Solatube Brighten Up 160 DS User manual

Solatube Brighten Up Series
Solatube 160 DS (250mm diameter) & Solatube 290 DS (350mm diameter)
Product Installation Guide
Please read this guide
fully before beginning
installation
Additional extension tubes?
You will receive a top tube and bottom
tube assembly in your Solatube Base
Kit. Together these assemblies give a
tube length (roof to ceiling) of up to
400mm (16"). This is generally sufficient
for flat roofs, vaulted ceilings, or very
shallow pitch roofs. For longer tube
lengths please check you have
purchased sufficient extension tubes to
meet your required install distance:
Tube length
up to mm (inches)
Extension
tubes req
400 (16”)
0
960 (38”)
1
1520 (60”)
2
2080 (82”)
3
2640 (104”)
4
3200 (126”)
5
3760 (148”)
6
4320 (170”)
7
Please ensure that all components have
arrived in perfect condition before
starting the installation
Solatube Base Kit
Items marked *comprise the
Solatube base kit which is
suitable for installations with
a roof to ceiling distance of
up to 400mm. For distances
greater than this, extension
tubes will be required –
please see chart right.
Extension tubes
610mm long
(quantity as specified)
*Top tube
assembly
(with integral
adjustable angle)
*Bottom tube
assembly
(with integral
adjustable
angle)
*Roof dome with
Raybender®3000
Technology
*Roof flashing
(as specified,
supplied with
flashing insulator)
*Decorative
fixture/ Diffuser
and natural effect lens
*Seal & fastener kit(not shown)
▪Flashing sealant (if specified)
▪Roll aluminium tape
▪Flashing screws (53mm)
▪Dome ring screws (35mm)
▪Tube screws (15mm)
▪Ceiling flange screws (40mm)
▪Expansion joint seal
▪LightTracker™ dome reflector
(use reflector only on steep, north facing
roofs or wall-mounted installations)

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Warning
Do not proceed with the installation until you have read and understood the entire installation guidelines, including the points below.
If you have any questions or require clarification of any installation procedures, please contact your Solatube supplier.
Solatube (or seller) assumes no responsibility or obligation whatsoever for the failure of an architect, contractor, installer or building
owner to comply with all applicable laws, ordinances, building codes, energy codes, fire and safety codes and requirements, and
adequate safety precautions. Installation of this product should be attempted only by individuals skilled in the use of the tools and
equipment necessary for installation. The supplier accepts no responsibility for incorrectly installed or non-appropriate applications.
Protect yourself and all persons and property during installation. If you have any doubt concerning your competence or expertise,
consult a qualified expert before proceeding. In addition, please check the Health & Safety Executive website for advice on safe working
at height http://www.hse.gov.uk. Installation is at your own risk.
Solatube product installations may be dangerous owing to the locations of the work to be undertaken. The hazardous conditions include,
but are not limited to, the following:
•During installation, the Solatube reflective tubes may focus sunlight potentially causing concentrated light
and heat. Keep the protective film on the reflective tubing prior to installation and the tubing away from
potentially flammable material.
•Sheet metal edges may be sharp. Use protective gloves to avoid lacerations.
•Installation may require climbing and working at dangerous heights, including on ladders, scaffolding, roofs
and in attic spaces. Use extreme caution to minimize risk of accidental injury and property damage
including, but not limited to, the points below:
oDo not work alone –we recommend a team of at least two people
oClear the area below your workspace of all people, animals and other items.
oAvoid working on surfaces that are slippery or wet and use footwear with excellent traction.
oUse only strong, well-supported and appropriate ladders.
oWork only in calm, dry weather.
oWhen in the attic, ensure that your weight is supported at all times with structurally sound framing;
dry wall material is not designed to carry a person’s weight.
oReduce the risk of fire, electric shock, and personal injury by following basic safety precautions
when using electric tools; always wear safety goggles or other suitable eye protection and ensure
work area is clear of all electrical wires, gas pipes, water pipes and other obstacles.
oWhen working in the attic or other dusty areas, use of a mask or respirator is recommended to
avoid lung irritation. Attic spaces may be dark, confined, and subject to extreme temperatures.
Beware of sharp protruding objects. Do not attempt installation without having someone within
range of your voice or close enough to come to your aid if necessary.
oOnly suitably qualified persons should undertake any electrical wiring.
Installation tips & safety advice
This guide offers a step-by-step guide for the installation of a Solatube 160DS and 290DS.
In general, a Solatube 160DS can provide enough daylight to illuminate a dark area of up to 10 sqm. A Solatube 290DS can provide
enough daylight to illuminate a dark area of up to 18 sq m. Both examples are based on a 2.44 m ceiling height with a 1.83 m tube
length. For larger areas, you may need to install more than one Solatube. This information is for guidance purposes only.
Allow at least 4 hours for the installation, particularly if this is your first installation.
During the day, turn off all the lights in the room to see how much natural light comes in through the windows (if any). You should then
be able to determine the best position for the Solatube diffuser.
Avoid roof dome locations shaded by trees, ridges and chimneys, or near water channels or valleys.
Avoid attic areas with obstructions such as gas, water or drain pipes, air ducts, flues or furnaces, fixed storage tanks.
Measure the distance between the roof and the ceiling to ensure you have ordered sufficient reflective tubing to cover the distance.
All reflective extension tube joints should overlap a minimum of 50mm and be fixed together using the aluminium tape (and self-tapping
screws if required).
All adhesives, seals and tapes should be applied to a dry and dust-free surface. The ideal working temperature is approximately 22°C.
Ensure all joints (including seams) are taped sufficiently and all edges well rubbed in (tip: use the tape backing paper) to
prevent the adhesive drying out.
Ensure your roof is in an appropriate condition to support the work necessary for a Solatube installation without damaging its
waterproofing properties.
Solatube will generally perform best if the roof dome is located on the south, east or west elevation. If the roof dome is to be positioned
on a north facing elevation, positioning the roof dome as high as possible on the roof will enhance performance.
You may choose to support any extension tubes with a wire or similar retainer fixed to the rafters if the extension tubes are at a
significant angle away from the vertical.
When the Solatube is initially installed, it is not uncommon for it to condensate lightly on the inside of the dome for the first few weeks
until humid air inside the tube dissipates; the dome is designed to collect any internal condensation and direct it to the outside of the
flashing. The flashing insulator provided is essential to reduce the possibility of condensation, but in particularly cold climates, it is also
advisable to tape a jacket of insulating material (optional extra) around the outside of the extension tubes and up into the void between
the top tube assembly and roof flashing; this is to prevent the possibility of condensation build-up on the exterior of the components
within the roof void.

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Solatube 160 DS & Solatube 290 DS Product Installation Guide
Step 1 Selecting the location for the ceiling diffuser …
Decide on the preferred location for your ceiling diffuser. Locate this
point in the roof void –it may help if you measure the distance from your
loft hatch to the desired location first or use other clues such as spot
lights, light fittings or flues to confirm the location.
Find a clear space between joists as close to the desired location as
possible and unobstructed by pipes, cables or other obstacles. Draw a
275mm circle for the 160DS or a 375mm circle for the 290DS on the upper
side of the plasterboard ceiling. Do not cut the ceiling hole until you are
sure that the roof flashing will also fit in the desired location and that the
top and bottom tube assemblies will align.
Diagram A
275mm Ø hole for 160DS
375mm Ø hole for 290DS
… and the roof flashing
The roof flashing can be positioned either vertically above the diffuser
location or up to an angle of 30from vertical in any direction from the
diffuser position by rotating the two angle adaptors supplied (diagram
A). The diagram shows two possible positions for the roof flashing
relative to the position of the top and bottom tube assemblies.
Note: 0-90angle adaptors are available if a greater degree of variation
is required.
Ensure that the route between the roof flashing and the ceiling
diffuser is clear and unobstructed.
Step 2 Mark the roof flashing and diffuser position
Cut a small hole in the roof felt and identify the roof position (tile) from
inside using a long nail or wire probe so you can locate it again later from
the roof side
Once you are sure that the circle you drew earlier on the upper side of the
plasterboard ceiling is in the correct location, screw a marker screw
through the ceiling from above, leaving approximately an inch showing in
the roof void –you can use this later as a ‘handle’ when cutting the hole
(diagram B).
Diagram B
Step 3 Confirm and cut the diffuser location
Check the marker screw from the room below to confirm the centre of the
diffuser location is correct.
In the roof void, cut around the marked circle, taking care to hold onto
the screw ‘handle’ to prevent the cut-out falling (diagram C).
Tip: To contain dust and debris when cutting the ceiling hole, one
person could hold an empty box under the ceiling while the other cuts
the hole from above. Alternatively, lay a dust sheet below.
Diagram C
Step 4 Installing the bottom tube assembly
Insert the bottom tube assembly up into the ceiling and, if the installation is
not vertical, rotate the angle adaptor to point towards the roof flashing
location. Using a crosshead screwdriver, rotate and tighten two of the
twist-lock fastening clamps to temporarily attach the bottom tube assembly
to the ceiling (diagram D). Do not remove the protective liner from the
inside of the bottom tube at this point.
Tip: Affix a plastic bag over the end of the bottom tube assembly to
capture any dust and debris that may be created when carrying out the
roof works.
Diagram D
or
Roof
Ceiling

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Step 5 Installing the roof flashing
The roof flashing is supplied according to the roof type/flashing you specified on your order.
To complete this step, please refer to the separate roof flashing installation guide supplied with the flashing
Step 6 Aligning the top tube assembly
Insert the top tube assembly into the roof flashing from the outside.
If necessary, rotate the angle adaptor so that the top tube assembly points
towards the bottom tube assembly in the ceiling. The lengths “L1” and “L2”
(diagram E) should be equal to ensure alignment.
Note: For flat roof/vaulted ceiling applications where no extension tubes
are required, the bottom tube assembly will be fitted up inside the top tube
assembly.
Diagram E
Step 7 Installing the top tube assembly
Remove the top tube assembly from the roof flashing. Tape the angle
adaptor joint and tube seams of the top tube assembly with the foil tape
provided (diagram F), smoothing the tape with tape backing material to
ensure the tape is well adhered.
Remove the protective lining film from the inside of the tube and insert the
top tube assembly into the roof flashing, aligning it again in the direction of
the bottom tube assembly. Securely fasten the dome ring of the top tube
assembly to the flashing using the dome screws provided.
Diagram F
Step 8 LightTracker™ reflector (if used)
The LightTracker reflector should be used only for steep, north-facing
roofs or wall mounted applications; it is not required for flat roofs or south,
east or west roof aspects.
For steep, north-facing roofs, position the LightTracker dome reflector in
the north side of the dome, with the reflective side facing due south. For
wall-mounted applications the LightTracker should be placed at the bottom
of the dome facing skywards.
To fix the LightTracker in place, align the holes in the reflector with the
tabs inside the dome and snap into place. Peel the protective film from the
reflector (diagram G).
Diagram G
Step 9 Installing the roof dome
Align the four tabs on the dome base with the click locks on the dome ring
and press down firmly to click into place. Check to make sure that all four
locks are fully engaged (diagram H).
Diagram H
Step 10 Connecting the top & bottom tube assemblies
For short installations with no extension tubes proceed to Step 12.
For longer installations with extension tubes continue with Step 11.
RUB SMOOTH ALL TAPED SEAMS WITH TAPE BACKING MATERIAL TO ENSURE THE TAPE IS WELL ADHERED
or
L1
L1
L2
L2

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Step 11 Assembling extension tubes
Remove the protective liner from the extension tube(s) before assembly.
Extension tubes have deep and shallow notches at each end so that they
may be formed into slightly tapered tubes. Weave one end of the tube
through a deep notch, the other end through a shallow notch, ensuring the
tube is also held in the centre notch (diagram I).
Tape the tube seam with a short piece of foil tape at either end to hold the
joints temporarily in position. The smaller diameter tube end (deep notch)
should always point towards the bottom tube assembly. Assemble all the
required extension tubes, telescoping them together to provide the total
length of tube required. Note the joint overlap indication lines (50mm
overlap). At this stage, use small pieces of foil tape to hold the tubes
together.
Check that the assembled tube length is correct by holding the extension
tube(s) alongside the top and bottom tube assemblies. Adjust the tube
length as necessary. For very long or angled tube lengths, self-tapping
screws are provided to fasten the extension tubes together. Tape all tube
joints and seams securely, smoothing the tape to create a good, firm seal.
Diagram I
Step 12 Applying the expansion joint seal
For short installations with no extension tubes the expansion joint seal is
applied 25mm from the top edge of the bottom tube assembly.
For installations using extension tubes, the expansion joint seal is applied
25mm from the top edge of the uppermost extension tube.
The expansion joint seal should be applied to the outside diameter of the
tube: remove the backing strip from the expansion joint seal and adhere it
25mm from the top edge of the tube. The seal should wrap twice around
the tube, not overlapping but butting up closely (diagram J).
Diagram J
Step 13 Installing the bottom tube assembly
If any angle adjustment is required to the bottom tube assembly to align it
with the top tube assembly this should be done now; use a crosshead
screwdriver to loosen the twist-lock fastening clamps. Remove the
assembly from the ceiling, and rotate the angle adaptor if necessary to
ensure alignment with the top tube assembly and reposition it back into
the ceiling.
If extension tubes are being used please go to Step 14.
If no extension tubes are being used, tape the seams and re-insert the
bottom tube assembly, sliding it up into the top tube assembly and then
lock all four twist-lock fastening clamps into the ceiling (diagram K).
Note: If the ceiling clamps cannot be engaged owing to the thickness of
the ceiling or because of proximity to joists, the bottom tube assembly can
be secured with the screws provided into the ceiling/joists through screw
position indicators in the ceiling flange.
Do not over tighten the bottom tube assembly to the ceiling as this may
prevent fitting of the diffuser.
Remove the protective film from the inside of the bottom tube assembly.
Diagram K
Step 14 Installing extension tubes
For installations with extension tubes, remove the protective film from
the inside of the bottom tube assembly and all other tubing if not already
done so. Tape the seams and re-insert the bottom tube assembly and
then lock all twist-lock fastening clamps into the ceiling.
Insert the extension tube with the expansion joint seal (a) up into the top
tube assembly. Then insert the other end (b) into the bottom tube
assembly (diagram L). Ensure there is a minimum 50mm overlap at either
end. Tape all joints together and use self tapping screws for additional
rigidity if necessary.
RUB SMOOTH ALL TAPED SEAMS WITH TAPE BACKING MATERIAL TO
ENSURE THE TAPE IS WELL ADHERED
Diagram L
expansion
joint seal
a
b
shallow
notch
deep
notch

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Step 15 Installing the Natural Effects Lens and diffuser
Insert the Natural Effects Lens straight up into the bottom tube assembly
until it sits into the recess at the base of the bottom tube assembly, with
the clear plastic tab pointing downwards. Then place the ceiling
diffuser/fitting up into the lower edge of the bottom tube assembly, aligning
the male and female lugs, and twist clockwise to secure in place (diagram
M).
In order to clean the diffuser or to replace the lamp in the optional
Solatube integral electric light kit, you may remove the diffuser by twisting
the diffuser anti-clockwise to release it and then remove the lens by pulling
gently down on the clear plastic lens tab.
You have now completed installation of your
Solatube Daylighting System.
Diagram M
If you have any questions regarding the installation of your
Solatube Daylighting System please contact us –we shall be delighted to help.
Tel: [phone] | Email: [email protected]
Daylight Systems Southern Limited
Solatube options and accessories
Solatube offers an inspiring range of accessories that install neatly into your Solatube Daylighting System transforming
it into a truly multi-functional system. If you have purchased any Solatube accessories, please read the instructions
supplied with the accessory before proceeding with the Solatube installation as some accessories cannot be installed
as a retrofit.
Integral electric light kit*
Available for both Solatube sizes,
provides the convenience of a
switched light for night time use.
Edison screw fitting rated up to 75
watt.
Additional 0-90° angle
Available for both Solatube sizes,
allows easy installation around
obstructions or corners.
Bathroom ventilation kit*
Available for the Solatube 160DS only,
offers discreet style and high
performance, ideal for bathrooms and
shower rooms (shown with OptiView
diffuser). Optional universal roof exit
vent is also available.
Extension tube
Available for both Solatube sizes,
may be joined together to meet
the required install distance –see
front page for details.
Electric daylight dimmer kit*
Available for all Solatube sizes,
controls the amount of daylight
required from the convenience of a
wall-mounted switch or optional
remote control.
Solar powered night light
Integrated solar panel collects
energy during the day, recharging
NightLight batteries. A sensor
automatically triggers dusk-to-dawn
night lighting.
Items marked * require connection to an electrical circuit; we recommend they are installed by a suitably qualified person.
Effects lens
Ceiling diffuser/fitting