Installation. ng Kitt

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1 Installation Instructions Alpha SolarSmart 100 Roof Integrated Flashi ng Kitt for the Installation of Alpha Solar Collectors into Tiled Roofs 1

2 Integrated Flashing kit for Alpha SolarSmart 1000 CONTENTS 1. Introduction 2. Portrait flashing Tray Installation 3. Landscape flashing Tray Installation 4. Mounting the Solar Collector 5. Connecting the Pipes, Sensor, Cover Plate andd replacing the Tiles 6. Twin Collector Flashing Kit 1. INTRODUCTION The integrated roof flashing kits detailed below have been designed to allow either an Alpha Landscape or Portrait SolarSmart solar collector to be fitted directly into either tile or slate type roofs. Thee kits required are as follows:- Landscape kit Part No Portrait kit Part No Twin Collector Portrait kit..partt No Note: The integrated roof flashing kits have been designed to fit into a roof with w large inter-lockintaking into consideration the tile type clay/concrete tiles, or small plain clay/concrete tiles. It is very important to choose the correct location for the collector on the roof and the collector height and pipe positions for connection to the drain back unit. Before assembling and installing the collector youu should read these instructions carefully together with the Alpha SolarSmart 100 system and associated installation instructions. The collector must be mounted level on the roof for it to function correctly and prevent damage from f freezing. Installation of integrated roof flashing kits and collector should be performed by a recognised installer and roofing contractor. The manufacturer will not be held responsible for damage resulting from improper installation. It is the responsibility of the installer to make sure the connection between the flashing trayy and the roof tiles is weather resistant. Whilst this kit has been developed to work with ass many tile types as possible; due to the wide variation in roofing tiles on the market it may be necessary to cut andd modify the tiles to align correctly with thee flashing tray. Collector Dimensions: Weight Dim X ( mm) Dim Y (mm) 40Kg Dimm Z (mm) 83 2

3 2. PORTRAIT FLASHING KIT CONTENTS OF PORTRAIT FLASHING KIT Part No IMPORTANT: For the system to work correctly the Flashing and the Solar Collector must be mounted level! 3

Assembly and Installation of the Portrait Kit When choosing the location of the

back to the drain back unit when the drain back unit is installed in the roof

Install thee flashing to within two rows of tiles from the ridge if possible.

positioned centrally in the space between the tiles and 140mm from the top of the

Using the 70mm Torx screws, fix the strip to the rafters making suree it is level.

apron over the tiles and push against thee apron to make sure it sticks.

4 Assembly and Installation of the Portrait Kit When choosing the location of the flashing consideration must be given to thee pipe work too allow a constant fall back to the drain back unit when the drain back unit is installed in the roof space. Install thee flashing to within two rows of tiles from the ridge if possible. To fit the flashing tray remove the tiless to expose thee roof battens to an area of approximately 1.9m x 3m (W x H). There is a wooden strip supplied with the portrait kit (key item 5) which must be positioned centrally in the space between the tiles and 140mm from the top of the lower tile batten to the top of o the wooden strip. Using the 70mm Torx screws, fix the strip to the rafters making suree it is level. Roll out the lower apron seal (key item 6) and cut to the same length as the plastic p flashingg tray. Peel the plastic backing off of the apron and stick the apron to thee wooden batten previously fixed to the roof. Make sure the top edge of the apron is lined up with the top edge of the batten and is central. Firmly push thee apron onto the batten to make sure it sticks, neatly lay the apron over the tiles and push against thee apron to make sure it sticks. On profiled tiles, it will be necessary to dress the apron into shape using a suitable dressing tool. Roll the plastic flashing tray out on the roof battens with the lugs at the bottomm resting along the length of the apron batten and centralize the tray. To secure thee tray to the roof, screw thee self-drilling 70mm Torx screws through the two outer raised ribs into the roof battens bellow. Lay the aluminium strip (itemm 11) along the bottom of the tray with the hooked section butted up to thee bottom edgee and secure the t strip into position using the 30mm Torx screws. 4

5 3. LANDSCAPE FLASHING KIT CONTENTS OF LANDSCAPE FLASHING KIT PART No Assembly and Installation of the Landscape Kit When choosing the location of the flashing consideration must be given to thee pipe work too allow a constant fall back to the drain back unit when the drain back unit is installed in the roof space. Install thee flashing to within two rows of tiles from the ridge if possible. To fit the flashing tray remove the tiless to expose thee roof battens to an area of approximately 3m x 1.9m (W x H). 5

There are two wooden strips supplied with the landscape kit (key item 5), one will need to be cut so that when laid end to end they are the same length as the flashing tray.

6 There are two wooden strips supplied with the landscape kit (key item 5), one will need to be cut so that when laid end to end they are the same length as the flashing tray. Position the wooden strips centrally in the space between the tiles and 140mm from the top of the lower tile batten to the top of the wooden batten. Using the 70mm Torx screws, fix the battens to the rafters making sure they are level. Roll out the lower apron seal (key item 6) and cut to the same length as the plastic flashing tray. Peel the plastic backing off of the apron and stick the apron to the wooden batten previously fixed to the roof. Make sure the top edge of the apron is lined up with the top edge of the batten and is central. Firmly push the apron onto the batten to make sure it sticks, neatly lay the apron over the tiles and push against the apron to make sure it sticks. On profiled tiles, it will be necessary to dress the apron into shape using a suitable dressing tool. Roll the plastic flashing tray out on the roof battens with the lugs at the bottom resting along the length of the apron batten and centralize the tray. To secure the tray to the roof, screw the self-drilling 70mm Torx screws through the centre and two outer raised ribs into the roof battens bellow. Lay the aluminium strip (item 11) along the bottom of the tray with the hooked section butted up to the bottom edge and secure the strip into position using the 30mm Torx screws. 70mm Torx screws 70mm Torx screws 70mm Torx screws Aluminium Strip Sealing apron 6

7 4. Mounting the Solar Collector (Portrait and Landscape) Remove the packagingg from the collector and position it the correct way up with w the sensorr hole at the top left corner, ready to be lifted onto the flashing tray; doo not lift the collector by the copper pipes.. Lift the collector onto the flashing, slide it down the tray so that the lip att the bottom of the collectorr frame tucks behind the stainless steel plates fixed to the tray (shown below) and centralize so that the lugs sticking up at thee two corners sit round each corner of the collector. Fit the top fixing bracket into the lip at the back of the collector and secure to the flashing tray using the bolts provided (do not over tighten). Sensor IMPORTANT: For the system to workk correctly the collector must m be mounted level! 7

5. Connecting the pipe work Supplied in the connection kit box are the flexible insulated pipes and fitting adaptors for the collector connections.

There are four brass inserts supplied with the kit, these must be inserted into each pipe connection of the solar collector before the compression caps or adaptors can be fitted.

Fit and tighten the adaptors to accept the flexible pipes.whilst tightening always hold the adapter with another spanner to avoid twisting the collector pipe and causing damage.

The flexible pipes can be bent to a tight radius to enable the nut and washer to be connected.

Once the pipes are connected, push any excess pipe into the roof space and make sure there is a constant fall back to the drain back unit.

8 5. Connecting the pipe work Supplied in the connection kit box are the flexible insulated pipes and fitting adaptors for the collector connections. Before the flexible pipes can be fed through the holes in the flashing tray any felt, membrane or boarding will need two holes cut through to allow the pipes to enter the roof space. There are four brass inserts supplied with the kit, these must be inserted into each pipe connection of the solar collector before the compression caps or adaptors can be fitted. The compression caps are to seal the open pipe ends on the oposite side of the collector, these are used when connecting multiple collectors together. Fit and tighten the adaptors to accept the flexible pipes.whilst tightening always hold the adapter with another spanner to avoid twisting the collector pipe and causing damage. Pass the flexible pipes through the holes in the flashing tray, smaller diameter pipe to the top, leaving enough pipe to connect to the collector. The flexible pipes can be bent to a tight radius to enable the nut and washer to be connected. When tightening the pipes to the collector always hold the adapter with another spanner to avoid twisting the collector pipe and causing damage. Once the pipes are connected, push any excess pipe into the roof space and make sure there is a constant fall back to the drain back unit. Use the compression caps provided to cap the connections on the right hand side of the collector. Wrap the short pieces of pipe insulation around the pipe connectors and secure in place with the tape provided. Fitting the Sensor The sensor is supplied with a heat proof sleeve. Slide the sleeve over the end of the sensor wire and feed it along the wire until it touches the sensor probe, insert the probe into the sensor pocket through the grommet in the left side of the collector. The sleeve is designed to keep the sensor probe deep in the pocket. Then feed the other end of the wire through either one of the pipe holes into the roof space. When joining two collectors together only one sensor is required and must be fitted to the first collector i.e. the one with the flexible pipes attached. 8

9 Fitting the Pipe Cover Landscape/Portrait Before fitting the pipe cover to the flashing tray the sealing strip must be stuck to the undersidee of the cover that rests on the collector. Lay the cover over the pipes, line up the fixing holes with the top and bottom collector brackets and screw into place using the self-tapping screws supplied. Replacing the Tiles Apply the two foam strips to the bottom side edges of the flashing sticking them onto the tray and over the aluminiumm strip apron. Replace the tiles t starting from the bottom making suree they overlap p the ribs on the flashing tray. Some types of tiles might need to have the top lug removed where the tile sits on the raised ribs of the tray; this allows the tile to sit correctly on the roof. Depending on the spacing and position of thee flashing tray, it may also be necessary to cut the tiles to give the correct overlap without touching the collector. Slide the top row of tiles back in position, it might be necessary to fix a wooden batten to the roof under the topp row of tiles to lift the tiles to maintain the correct level tile line above thee collector. 9

10 6. TWIN COLLECTOR FLASHING INSTALLATION Part No To install twin collectors requires the twin portrait collector flashing, this kit consists of two flashing trays, one left hand and one right hand. To fit the flashing trays remove the tiles to expose the roof battens to an area of approximately 3.8m x 3m (W x H). There is a wooden batten supplied with each flashing kit (key item 5) which must be positioned end to end, centrally in the space between the tiles and 140mm from the top of the lower tile batten to the top of the wooden batten. Using the 70mm Torx screws, fix the battens to the rafters making sure they are level. Roll out the lower apron seal (key item 6) and cut to the same length as the plastic flashing trays. Peel the plastic backing off of the apron and stick the apron to the wooden batten previously fixed to the roof. Make sure the top edge of the apron is lined up with the top edge of the batten and is central. Firmly push the apron onto the batten to make sure it sticks, neatly lay the apron over the tiles and push against the apron to make sure it sticks. On profiled tiles, it will be necessary to dress the apron into shape using a suitable dressing tool. Roll the left hand plastic flashing tray out on the roof battens with the lugs at the bottom resting along the length of the apron batten making sure the right most raised rib (at the edge of the tray) is central to the opening. To secure the tray to the roof, screw the self-drilling 70mm Torx screws through the two outer raised ribs into the roof battens bellow making sure it is level. Roll the right hand plastic flashing tray out on the roof battens with the lugs at the bottom resting on the apron batten and overlap it on to the left hand tray so that the small rib on the left hand tray slots into the back of the rib on the right hand tray. Make sure the tray is level and the collector fixing brackets are level between the two trays before fixing into position with the Torx screws. Lay the aluminium strip (item 11) along the bottom of the trays with the hooked section butted up to the bottom edge and secure the strip into position using the 30mm Torx screws. 10

Lay the aluminium channel over the joint betweenn the two trays and secure into position using the 30mmm Torx

Mounting the Collectors Mount the first collector on the left tray and connect the pipes follow the samee method

The brass inserts and compression coupling unions cann then be loosely fitted to the right hand pipes of the left

Fit the inserts into the second collector pipes and then carefully slide the second collector into position.

lift the first collector to allow the second to align.

11 Lay the aluminium channel over the joint betweenn the two trays and secure into position using the 30mmm Torx screws into the roof battens below. Mounting the Collectors Mount the first collector on the left tray and connect the pipes follow the samee method described earlier for single collector installation. The brass inserts and compression coupling unions cann then be loosely fitted to the right hand pipes of the left collector. Fit the inserts into the second collector pipes and then carefully slide the second collector into position. Note do not fitt the top support brackets until both collectors are position as it may be necessary to slightly lift the first collector to allow the second to align. Fit the pipe inserts and compression caps to the right hand collector pipes and then tighten all the pipe couplings and fittings. The left picture above shows the single collector cap connections consisting of componentt No1 the insert No 2 the compression fitting No 3 a washer and No 4 the end cap. These are supplied in the pipe connection kit for portrait or forr landscape together with the sensor, flexi pipes and pipe connections. The kit in the above right picture is the second additional collector connectionn kit Part Number consisting of No 1 two inserts and No 5 a compression coupling for joining the collectors together. 11

12 IN ROOF INTEGRATED FLASHING KIT INSTRUCTIONS Doc No rev /000 12

Installation Instructions

Installation Instructions Alpha SolarSmart On Roof Kits for the Installation of Alpha Solar Collectors onto Tile and Slate Type Roofs For Technical help or for Service call... ALPHA HELPLINE Tel: 0 77