT FEED ...

Page 9: ...AP END CAP RETURN END CAP END CAP END CAP FIGURE 5 5 SERIES PARALLEL FEED FIGURE 5 4 SERIES FEED Shown below are the some common solar collector installations Fig 6 4 SERIES FEED Fig 6 5 SERIES PARALLEL FEED INSTALLATION MANUAL HELIOCOL SOLAR POOL HEATER 2014 UMA Solar Fig 6 4 SERIES FEED Fig 6 5 SERIES PARALLEL FEED ...

Page 10: ...thout a reverse rack in the northern hemisphere CHOOSING THE RIGHT SIZE COLLECTOR The roof space available to you will determine which model collector to use Since Heliocol manufactures collectors in eight different sizes you have great flexibility in what you can design The eight panels sizes are PANEL CONFIGURATIONS There are many ways to configure a solar array The most common and preferred is ...

Page 11: ...r Heliocol representative for the proper pipe size or alternative series plumbing techniques which will reduce the necessary flow rates on larger systems Plumbing runs should be as short as possible and the hot return pipe should have the shortest run to reduce potential heat loss in this pipe Pipes should be supported with pipe clamps or G clamps at least every 4 feet to prevent sagging Check wit...

Page 12: ...ocol solar pool panels are warranted against internal freezing when installed to allow for drain down To allow for the water to drain a vacuum breaker 2 1410 023 is installed on the solar feed line above the non positive three way valve as shown in Fig 13 1 page 22 Non positive means that the valve allows for water to drain back through the valve even while in the off position If you have If you h...

Page 13: ...into the opposite header groove and placing the ends of both headers into the open space in the panel clamp bottom Fig 7 1 D Use channel lock pliers to tighten the clip grip by squeezing it with reasonable force until it seats flush or even slightly farther so it cannot slide out of its position Fig 7 1 G Spray the gasket with silicon and insert it into the groove of one of the headers Make sure t...

Page 14: ...CONNECTING THE SOLAR PANELS TOGETHER 13 7 Connecting the Solar Panels Together Cont Fig 7 1 INSTALLATION MANUAL HELIOCOL SOLAR POOL HEATER 2014 UMA Solar ...

Page 15: ... this center point The center panel of an array may be locked in place by locating the gator clamps on that panel adjacent to the left and right of one of the header ribs see Fig 8 3 page 15 These gators should be attached using 2 lag bolts as opposed to 1 Do not use this procedure more than once on any array of panels Position the first gator clamp on the chalk line 6 from the top corner of the f...

Page 16: ...s are at least 2 away from each ridge along the heading Fig 8 4 D Once all gators are properly lagged to rack or roof surfaces and all the collectors are hung in place connect the top headers of each collector using 2 1410 004 panel clamps Snap the top portion of each gator clamp over the panel header onto the bottom portion of each gator clamp by pushing down firmly Fig 8 4 C Install 2 SS Screws ...

Page 17: ...l gator clamps are required for surfaces with a pitch of 10 12 or greater NOTE To allow for vertical expansion and contraction any gators installed on the bottom header must be positioned so that the header is in the middle of the cradle Fig 8 6 Fig 8 5 Fig 8 6 INSTALLATION MANUAL HELIOCOL SOLAR POOL HEATER 2014 UMA Solar ...

Page 18: ...created by wind blowing on the back side of the rack However if this wind is eliminated by other site specific conditions e g windbreaks or fences substrates are not necessarily required There are all types of flat roof surfaces and as the installing contractor you are responsible for making sure that the installation will not damage the roof surface If for example you have a very soft or rubberiz...

Page 19: ...o around small obstructions When you need to install panels over an obstruction larger than 6 wide or if the obstruction is less than 1 from a panel header you ll need a row spacer kit to circumvent the obstruction 1 2 3 4 Connect 4 of the 2 1410 005 pipe connectors to the headers of the collectors to be connected with a 2 1410 004 plastic panel clamp using the same procedures outlined in the sect...

Page 20: ... the feed and returns lines will be using the 2 1410 004 plastic panel clamp See Fig 11 2 B The 2 1410 005 pipe connector allows a 1 PVC Street 90 to be glued directly into the socket or a 2 PVC 90 to be glued on the side CPVC glue should be used when attaching PVC fittings or pipe to the pipe connectors to provide for a durable connection A 90 PVC fitting and vertical pipe run of at least 5 shoul...

Page 21: ...sible Once you are satisfied with the plumbing arrangement go back and cement all of your joints together using the good plumbing techniques explained in the Getting Started section Secure long pipe runs with C clamps or G clamps one size larger than the pipe diameter using 1 5060 011 1 4 x 4 stainless steel lag bolts and polyurethane caulk Secure vertical pipe runs on the side of buildings with p...

Page 22: ...rn line attached to the top header and an end cap on the bottom header The photo insert center the return line connection in detail The above photo right shows the feed line attached to the bottom header and an end cap attached to the top header NOTE Be sure to support all of the weight of the plumbing with gator clamps or pipe straps The mounting hardware is not designed to support the weight of ...

Page 23: ...tive Seal 2 2015 066 Ball Valve 2 2015 019 TO SOLAR COLLECTOR COOL RETURN FROM SOLAR COLLECTOR WARM TO ROOF SENSOR VALVE ACTUATOR WIRE Install before this point From pool Cool Return to pool HOT TO POOL SENSOR NEW PLUMBING Chlorinator Heater Other pool accessories optional EXISTING PLUMBING PUMP FILTER Fig 13 1 Pressure Test Kit 2 3020 022 used here to pressure test the system INSTALLATION MANUAL ...

Page 24: ...xisting plumbing so this equipment is located after the solar system as indicated in Fig 13 1 Cut the pipe after the filter where you have decided to locate the check valve and where your solar return pipe will attach to your existing pool return line If your pool plumbing is 1 and you are running 2 plumbing to your solar system you should be using 2 valves and piping for all of your new plumbing ...

Page 25: ...clean rag pour PVC cleaner on it and then wipe the dirt and identification marks off the pipe Do this on all exposed pipe This is also good preparation if you plan on painting the pipe to match the house color IF YOU ARE INSTALLING AN AUTOMATIC SYSTEM The basic difference between the manual system just outlined and an automatic system is the use of a motorized 3 way valve This 3 way valve is opera...

Page 26: ...l the solar system If the pool pump is not operational shut off the ball valve on the feed line and use the garden hose to fill the system Once the solar system is completely full of water turn off the pool pump or turn the 3 way valve to bypass the solar system Quickly turn off the ball valves on both the feed and return lines Turn on the city water to the garden hose and open the ball valve on t...

Page 27: ...ry with geographical location and time of year Be sure all collector riser tubes are snapped into the spacer bars except where they go around obstructions When the solar system is running you should notice Be sure that collector riser tubes are NOT rubbing on the roof surface between the spacer bars If they are adjust the spacer bars as needed to prevent this or a hole may develop in the riser tub...

Page 28: ... are sure all the water has drained out of the collectors and plumbing Turn the pool pump on to filter the pool as needed During the cooler months of the year it is essential that the pool surface be covered at night with a pool blanket to maintain a comfortable water temperature Low nighttime temperatures can lower the water temperature more than the solar can recover during the day INSTALLATION ...

Page 29: ...mp and can see air bubbles in the trap run water over the lid and each joint individually to see if the air bubbles will clear up using a garden hose If there is not a clear lid listen to pump noise for a smoother operation repair any air leaks 2 Ifthevacuumbreakerisinstalledonthe roof there is not enough water pressure in the solar system to keep the vacuum relief valve closed and it is allowing ...

Page 30: ... flow Install issue A If the system is a single row array and there is adequate flow use the HBV on the return line to throttle the flow back to produce more back pressure on the system This will even out the flow through the panels If the array contains more panels than the maximum recommended on page 7 of this manual change the array to a double row or single row split feed as show in Fig 6 2 an...

Page 31: ... the spacer bars to prevent future damage 3 Birds or squirrels have damaged the tubes Contactdistributorforarepairkitandadjust the spacer bars to prevent future damage THE 3 WAY OR BALL VALVE WILL NOT TURN Internal parts need to be lubricated or replaced If the valve has a grease fitting turn it clockwise to inject grease into valve then turn the diverter past the grease fitting to spread the grea...

Page 32: ...nel should be less than 10 gallons per minute Adjust the 3 way valve to bypass some of the water 2 Seasonal normal operation In the cooler months of the year or on cool partly cloudy days temperature rise through the panels may only be 2 or 3 Use the back of your hand to feel the water temperature difference at the pool return inlet 16 Troubleshooting Cont INSTALLATION MANUAL HELIOCOL SOLAR POOL H...

Page 33: ... instructions for repair Utilizing the repair chisel cut the damaged riser as close as possible to the header carefully avoiding damaging adjacent riser The sloped side of the chisel should face away from the header Spray the shaft of the insert tool and the rubber insert with silicone spray Insert the insert tool into the rubber insert While holding the rubber insert with one hand and the insert ...

Page 34: ...d length and slide it over the stub of the poly insert for a straight eye pleasing fit Repeat steps 1 4 for the other end of the riser tube At the opposite header 17 Repair Procedures Cont 4 5 INSTALLATION MANUAL HELIOCOL SOLAR POOL HEATER 2014 UMA Solar ...

Page 35: ...ing processes were all carefully scrutinized and found deserving of ISO 9001 2008 The solar energy system described by this manual when properly installed and maintained meets or exceeds the minimum standard established by the Solar Rating and Certification Corporation SRCC This certification does not imply endorsement or warranty of this product by the SRCC An Environmentally Safe Product is one ...

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