SolaMate® Installation Guide - CoverTel Power · Installation ~ Quick-Start Guide Step 1: Determine preliminary position of panel on roof. - Inclined North facing roof surface -

Page 1 of 28 SM2157-B04

SolaMate® Installation Guide

(For Schletter Type Mount Kits)

Page 2 of 28 SM2157-B04

Introduction The following document outlines the recommended procedures and guidelines for installing and commissioning the SolaMate® solar thermal heating and cooling system.

Disclaimer: SolaMate should only be installed by qualified personnel as required and in accordance with local laws and regulations relating to.

- Electrical mains wiring - Roof penetration and ducting in ceiling*.

(*The Victorian Plumbing Industry Council requires installation to be certified by plumber with Mechanical Services accreditation)

Warnings: Safety harnesses and barriers are required when working on roofs of a certain elevation or pitch. Furthermore, under certain weather conditions and/or on certain types or pitches of roofs SolaMate can be potentially hazardous to install and as a consequence can present a falling hazard. It is the responsibility of the installer to ensure that all necessary safety precautions are taken.

The SolaMate Fan Control Box comes with a 3-pin plug for connecting to 240V mains power. A mains power point, or GPO, is therefore required to be installed by a qualified electrician in the roof cavity near where the fan is to be mounted. This can be done at any stage prior to prior to installing the system.

Page 3 of 28 SM2157-B04

Equipment & Components

The SolaMate Do-It-Yourself kit comprises of three groups of components. 1. SolaMate panel/s and mounting kit (above the roof)

2. Air handling kit (in the ceiling cavity)

3. System control kit

Page 4 of 28 SM2157-B04

1. Panel & Mount Kit

Metal Roof Mount Kit Tile Roof Mount Kit

Note: Tile Roof Mount Kit has 4 of each of the Roof Hooks and Eco Angles. Only 1 of each shown in photo.

Check Item # Description

1 SolaMate® panel

2 2 x 1.3m long Module Bearing Profiles

3 1 x 200mm galvanized Pop

4 1 x Plastic Flashing

5 1 x Weathershield

6 Either Metal or Tile Roof Mount Kit

2 3

4

1

5

6

Page 5 of 28 SM2157-B04

2 Air Handling Kit

Check Item # Description

12 1 x Insulated 3-way Duct Branch

13 1 x Galvanised Pop

14 3 x Round Cone Centre Diffusers

15 1 x Filter Housing (two halves)

16 2 x 200mm Insulated Poly Duct Connectors

17 1 x spare 150mm Duct Joiner

18 3 x Vibration Isolation Mounts

19 Duct tape and Duct Hanging Strap

20 1 x 240 V, 80 W Fan

1 bag x 200mm x 6m long insulated duct (panel to fan)

3 bags x 150mm x 6m long insulated duct

1 x Filter

16

18

13

12

19

14

17

20

15

Page 6 of 28 SM2157-B04

3. System Control Kit

Check Item # Description

25 1 x Fan Control Box

26 1 x 10m length of RJ12 cable (terminated)

27 1 x SolaPro Thermostat wall mounted controller

28 1 x Duct temperature sensor probe (terminated)

25

26

27

28

Page 7 of 28 SM2157-B04

Installation ~ Quick-Start Guide

Step 1: Determine preliminary position of panel on roof.

- Inclined North facing roof surface

- Free from shadows

- Not close to chimneys or exhaust vents

- Close to roof ridge line and not overhanging gutters

Step 2: Determine preliminary position of duct outlets inside rooms.

- Position so air flows across room

- Not close to or directly above windows

- Not in bathrooms or rooms with exhaust fans

Step 3: Determine position of SolaPro thermostat control unit inside building.

- Central location where temperature is realistic (Not near an oven, direct sunlight, or inside a cupboard).

- Maximum cable length approx 10m

Step 4: Check inside roof cavity to confirm fan location.

- Within 6m of panel

- Reasonably central to duct outlets

- Can be easily mounted and ducts run without obstruction

Step 5: Mount SolaMate® panel on roof and cut duct hole.

Step 6: Confirm duct outlet positions and cut holes.

- Check inside roof cavity to ensure hole is clear of beams, cables, and other obstructions before cutting hole

Step 7: Mount fan, filter housing & duct temperature sensor inside roof cavity.

- Pre-assemble as many items as is practical at ground level

Step 8: Connect ducting.

Step 9: Mount SolaPro® controller and fan control box.

- SolaPro® in room to be within 10m of fan control box in ceiling

- Fan control box to be within 2.5m of Panel outlet duct in ceiling

- Fan control box to be within 2.5m of power point (GPO) in ceiling

Page 8 of 28 SM2157-B04

Installation ~ Detailed Guide Step 1: SolaMate® Panel Positioning - Panels may be mounted “vertically” on mounting rails fixed to the roofing

battens, or “horizontally” on mounting rails fixed to the rafters.

- To be effective the panels must be installed on an inclined, North-facing roof surface.

- Shade from trees or other buildings will reduce the performance of the panel. Remember that shadows will be cast differently depending on the time of the day and year. Some trees lose their leaves during winter.

- It is preferable to locate the SolaMate panel outlet manifold near the roof ridge line so weather shield flashing can be inserted beneath the ridge cap flashing.

- The fan inside the ceiling beneath the panel must be within 6m of the panels. The more centrally the panels are located the easier it generally is to connect fans and ducting inside the roof cavity.

- If multiple panels are controlled by a single control system, they must be located closely together and at same orientation so as to both receive the same sunlight and operate at the same temperature.

- The inlet of the SolaMate® panels cannot be located close to chimneys or exhaust vents as smoke or fumes may be drawn into the building (please refer to local regulations).

- Panels should not overhang guttering.

Page 9 of 28 SM2157-B04

Step 2: Outlet Duct Diffuser Positioning The SolaMate® system draws outside air through the panels and pushes it through a filter and ducting into the building creating a very slight positive pressure inside the building. Air entering the building will, therefore, naturally want to escape via the easiest path such as the gaps around windows and doors, or through exhaust fans etc. The positioning of each outlet duct is quite important so as to make good use of the natural flow path of the air and so as to not unnecessarily waste the fresh air from the SolaMate® system In general try to avoid placing duct outlets: - Above or close to windows.

- In bathrooms or rooms with ceiling exhaust fans.

- Near kitchen range hoods.

In a bedroom it is generally good practice to position the duct outlet above the doorway so as air is not flowing directly down on the sleeping area. Some examples of poor and good outlet duct positions are shown below:

Page 10 of 28 SM2157-B04

Step 3: SolaPro Thermostat Controller positioning The SolaPro® Thermostat inside the building should be positioned no more than 10m from the Fan Control Box in the ceiling. The Fan Control Box must be located within 2.5m of the SolaMate® Panel, so the total distance between the Panel and the SolaPro® Thermostat should be no greater than 12.5m As the SolaPro® Thermostat controller also contains the room temperature sensor it is important to locate it in a position where it will record the temperature accurately and not to be effected by things such as:

- Heat from stoves or ovens - Heat from direct sunlight coming through windows - Hot air from heaters or fireplaces - Cold air from air-conditioning units of fans

Step 4: Confirm location of Fan & Filter inside ceiling It is good practice to try to place the fan as centrally as possible between the outlets so as to have similar air flow in each duct.

Page 11 of 28 SM2157-B04

The Fan and Filter Box should be aligned such that the 3-Way Duct Branch is pointing in the correct direction so the ducts can be laid out in a reasonably straight line to the duct outlet holes without too many kinks or bends. The Fan inlet must be within 6m of the Panel as that is the maximum length of the inlet ducting. Each outlet duct is 6m in length. Should there be a need to run a duct longer than 6m, use the 150mm Joiner piece to connect an off-cut piece from one of the other ducts.

Step 5: Mount SolaMate® Panel

Step 5.1A: Mounting Rapid Rails on TILE ROOFS

Measure exact location of panels:

- There must be at least 2 tiles distance between the ridge cap and where the flashing tucks underneath the tiles.

- There must be at least 3 tiles distance between the ridge cap and the top of the panel.

WARNING: If the top row of tiles is moved during the installation process, it may damage the mortar seal between the tiles and ridge cap. Any such damage must be repaired to prevent potential water leaks.

Remove tiles for flashing. Remove enough tiles so that the Pop may fit through the gap. Position the plastic Flashing Sheet in location where Pop is to go.

Page 12 of 28 SM2157-B04

Determine position of Rapid Rails. Ideally the Rapid Rails should be spaced ½ the length of the panel apart or approximately ¼ of the panel length in from each end of the panel. Remove tiles where Module Bearing Profiles are to be secured to the rafters.

Secure Eco Angle to rafter using 2 or 3 Torx screws; predrill holes before inserting the screws. After the angle is attached, Attach the Roof hook using supplied M8 carriage bolts and M8 flange nuts. Bolt inserted with thread pointing up so flange nut can be attached easily from the top. The roof hook can be shifted left or right to suit where the module bearing profile is attached.

M8 carriage bolts and M8 flange nuts.

Space these so weight is evenly distributed.

½

¼

Page 13 of 28 SM2157-B04

The Roof Hook can be adjusted to suit different heights of tiles. Adjust to correct height so tiles can be replaced.

Replace tiles once all 4 Eco Angles and Roof Hooks have been secured to rafters. Module Bearing Profiles can now be attached to the Roof Hooks. Slide an M10 square head screw on the bottom of the Module Bearing Profile.

M10 Square Head Screw and M10 Flange Nut

Ridge Cap

Roof slope this way

Page 14 of 28 SM2157-B04

The two lengths of Module Bearing Profile will then be attached as so (only one shown in picture).

Step 5.1B: Mounting Rapid Rails on METAL ROOFS The duct outlet hole should be towards the ridge of the roof and close enough to ensure the Weather Shield flashing can fit beneath the ridge cap flashing. With the exact position of the SolaMate® panel now confirmed, select the roof the battens to mount the Rapid Rails to. Ideally the Rapid Rails should be spaced ½ the length of the panel apart or approximately ¼ of the panel length in from each end of the panel. Measure and mark out the location for the roof penetration. Cut out the duct hole ensuring there is some clearance for the Pop to easily be inserted once the panel is installed.

½

¼

Page 15 of 28 SM2157-B04

Remove screws holding down roof cladding so Module Bearing Profiles can sit flush on top of cladding. Secure Module Bearing Profiles to roof battens:

- Re-insert old screws into old screw holes to secure roofing iron back in position and prevent leaks.

- IMPORTANT: Ensure each Module Bearing Profile is secured using 2 x Fixation Kit for Corrugated Roofs provided and that they are inserted into fresh timber and not into old screw holes.

Predrill a hole in the batten so you do not split the wood. Insert Fixation Screw. Tighten bottom flange nut down on the black rubber seal so the hole is properly water-proofed.

Adjust the height of the clamp on top so that the Module Bearing Profile clears the corrugation. Once two Fixation Screws have been attached on respective battens, secure the Module Bearing Profiles onto the clamp teeth. Secure them by tightening the flange nut, as shown.

Page 16 of 28 SM2157-B04

If the hole location is quite close to the ridge cap, excess material can be trimmed from the Flashing Sheet as it is not required to go under the ridge cap.

Position Flashing Sheet over duct inlet hole and tuck beneath ridge cap.

- Ensure tapered edge of raised section of Flashing Sheet is on lower side.

Take note that M8 channel always points up. The bottom is M10 (the only side that can be attached to the clamp teeth

Page 17 of 28 SM2157-B04

Step 5.2: Fixing SolaMate® Panel to Module Bearing Profiles

Push M8 KlickIn Component into Module Bearing Profile slot. Then insert M8 square nut, push down until nut clicks inside the slot.

Take a Z-Bracket and put it in place. These are used to clamp panel onto the Module Bearing Profiles. Loosely screw the M8x20 screw and flange nut to hold Z-bracket in place, but don’t tighten completely.

To make the module bearing profiles waterproof, use a mallet to secure end caps to the ends.

M8 x 20 screw and M8 flange nut

Page 18 of 28 SM2157-B04

Whilst still on the ground, run a bead of silicon around Pop flange to create an air seal between the Pop and the manifold. Bend 4 metal tabs on panel manifold outwards to centre the Pop

Fasten the Pop in position with 8 evenly spaced Teks® screws.

Important: Ensure the slot in the flange is positioned as shown to ensure the temperature sensor is facing in the right direction.

Attach the temperature sensor to the bracket inside the Pop and attach the cable gland Tape cable inside the Pop to protect it until the panel is mounted on the roof.

Page 19 of 28 SM2157-B04

Important: Ensure main body of cable gland is inside the Pop and not on the outside as it will not be able to fit through the Weather Shield on the roof). Attach the Panel Brace Bar to the underside of the SoloMate panel by first inserting both halves of the Panel Join Bracket assembly into the thin slot in the centre of the SolaMate panel, then sliding them together to form a single bracket.

Slide the Panel Brace Bar thorugh the bracket assembly and secure into position using a Teks® screw at either end. The bracket should be located approximately equal distance from either end of the panel.

Page 20 of 28 SM2157-B04

Transfer the SolaMate® panel to the roof. On a standard height roof (ie. low angle, single story) it is possible for two people to lift the panel onto the roof. Lay the SolaMate® panel on top of the Module Bearing Profiles with the Pop through the hole into the roof cavity.

- Slightly raise panel so Pop sits neatly in centre of hole and does not support the weight of the panel.

First screw Z-Brackets to panel using Teks® screws, then tighten M8x20 screw to firmly secure SolaMate® panel in position.

Page 21 of 28 SM2157-B04

Put Weather Shield flashing in position and screw to manifold:

- For metal roof installations the Weather Shield is to tuck beneath the ridge cap flashing. You may need to first trim off excess material.

- For tile roof installations the Weather Shield sits beneath the next row of tiles and may need to be formed into shape to match the tile profile. This is easily done by standing on the aluminum

Step 6: Confirm duct outlet positions and cut holes With one person inside the building and a second person inside ceiling cavity, have the person inside the ceiling cavity identify the exact location of the proposed duct outlet holes.

- A good way is to tap the ceiling from both sides until both people have confirmed the exact location

- The person in the ceiling can then use the diffuser cut-out template from the diffuser box to see if there is sufficient clearance for the hole from beams, wiring etc.

Once the intended hole position has been confirmed, simply push a sharp object such as a screw driver through the centre of the intended hole and double check the location is correct before cutting.

Page 22 of 28 SM2157-B04

When cutting hole from below it is useful to place a bucket or a box beneath the cutout before it is removed and lowered, to contain dust and roofing insulation that may fall into the room. Step 7: Mount Fan, Filter Housing & Duct Temperature Sensor At Ground Level Assemble the Filter Housing and insert the filter

- Take note of airflow direction indicator on side of filter before assembly. - Ensure rubber sealing faces of filter are properly seated between both

halves of housing. - Make a note of the airflow direction. Drawing an arrow with a marking

pen on the outside of the Filter Housing is a good idea.

Connect the Filter Housing to the Fan outlet using one of the 200mm Poly Connectors and duct tape as shown below and ensure that filter airflow direction is correct. Depending on the size of the ceiling access hole, it might also be useful to connect one end of the 200mm flexible ducting to the inlet of the fan before lifting it into the ceiling cavity

Page 23 of 28 SM2157-B04

When connecting insulated flexible ducting it is vital for preventing leakage that the inner layer is first properly fitted, taped and sealed before the insulation layer and outer sheath are taped into position.

When connecting one end of the flexible ducting, it is also advantageous to leave the majority of the ducting still compressed inside its bag so it is manageable until it is transferred to the ceiling cavity. A useful tip is to tape the bag to the exposed duct to stop it unraveling.

Page 24 of 28 SM2157-B04

Again, depending on size of ceiling access hole, connect the three outlet ducts to the 3-Way Branch Duct and also connect the second 200mm Poly Connector which will be joined to the outlet of the Filter Box once inside the roof cavity

Transfer all items into the ceiling cavity.

Inside the Ceiling Cavity Lay the 3-Way Duct Branch and the three outlet ducts in approximately the right location and orientation Position and orient the Fan & Filter Box assembly in the correct location as determined at Step 4. Join the Filter Box outlet to the 3-Way Duct Branch using the 200mm Poly Connector and duct tape. Secure the entire assembly in position using the Vibration Isolation Mounts. It is a good idea to first screw a piece of board to the

Page 25 of 28 SM2157-B04

rafters so the Vibration Isolation Mounts can then be easily secured to the board. Ensure the Fan electrical terminals are facing upwards so as to prevent water accumulating in the terminal housing if the roof were to leak.

Step 8: Connect Ducting

Remove ducting from bags and extend to each of the outlet holes. Carefully push the entire length of duct through the hole until the section of duct in the ceiling is nice and straight and free from kinks.

Inside the rooms, cut off excess duct leaving enough protruding to allow the diffuser to be taped and sealed to the duct. Once the diffuser is fitted to the duct, push it up inside the hole and snap into position. The centre cones of the diffusers can be adjusted to vary the airflow as required.

Page 26 of 28 SM2157-B04

Connect the Fan inlet ducting to the Pop using the long Cable Tie over the top of the ducting securing the inner sleeve. This prevents the tape from stretching or becoming loose over time and the duct from slipping off the Pop. Run the Duct Temperature Sensor cable through the gland in the Pop and tighten the gland. (The green connector may have to be first removed. Note: It does not matter which terminal the blue and white wires are connected to.)

Use the Duct Hanging Strap tape to elevate and support all ducting where necessary.

Diffuser in position

Page 27 of 28 SM2157-B04

Step 9: Mount SolaPro Thermostat and connect Fan Control Box

IMPORTANT: All mains voltage electrical wiring must be completed and certified by a qualified electrician. - A mains electricity power point or GPO is required in the ceiling cavity to

connect the Fan Control Box to. - Ensure mains power is disconnected from the Fan Control Box until after the

wall mounted SolaPro Thermostat is connected. Run the supplied RJ12 Cable from the Fan Control Box in the ceiling down the wall to the SolaPro Thermostat location. Remove the SolaPro Thermostat fascia panel and connect the RJ12 cable to the connector on the back of the rear panel.

Screw the rear panel to the wall before replacing the front fascia panel and tightening the small retaining screw at the bottom.

In the ceiling, position Fan Control Box such that it is within reach of the Duct Temperature Sensor cable and the SolaPro Thermostat cable. DO NOT cut or extend these cables.

Page 28 of 28 SM2157-B04

Mount the Fan Control Box in a central location and connect cables in following sequence: (1) Duct Temperature Sensor cable, (2) SolaPro Thermostat cable, (3) Fan cable/s, and finally, (4) connect Fan Control Box power cable to the mains power GPO and last of all, turn on the power. If Error 14 appears on screen it means the Duct Temperature Sensor Cable was either not connected before the power was turned on, or there is a loose connection with the terminal connector. Turn the power off, check terminal connection, reconnect the cable, and then turn power on again.

The SolaPro Thermostat should now be activated and ready for use. Refer to SolaMate User Manual for instructions on how to operate and program the system

Congratulations! Your SolaMate® is now installed and ready for use.

1

2

3

4