FKB-1 / FKC /200/300 l system. Thermosiphon for flat roofs and rooftops. Installation instructions (2010/06) GR

Transcription

1 RS Thermosiphon for flat roofs and rooftops FKB- / FKC- 50/00/00 l system Installation instructions (00/06) GR

2 Contents GR Contents Key to symbols and safety instructions Key to symbols Safety instructions For 00 l system: positioning second collector Installing the single sided collector tensioner on the left Information about the installation set Intended use Specification Before installation General notes Component description Installation set for flat roofs Rooftop installation set Hydraulic connection for installation on flat roofs and rooftops Other equipment required Transport and storage Estimating your space requirements Installing the flat roof frame and the rooftop support Flat roof Installing flat roof frame 50/00 l system - building not taller than 0 m Installing flat roof frame 00 l system - building not taller than 0 m Additional supports for buildings taller than 0 m or wind speeds of 5 km/h Roof connection Rooftop installation Roof connection for rooftop installation. 5.. Roof connection with double ended screws Roof connection with roof hooks For 50/00 l systems: fitting the rooftop installation system For 00 l system: installing profile rails Installing the cylinder Installing the cylinder in flat roof systems 8 7. Installing the cylinder in rooftop systems Securing the cylinder with cylinder straps Installing connection lines Connecting the flow line in a 50/00 l system Conneting the flow line in a 00 l system 4 8. Connection of the return pipe Installing the retainer for the return line Connecting DHW lines Insulating connection lines Commissioning Filling the DHW circuit Filling the solar circuit Checks following commissioning and maintenance Maintenance Environmental protection/disposal Collector installation Preparing to install the collectors Pre-assembling dummy plugs For the 00 l system: pre-mount the joining set Hydraulic connection Securing the collectors Inserting the single sided collector tensioner on the right Positioning the first collector For 00 l system: inserting the double sided collector tensioner (00/06)

3 GR Key to symbols and safety instructions Key to symbols and safety instructions. Key to symbols Warning information Warnings in this document are identified by a warning triangle and printed against a grey background. If there is a risk of electrocution, the exclamation mark in the warning triangle is replaced by a lightning symbol. Signal words at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. NOTE indicates that material losses may occur. CAUTION indicates that minor to medium injury may occur. WARNING indicates that severe injury may occur. DANGER indicates that fatal injury may occur. Important information Important information where there is no risk to people or property is indicated with the adjacent symbol. It is bordered by horizontal lines above and below the text. Additional symbols Symbol B Explanation Action step Cross-reference to other parts of this document or to other documents List/list entry Tab. List/list entry (second level) (00/06)

4 4 Key to symbols and safety instructions GR. Safety instructions This chapter explains how the information in these installation instructions is laid out, and gives general safety instructions for safe and trouble-free operation. Safety instructions and user notes relating specifically to installation are found in the installation instructions alongside the specific installation steps. Please read the safety instructions carefully before starting the installation. If safety instructions are ignored, severe or even fatal injuries may result, as well as material losses and environmental damage. Danger when working on roofs B Take appropriate action to prevent accidents during all work on roofs. B Take precautions against a possible fall while working on roofs. B Always wear your own protective clothing and safety equipment. B After completing the installation, check the installation set, the collectors and the cylinder are securely positioned. Maintenance B Customer recommendation: Arrange an inspection/ maintenance contract with an approved heating contractor, and have the appliance serviced every year. B The user is responsible for the safety and environmental compatibility of the appliance. B Only use genuine Buderus spare parts. Instructing the customer B Instruct the customer in the functions and operation of the appliance. B Inform the customer that they must not carry out any modifications or repairs. Installation and maintenance B Only have the appliance installed or modified by an approved heating contractor. B Only use the cylinder for heating domestic hot water. Risk of scalding! Always monitor operation if temperatures are above 60 C. B We recommend installing a DHW mixing valve downstream of the "DHW outlet" connection. Risk of burns! If the collector and installation material have been exposed to the sun's rays for a prolonged period, touching certain components may cause burns. B Always wear your own protective clothing and safety equipment. B Before and during installation, cover the collector (for example with a towel) and installation material to protect against high temperatures caused by the sun's rays. It is worth leaving the equipment covered until the system is commissioned (00/06)

5 GR Information about the installation set 5 Information about the installation set. Intended use The rooftop installation set is designed to hold solar thermal collectors and their associated cylinder, which are installed on pitched roofs at an angle of 5 to 45. If the angle of the roof is steeper than 5, use special double ended screws for the installation. The flat roof installation set can be used with a roof slope of up to 5 towards the collector. Never damage the structure of the building while installing the solar thermal system. Conditions of use Only fit the installation set on roofs with sufficient loadbearing capacity; if necessary, ask a structural engineer or professional roofer for guidance. The installation set is suitable for a maximum standard snow load of.0 kn/m ² and an installation height of no more than 0 m. Never use the rooftop and flat roof installation sets to fix any other objects to the roof. It is designed only to enable the solar collectors and cylinder to be securely fixed. Observe all standards and directives applicable to the installation and operation of this heating system in the country in which it is used. Germany Installation and equipment of DHW cylinders Installation work on roofs DIN 88, VOB, part C ) : Roof covering and sealing work. DIN 89, VOB, part C: Plumbing work. DIN 845, VOB, part C: Scaffolding work. DIN 055, part 4: Design loads for buildings. Connection of solar thermal systems EN 976: Solar thermal systems and their components (prefabricated systems). ENV 977: Solar thermal systems and their components (bespoke systems). DIN 988: Technical regulations for potable water installations (TRWI). Installation and equipment of DHW cylinders DIN 475, part : Water heaters and water heating systems for potable and process water; requirements, identification, equipment and testing. DIN 880, VOB: Heating and DHW heating systems. DIN 88, VOB: Gas, water and waste water installation work. DIN 84, VOB: Insulation work on heating systems AVB ) WasV: Regulation on general conditions for water supply. DVGW W 55: DHW heating systems and DHW pipework systems; technical measures to inhibit the growth of legionella bacteria. Tab. Technical directives and regulations for the installation of solar thermal systems (selection) in Germany ) VOB: Contract procedures for construction work; part C: General technical contract procedures for construction work (ATV). ) Tenders for construction work in buildings above ground level, particularly with regard to residential buildings (00/06)

6 6 Information about the installation set GR Lightning protection The components of the thermosiphon solar thermal system which conduct electricity must be connected by an electrician to an earth cable of at least 6 mm and to the equipotential bonding. If a lightning protection system is installed, an electrician must check the connection of the thermosiphon solar thermal system to this system. If the height of the building (installation height) is less than 0 m and the system has no electrical heating resistance, no special measures are required for lightning protection (00/06)

7 GR Specification 7 Specification Thermosiphon system TSS50 / TSS00 / TSS00 Certificates 006 DIN Further details TSS 50 TSS 00 TSS 00 Approximate operating weight kg Clearance between supports mm Dimensions of the system installed ) : L x W x H Tab. System specification ) flat roof mm 50x65x705 0x65x705 0x65x705 Collectors FKB-TSS / FKC-TSS Length mm 070 Width mm 45 Height mm 90 Clearance between collectors mm 5 Absorber capacity, vertical version l 0.86 External surface area (gross) m.7 Absorber surface area (net) m. Net weight, vertical version kg 4 Permissible collector operating pressure bar 6 Tab. 4 Collector specification Cylinders TSS50 / TSS00 / TSS00 Version 50 l 00 l 00 l Weight (dry) kg Volume, primary circuit l 0 Volume, secondary circuit l Max. operating pressure, primary circuit bar.5 Max. operating pressure, secondary circuit bar 0 Diameter mm 580 Width mm Tab. 5 Collector specification (00/06)

8 8 Before installation GR 4 Before installation 4. General notes We recommend that you engage the services of a roofing contractor, as they are experienced in working on roofs and are aware of the risks involved. DANGER: Risk to life through falls and falling parts! B Take precautions against a possible fall while working on roofs. B Always wear your own protective clothing and safety equipment. B After completing the installation, check the installation set, the collectors and the cylinder are securely positioned. Before installation, familiarise yourself with the on-site conditions and local regulations. Check That the delivered material is complete and undamaged. The structure of the roof for sufficient load-bearing capacity and damage (e.g. leaks). The optimum orientation of the solar collectors. Take solar radiation into account (southerly orientation ). Avoid shade from high trees or similar. The stability of the installation surface. Remove gravel or similar material. Fig. Fig RS Full view of flat roof frame (here 00 l system) RS Full view, rooftop installation (here 00 l system) Only use original spare parts from the manufacturer and replace faulty parts immediately. Have a professional roofer carry out all difficult roof repairs, particularly sealing bitumen layers. Deviations from the optimal orientation do not result in noticeable differences in output. For further information on the output curve of the system in cases where the orientation/slope deviates, see the technical documentation. ) Align systems in the southern hemisphere to the north (00/06)

9 GR Before installation 9 4. Component description 4.. Installation set for flat roofs The installation sets are designed to hold and secure the cylinder and collectors O Fig. Installation sets for collectors: standard installation set, extension installation set Flat roof, standard installation set for 50/00 l system: Flat roof, extension installation set for 00 l system: Pos. Qty. Description Pos. Qty. Description x Cylinder strap x Cylinder support bracket (5/0) x Flat roof/rooftop profile rail x Cylinder strap 4 4x Cylinder support rail (400 mm - 45/0) x Flat roof/rooftop profile rail 6 x Anti-slip bracket 4 x Cylinder support rail (400 mm - 45/0) 8 x Lower support 5 x Joiner 9 x Lower support rail (070 mm - 5/0) 6 x Anti-slip bracket x Collector support rail (950 mm - 45/0) 7 x Double sided collector tensioner x Wind brace 8 x Lower support x Cross brace 9 x Lower support rail (070 mm - 5/0) 4 4x Single sided collector tensioner x Collector support rail (950 mm - 45/0) 0x Round head screw M8x0 x Wind brace 0x M8 nut x Cross brace x Self-adhesive foam pad x Self-adhesive foam pad Tab (00/06)

10 0 Before installation GR 0x 0x Round head screw M8x0 M8 nut Flat roof, additional support, standard installation set Flat roof, additional support, extension: Pos. Qty. Description Pos. Qty. Description x Flat roof/rooftop profile rail x Flat roof/rooftop profile rail 0 x Additional support (750 mm - 45/0) 5 x Joiner 4 x Single sided collector tensioner 7 x Double sided collector tensioner 6x Round head screw M8x0 0 x Additional support (750 mm - 45/0) 6x M8 nut x Round head screw M8x0 Tab. 6 x M8 nut (00/06)

11 GR Before installation 4.. Rooftop installation set The installation sets are designed to hold and secure the cylinder and collectors. Fig. 4 Installation sets for collectors: standard installation set, extension installation set Standard installation set for 50/00 l system: Extension installation set for 00 l system: Pos. Quantity Description Pos. Quantity Description x Cylinder strap x Cylinder strap x Cylinder profile rail x Cylinder profile rail 4x Single sided collector tensioner 4 x Flat roof/rooftop profile rail 4 x Flat roof/rooftop profile rail 5 x Collector profile rail 5 x Collector profile rail 7 x Double sided collector tensioner 6 x Anti-slip bracket 6 x Anti-slip bracket 8 0x Locking bolt 8 5x Locking bolt 0 x TSS joiner 9 x Joiner x Screw M8x50 x Positioning bracket x Washer x Hexagon bolt M8x50 4x M8 nut x Washer x Round head screw M8x0 x M8 nut 6x Round head screw M8x0 Tab (00/06)

12 Before installation GR 4.. Hydraulic connection for installation on flat roofs and rooftops For the hydraulic connection, you will need a connection set and a joining set for the connections between collectors. Fig. 5 Connection set and joining set (shown with vertical collectors) (Connection set TSS Fig. 5): Pos. Quantity Description Pos. Quantity Description x Solar hose 00 mm x Fem. connection ¾ " (only TSS 50/ 00) 4x Hose clip x Safety valve ½ ".5 bar x Angled ferrule GxD x Safety valve ¾ " 0 bar 4 x Clamping disc x Cap ½ " 5 x Union nut G x Hose ferrules 8 x ¾ " 6 x Dummy plug x Elbow ¾ 7 x Solar hose 55 mm x Reducer ¾" to ½" 8 x Size 5 spanner x Sealing disc 9 x Retainer for flow line Tab. 8 Joining set for each collector (in two transport corners, Fig. 6) Pos. Quantity Description 4x Hose clip x Solar hose 95 mm long (only for FKB-TSS) Tab SD RS Fig. 6 Two transport corners with one joining set ([] - only one corner of the FKB-TSS) (00/06)

13 GR Before installation 4. Other equipment required Brace/cordless screwdriver Tape measure Wood drill, Ø 6 mm (drill bit length chapter 5..) Metal drill bit, Ø mm Spanner sizes, 5, 9 and 0 Spirit level Plumb line Vacuum pump Safety harness with safety line Material for pipe insulation Scaffolding Roofing ladder or equipment for sweeping chimneys Crane or mobile hoist For flat roofs: spanner for roof connection Pipe cutter 4.4 Transport and storage All components are protected by transport packaging. Transport protection for collector and cylinder connections The collector connections are protected against damage with plastic caps. NOTE: System damage due to damaged sealing faces. B Do not remove the plastic caps [] until immediately prior to installation RS Fig. 7 Plastic caps on collector connections Storage Store the collectors in a dry location (00/06)

14 4 Before installation GR 4.5 Estimating your space requirements NOTE: System damage through wind eddies and pressure peaks at the flat roof perimeter. B Before commencing installation, ensure that a clearance of at least one metre is allowed between the flat roof frame and the roof perimeter ( Fig. 8). B Allow sufficient installation surface. Number of collectors Dimension A Dimension B (50/00 l) 45 mm 65 mm (00 l) 5 mm 65 mm Tab. Space requirement for flat roofs Take the pipework into consideration when calculating in the space requirement. For the pipes on the right and left of the collector array, allow at least an extra 0.5 m on either side. > m > m RS Fig. 8 Distance from roof perimeter (here 00 l system) B A RS Fig. 9 Space requirement, collector array The dimensions (Tab. 0 and Tab. ) relate to the required roof surface. Number of collectors Dimension A Dimension B (50/00 l) 45 mm 770 mm (00 l) 5 mm 770 mm Tab. 0 Space requirement for rooftop installation (00/06)

15 GR Installing the flat roof frame and the rooftop support 5 5 Installing the flat roof frame and the rooftop support DANGER: Risk to life through falls and falling parts! B Take appropriate action to prevent accidents during all work on roofs. B Secure the collector support rails at the top to the cylinder support rail (Fig., []), and at the bottom to the support []. 5. Flat roof 5.. Installing flat roof frame 50/00 l system - building not taller than 0 m To facilitate installation, first tighten all screws by hand. B Join two cylinder support rails together in the centre to form a cross (Fig. 0, []), and fit to the lower support rail [] in such a way that the surface lying on the ground comes to face inwards. B Join the lower support (Fig. 0, []) to the end of the lower support rail. Fig. Fitting the collector support rail RS B Secure the cross brace (Fig., []) to the two cylinder support rails and the collector support rail RS Fig. 0 Securing the lower support rail to the cylinder support rails Fig. Inserting the cross brace RS (00/06)

16 6 Installing the flat roof frame and the rooftop support GR B Make a second side triangle (Fig., []) as a mirror image of the first []. B Affix the self-adhesive foam pads to the cylinder straps RS RS Fig. Second side triangle Fig. 5 Securing flat roof/rooftop profile rails B Join the wind braces together in the centre to form a cross (Fig. 4, []) and attach the two side triangles to it. As you do so, fit the cylinder straps as well (Fig. 4, []). The flattened screw head must point in the direction of the DHW cylinder (which is fitted later). B Ensure that the first wind brace is installed from the top back right down to the bottom front left. the second wind brace is installed from the top back left down to the bottom front right. Fitting anti-slip brackets To prevent the collectors from slipping, affix two antislip brackets for each collector to the lower flat roof/ rooftop profile rail. B Push each anti-slip bracket (Fig. 6, []) in the inner slots [] from the outside over the profile rails until it clicks into place []. Fig. 6 Hooking in the anti-slip brackets RS RS Fig. 4 Installing the wind brace B Join the top and bottom flat roof/rooftop profile rails (Fig. 5, []) in the centre to the collector support rail. B Align the lower support rails (Fig. 5, []) so they are parallel to each other. B Tighten all screws (00/06)

17 GR Installing the flat roof frame and the rooftop support Installing flat roof frame 00 l system - building not taller than 0 m To facilitate installation, first tighten all screws by hand. B Secure the cross brace (Fig. 9, []) to the two cylinder support rails and the collector support rail. B Join two cylinder support rails together in the centre to form a cross (Fig. 7, []), and fit to the lower support rail [] in such a way that the surface lying on the ground comes to face inwards. B Secure lower support (Fig. 7, []) to the end of the lower support rail RS Fig. 9 Inserting the cross brace B Make two further side triangles: the centre triangle (Fig. 0, []) as a mirror image of the first [], the left triangle (Fig. 0, []) the same as the first side triangle [] RS Fig. 7 Securing the support rails B Secure the collector support rails at the top to the cylinder support rail (Fig. 8, []), and at the bottom to the support [] K Fig. 0 Further side triangles Fig. 8 Fitting the collector support rail RS (00/06)

18 8 Installing the flat roof frame and the rooftop support GR B Make crosses from 4 wind braces (Fig., []). B Connect the three side triangles to the wind brace crosses. Ensure that the planes of both wind brace crosses are in opposite directions. Initially only secure the wind brace cross at the bottom. B With the right wind brace cross, ensure that the first wind brace is installed from the top back right down to the bottom front left. the second wind brace is installed from the top back left down to the bottom front right. B Attach cylinder straps (Fig., []) between the two cylinder support brackets. Ensure that the flattened screw head points in the direction of the DHW cylinder (which is fitted later) RS Fig. Attaching the cylinder straps The flat roof/rooftop profile rails must be linked with joiners. Each collector has been provided with an upper and lower profile rail. Fig. Fitting the wind braces RS B Initially only secure cylinder support bracket (Fig., []) at the right and left to the wind brace cross and cylinder support rail. B Push joiners (Fig. 4, []) as far as they will go into both profile rails []. B To lock, tighten the two prefitted threaded studs M0 (Fig. 4, [4]) in the joiner with a size 5 spanner RS Fig RS Connecting the flat roof/rooftop profile rails Fig. Securing the cylinder support bracket Joiner Flat roof/rooftop profile rail Hole in joiner 4 M0 threaded stud B Initially secure flat roof/rooftop profile rails (Fig. 4, []) to the centre collector support rail, using hole [] in the joiner. B After this, connect the profile rails on both sides to the collector support rails (00/06)

19 GR Installing the flat roof frame and the rooftop support 9 B Align the lower support rails (Fig. 5, []) so they are parallel to each other. B Tighten all screws. B Affix the self-adhesive foam pads supplied to the cylinder straps. B Secure additional supports []. B Secure additional profile rail []. B Secure all lower support rails to the ground using one further screw (core diameter 0 mm) [] RS Fig. 5 Fitting the flat roof/rooftop profile rails Fitting anti-slip brackets To prevent the collectors from slipping, fasten two antislip brackets to the lower flat roof/rooftop profile rails for each collector. B Push each anti-slip bracket (Fig. 6, []) in the inner slots [] from the outside over the profile rails until it clicks into place []. Fig. 7 Additional supports for flat roof systems (here for 50/00 l system) 5..4 Roof connection Av NOTE: System damage due to inadequately secured lower support rails. B Ensure the support rails are adequately secured given the surface on which they are mounted; consult a structural engineer if necessary. B Take the influence of wind forces into account. Secure the lower support rails to the surface using three screws (core diameter 0 mm) per rail ( Fig. 8). B Secure the lower support rail at the back near the cylinder with two screws. B Secure the lower support rail at the front near the collector with one screw RS Fig. 6 Hooking in the anti-slip brackets 5.. Additional supports for buildings taller than 0 m or wind speeds of 5 km/h For buildings taller than 0 m or if there are particularly heavy wind/snow loads, install additional supports. For the 50/00 l system, a standard installation set is required; for the 00 l system an extension set is also required (00/06)

20 0 Installing the flat roof frame and the rooftop support GR RS Fig. 8 Roof connection for flat roof system (here for 00 l system) Observe country-specific standards and guidelines regarding wind loads (00/06)

21 GR Installing the flat roof frame and the rooftop support In order to prevent the structure slipping or being damaged by wind, choose the fixing option that will not cause damage to the roof membrane: Fix profile rails directly to the roof Fix profile rails to steel girders Fix profile rails to concrete slabs Whichever method is used, take account of the structural integrity of the roof. Height of building Roof connection for flat roof installation Securing the lower profile rails Concrete slabs Wind speed Number and type of screws ) (Minimum weight) TSS 50/00 TSS 00 0 to 8 m 0 km/h x M0/8.8 0 kg 90 kg 8 to 0 m 9 km/h 0 kg 500 kg 0 to 00 m ) 5 km/h Tab. Values for required fixing for thermosiphon systems ) Per lower rail ) Only with additional supports Fixing the lower profile rails The flat roof frame can be secured with the fixings for the lower profile rails. As an example, the process is described using I-beams. Design the subframe in such a way that the thermosiphon system can withstand wind and snow loads that act on it. In addition, provide a means of fixing on site that stabilises the structure and prevents damage to the roof Av Fig. 9 Roof connection for flat roof system on I-beams; dimensions in mm (00/06)

22 Installing the flat roof frame and the rooftop support GR 5. Rooftop installation 5.. Roof connection for rooftop installation DANGER: Risk to life through falls and falling parts! B Take precautions against a possible fall while working on roofs. B Take appropriate action to prevent accidents during all work on roofs. B Always wear your own protective clothing and safety equipment RS Fig. 0 Pre-assembled profile rails for one collector (50/ 00 l system) Use a roofing ladder to provide a better footing on roofs or slide the roof tiles up at the edge of the collector array. Fig. Pre-assembled profile rails for two collectors (00 l system) (00/06)

23 GR Installing the flat roof frame and the rooftop support Determining clearances The dimensions given in the tables are guide values that should be approximately maintained. On tiled roofs, the corrugations determine the distance between the roof connections. Distance between the double ended screws/roof hooks Every profile rail is secured with two double ended screws/roof hooks [] ( Fig.,Fig.). See table for the distance between the roof connections. System Distance A Distance B Distance C Distance D Distance E 50 l 85 ± 75 mm 550 ± 70 mm 90 ± 70 mm 40 ± 70 mm - 00 l 05 ± 75 mm 550 ± 70 mm 90 ± 70 mm 40 ± 70 mm - 00 l 980 ± 80 mm 550 ± 70 mm 90 ± 70 mm 40 ± 70 mm 440 ± 80 mm Tab. Distance between the double ended screws/roof hooks B C D A RS Fig. Distance between the double ended screws/roof hooks in a 50/00 l system E B C D A Fig RS Distance between the double ended screws/roof hooks in a 00 l system (00/06)

24 4 Installing the flat roof frame and the rooftop support GR 5.. Roof connection with double ended screws DANGER: Risk to life due to breathing in fibres containing asbestos! B Work with materials containing asbestos must only be carried out by experts or persons who have been fully instructed on the correct procedures. B The necessary measures laid down by TRGS 59 (Technical Regulations for Hazardous Substances) must be strictly observed. y RS Fit double ended screws to secure the profile rails. Fig. 5 Installing boards/planks if required Fitting the double ended screws Fig. 4 Roof connection Screws Support block M nut 4 Washer 5 Sealing disc 6 M double ended screw SD RS Using the wood drill, drill precisely at a 90 angle through the roof subframe to obtain a flat, level surface between the support block and profile rail. To do so, we recommend preparing a drilling guide or template. Take a timber support approx m to.00 m long. Drill a hole (Ø 6 mm) vertically right through the timber support ( Fig. 6). B Determine the length of the drill bit for the wood drill required according to the following calculation ( Fig. 6): Height of tile peak + Height of drilling template + Required wood drill bit length from drill chuck (Ø 6mm) 90 mm = NOTE: System damage due to a subframe with inadequate load bearing capacity. B Check that the subframe has adequate load bearing capacity. To secure the double ended screws, timber supports at least 40 x 40 mm thick are required. B If necessary, install additional timber supports in order that the measurements in table, page can be maintained. Tab. 4 NOTE: Building damage due to leaking roof. B Never drill into a tile valley. B Drill through the corrugated roof using a metal drill bit (Ø mm), taking account of the positions of the double ended screws (Tab., page ). Do not drill into the wood beneath! B Feed wood drill bit (Ø 6 mm) through the template and drill vertically into the subframe (timber support). B When fitting the double ended screws, note the sequence of the individual parts ( Fig. 7). B Turn support block (Fig. 7, []) as far as it will go onto the double ended screw (Fig. 7, [5]) (00/06)

25 GR Installing the flat roof frame and the rooftop support 5 B Using a size 5 spanner, turn the pre-assembled double ended screws into the roof until dimension B is achieved ( Tab. 5). Height of tile peak Dimension A Dimension B When turning in the double ended screws, ensure that the distances ( Tab. 5, Fig. 8) are the same for all double ended screws. 5 mm 70 mm 40 mm 65 mm 45 mm 60 mm 50 mm 55 mm 55 mm 50 mm 60 mm 45 mm Tab. 5 Installation dimensions. Dimensions depend on the height of the relevant corrugated tile peak SD RS Fig. 6 Creating a drilling template RS 4 5 Fig. 8 Support block M nut Sealing disc Installed double ended screw SD RS Fig. 7 Fitting the double ended screws - sequence Support block M nut Washer 4 Sealing disc 5 M double ended screw B Tighten the nuts (Fig. 7, []) until the sealing disc (Fig. 8, []) fully touches the roof. The support block must be turned fully onto the double ended screw (00/06)

26 6 Installing the flat roof frame and the rooftop support GR 5.. Roof connection with roof hooks NOTE: Thermosiphon system may fall and cause roof damage. The system may only be installed on roof with a slope of 5 to 5 and a maximum height of 0 m, where the permissible snow load will not be exceeded. NOTE: Building damage. There must be at least one free row of tiles that is not subject to a load between the upper, central and lower roof hooks. NOTE: Water ingress through loose roof tiles. B Carefully cut away the contact points of the tile so the tile lies correctly over the roof hook. NOTE: System damage through subsequent loosening of the hexagon nut on the roof hook. When the nut is tightened, adhesive is activated which bonds the joint securely after one hour. B If the nut becomes loose after this time, tighten it on site (e.g. serrated washer). B Lay the front support on the tile in such a way that it will lie in a tile valley when subjected to a load ( Fig. 40, []). The roof hook must have some clearance at the upper edge of the tile ( Fig. 40, [4]). B Adjust the top of the tile if necessary. B Push the roof hook down until it comes to rest on the rafter or boards/planks ( Fig. 40, [6]). The serrated washer ( Fig. 40, [5]) must grip the serrations on the lower part of the roof hook. B Tighten the long hexagon nut ( Fig. 40, []). To do so, insert the size 5 spanner into the hole in the hexagon nut and turn. B Using suitable screws, secure the lower part of the roof hook to the rafter in at least the first ( Fig. 40, []) and second holes. NOTE: System damage. It is not permissible to install roof hooks without threaded fittings or without suitable screws. According to the roof hook positions ( Tab., page ), it may be necessary to attach boards/planks with adequate load bearing capacity to the rafters (horizontal battens) in order to fit the roof hooks. With some roof covers, it may be necessary to underlay the lower part ( Fig. 9, [4]) with boards/planks so that it lies on top of the roof tile. B Tighten the long hexagon nuts ( Fig. 9, []). B Push the screw into the upper hole ( Fig. 9, []). B Loosely fasten the lower part of the roof hook ( Fig. 9, []). Do not tighten the connection yet. NOTE: System damage if the roof hook breaks. B Position the screw in the upper hole to prevent an adverse application of force. Fig. 9 Fastening roof hooks to rafters Lower part of roof hook Long hexagon nut Upper hole for fastening the lower part 4 Underlay if necessary 5 Trim if necessary SD (00/06)

27 GR Installing the flat roof frame and the rooftop support B Secure collector profile rails (Fig. 4, []) with two screws each [] to the support block [], beginning in the lower slot. The collector profile rails must not sag due to differences in the rafter levels. Use a plumb line to check. If necessary, underlay the profile rails at the support block. Fig SD Roof hook fitted (some tiles have been removed for a better view) Long hexagon nut Screws for fastening roof hooks Front support 4 Adjust the tile as necessary to fit the roof hook 5 Serrated washer 6 Board/plank 5..4 For 50/00 l systems: fitting the rooftop installation system The diagrams show the installation with double ended screws. The procedure for installation with roof hooks is the same. Preparing the collector profile rails The collector profile rails must be equipped at the upper end with the TSS joiner for their subsequent connection to the cylinder profile rails. B Push TSS joiner (Fig. 4, []) into the collector profile rail [] and secure with M8x0 screws and M8 nuts. Fig. 4 Securing collector profile rail to support block Screw Support block Collector profile rail B Insert screw (Fig. 4, []) into the slots of the flat roof/rooftop profile rail [4] and loosely attach the locking bolt until a little resistance can be felt. B Position flat roof/rooftop profile rails (Fig. 4, [4]) in the notches [5] in the collector profile rail [] and align centrally RS Fig. 4 Inserting TSS joiner into collector profile rail TSS joiner Collector profile rail (00/06)

28 8 Installing the flat roof frame and the rooftop support GR B Position locking bolt (Fig. 4, []) in the collector profile rail [] and tighten screw. Fig Securing flat roof/rooftop profile rail to collector profile rail Screw Locking bolt Collector profile rail 4 Flat roof/rooftop profile rail 5 Notch RS B Push cylinder profile rail (Fig. 44, []) onto TSS joiners [] and secure with M8x0 screws and M8 nuts. B Secure cylinder profile rails (Fig. 44, []) with two screws each to the support block. B Insert screw into the front end of cylinder strap (Fig. 45, []) and loosely attach locking bolt [4] until a little resistance can be felt. B Insert screw into cylinder strap support bracket (Fig. 45, [5]) and loosely attach locking bolt until a little resistance can be felt. B Position front end of cylinder strap in notch (Fig. 45, [6]) and tighten screw. B Position cylinder strap support bracket (Fig. 45, [5]) in the second notch and tighten screw. B Fit screw, washer and locking bolt to end of cylinder strap (Fig. 45, []). Do not fasten this end yet! B Tighten all screws. 4 We recommend fitting the screws to the cylinder strap on the ground in advance. Subsequently fit the cylinder strap to the cylinder profile rail. 6 5 Fig. 45 Securing cylinder strap End of cylinder strap Cylinder strap Front end of cylinder strap 4 Locking bolt 5 Cylinder strap support bracket 6 Notch Fig. 44 Securing cylinder profile rail to flat roof/rooftop profile rail Cylinder profile rail TSS joiner Collector profile rail (00/06)

29 GR Installing the flat roof frame and the rooftop support 9 Fitting anti-slip brackets To prevent the collectors from slipping, fasten two antislip brackets to the lower roof profile rails for each collector. B Push each anti-slip bracket (Fig. 46, []) in the inner slots [] from the outside over the profile rails until it clicks into place []. B Secure collector profile rails (Fig. 48, []) with two screws each [] to the support block [], beginning in the lower slot. The collector profile rails must not sag due to differences in the rafter levels. B Use a plumb line to check. If necessary, underlay the profile rails at the support block. Fig. 46 Attaching an anti-slip bracket Fixing holes for the anti-slip brackets Attaching an anti-slip bracket Anti-slip bracket 5..5 For 00 l system: installing profile rails RS Preparing centre collector profile rail The centre collector profile rail must be equipped at the upper edge with the TSS joiner for subsequent connection to the cylinder profile rail. B Push TSS joiner (Fig. 47, []) into the collector profile rail [] and secure with M8x0 screws and M8 nuts. Fig. 48 Fastening the profile rail to the support block Screw Support block Collector profile rail RS Preparing flat roof/rooftop profile rails The profile rails must be linked using joiners. Each collector has been provided with an upper and lower profile rail. B Push joiners (Fig. 49, []) as far as they will go into both profile rails [] RS Fig. 47 Inserting TSS joiner into collector profile rail TSS joiner Collector profile rail (00/06)

30 0 Installing the flat roof frame and the rooftop support GR B To lock, tighten the two prefitted threaded studs M0 (Fig. 49, [4]) in the joiner with a size 5 spanner. B Position locking bolt (Fig. 50, []) in the collector profile rail [] and tighten screw Fig. 49 Connecting profile rails Joiner Flat roof/rooftop profile rails Hole in joiner 4 M0 threaded stud RS B Insert screw (Fig. 50, []) into the slots of the flat roof/rooftop profile rail [4] and loosely attach the locking bolt until a little resistance can be felt. B Position flat roof/rooftop profile rails (Fig. 50, [4]) in the notches [5] in the collector profile rail [] and align centrally. B Secure profile rails to the centre collector profile rail using the hole (Fig. 49, []) in the joiner. Fig. 50 Securing flat roof/rooftop profile rail to collector profile rail Screw Locking bolt Collector profile rail 4 Flat roof/rooftop profile rail 5 Notch B Push centre cylinder profile rail (Fig. 5, []) onto TSS joiner on centre collector profile rail and secure with M8x0 screws and M8 nuts. B Secure positioning bracket (Fig. 5, []) to the side cylinder profile rails [] using screws and nuts. B Hook the two side cylinder profile rails (Fig. 5, []) into the flat roof/rooftop profile rail [] (00/06)

31 GR Installing the flat roof frame and the rooftop support B Secure cylinder profile rails (Fig. 5, []) with two screws each to the support block. B Tighten all screws Fig. 5 Securing cylinder profile rails Cylinder profile rail Positioning bracket Flat roof/rooftop profile rail 4 Collector profile rail We recommend fitting the screws to the cylinder strap on the ground in advance. Subsequently fit the cylinder strap to the cylinder profile rail. B Insert screw into the front end of cylinder strap (Fig. 5, []) and loosely attach locking bolt [4] until a little resistance can be felt. B Insert screw into cylinder strap support bracket (Fig. 5, [5]) and loosely attach locking bolt until a little resistance can be felt. B Position front end of cylinder strap (Fig. 5, []) in notch [6] and tighten screw. B Position cylinder strap support bracket (Fig. 5, [5]) in the second notch and tighten screw. B Fit screw, washer and locking bolt to end of cylinder strap (Fig. 5, []). Do not fasten this end yet! Fig. 5 Securing cylinder strap End of cylinder strap Cylinder strap Front end of cylinder strap 4 Locking bolt 5 Cylinder strap support bracket 6 Notch Fitting anti-slip brackets To prevent the collectors from slipping, fasten two antislip brackets to the lower roof profile rails for each collector. B Push each anti-slip bracket [] in the inner slots [] from the outside over the profile rails until it clicks into place []. Fig. 5 Attaching an anti-slip bracket RS Fixing holes for the anti-slip brackets Clicking the anti-slip bracket into place Anti-slip bracket (00/06)

32 Collector installation GR 6 Collector installation Observe the following safety instructions and user information. DANGER: Risk to life through falls and falling parts! B Take appropriate action to prevent accidents during all work on roofs. B Take precautions against a possible fall while working on roofs. B Always wear your own protective clothing and safety equipment. After completing installation, check the installation set and collectors are securely positioned. DANGER: Risk of injury due to falling collectors. B During transport and installation, secure the collectors to prevent them falling. Fig RS View of flat roof installation (here 00 l system) NOTE: System damage due to damaged sealing faces. B Do not remove the plastic caps on the collector connections until immediately prior to installation. NOTE: System damage due to leaking solar hoses. B It is very important to ensure the hose clip (Fig. 56, [4]) is positioned correctly before removing the locking ring (Fig. 56, []). Subsequent loosening using pliers can impair resilience. Fig RS View of rooftop installation (here 00 l system) Use lifting equipment as used by professional roofers or -point suction handles with adequate load bearing capacity for the installation (00/06)

33 GR Collector installation 6. Preparing to install the collectors NOTE: System damage due to leaking solar hoses. B It is very important to ensure the hose clip (Fig. 56, [4]) is positioned correctly before removing the locking ring (Fig. 56, []). Subsequent loosening using pliers can impair resilience. B Remove plastic caps (transport protection) from the unused collector connections. DANGER: Risk of injury. Only tighten the locking ring once the hose clip is positioned over the solar hose. 4 The locking ring must be removed from the hose clip to close or secure the solar hose. To make installation easier, we recommend placing the solar hoses in hot water, especially when the ambient temperature is low. 6.. Pre-assembling dummy plugs Before beginning actual installation on the roof, preassemble the short solar hoses and dummy plugs on the ground to make work on the roof easier. B Push dummy plug ( Fig. 56, []) as far as it will go onto 55 mm solar hose []. B Bring hose clip ( Fig. 56, [4]) into position and pull locking ring [] to secure the plug. Fig. 56 Hose clip with locking ring and pre-assembled dummy plug Locking ring Solar hose 55 mm Dummy plug 4 Hose clip RS B Push pre-assembled dummy plugs (Fig. 57, []) with hose clips [] onto the two free connections on the collector array. B Once the hose clips are seated correctly, pull the locking rings to secure the connection SD RS Fig. 57 Hose clip with locking ring and pre-assembled dummy plug Pre-assembled dummy plug Hose clip with locking ring (00/06)

34 4 Collector installation GR 6.. For the 00 l system: pre-mount the joining set The hydraulic connection between two collectors is made using the joining set (95 mm solar hoses and hose clips from the transport corners). 6. Hydraulic connection As a general principle, connect the collectors according to the Tichelmann principle ( Fig. 59). The diagrams show the joining set with the first collector being installed on the right. 9 0 B Remove plastic caps (transport protection) from the relevant collector connections. B Push 95 mm solar hoses (Fig. 58, []) onto the r.h. connections of the second collector B Push hose clips (Fig. 58, []) over the solar hose (the second clip later secures the connection of the other collector). 5 B Once the hose clip is seated correctly, pull the locking ring to secure the connection (Fig. 58, []). 4 Fig. 59 Hydraulic connection according to the Tichelmann principle RS Cylinder Cold water connection Return connection, solar 4 Dummy plug 5 Return line 6 Flow line 7 DHW connection 8 Flow connection, solar 9 Safety valve connection, solar 0 Heat transfer medium filler Fig. 58 Fitting the joining set RS (00/06)

35 GR Collector installation 5 6. Securing the collectors The collectors are secured to the profile rails by the single sided collector tensioners (Fig. 60, []) at the ends of each flat roof/rooftop profile rail, and the double sided collector tensioners [] between the collectors. In addition, the anti-slip brackets (Fig. 60, []) prevent the collector slipping. DANGER: Risk of injury. B The collectors should always be installed by two people. B Place the first collector on the profile rails and let it slide into the anti-slip brackets (Fig. 6, []). Position the lower collector edge (Fig. 6, []) in the aperture of the anti-slip bracket. The plastic parts on the collector tensioners do not have any support function. They are simply intended to make installation easier RS Fig. 6 Laying the first collector on the profile rails Fig RS Collector fixing elements 6.. Inserting the single sided collector tensioner on the right B Push the single sided collector tensioner (Fig. 6, []) on the right into the flat roof/rooftop profile rails until it clicks into place in the first slot on the profile rail. B Carefully push the collector (Fig. 6, []) up against the single sided collector tensioner and level horizontally. B Secure single sided collector tensioner with size 5 spanner. The hold-down retainer (Fig. 6, []) on the collector tensioner now grips the lower collector edge. When the screw is tightened, the plastic guide at the pre-determined cut-off points breaks away RS Fig. 6 Inserting the single sided collector tensioner 6.. Positioning the first collector Begin placing the collectors on r.h. side of the profile rails. Fig RS Threaded single sided collector tensioner (00/06)

36 6 Collector installation GR 6.. For 00 l system: inserting the double sided collector tensioner B Place the double sided collector tensioner, with attached nut, into the aperture of the profile rail and joiner in such a way that the plastic spacer (Fig. 64, []) surrounds the profile rail. B Push double sided collector tensioner up against the collector frame. Do not tighten the screw until the second collector has been pushed up against the double sided collector tensioner For 00 l system: positioning second collector B Place the second collector with the pre-assembled solar hoses (Fig. 65, []) at the top of the profile rails and let it slide into the anti-slip brackets. B With both connections, push the second hose clip (Fig. 65, []) onto the solar hose []. B Push the second collector up against the first (Fig. 65, [4]) in such a way that the pre-assembled solar hoses are pushed onto the l.h. connections [] on the first collector SD RS Fig. 65 Pushing second collector towards the first SD RS Fig. 64 Fitting the double sided collector tensioner Solar hose Hose clip Connections on the collector side 4 First collector B Push the hose clip over the bead on the collector connection and pull the locking ring. NOTE: System damage due to leaking hose connections or dummy plugs. B Secure solar hoses and dummy plugs to collector connection with a hose clip ( Fig. 66). B Tighten the screw on the double sided collector tensioner with the size 5 spanner. The hold-down retainer (Fig. 67, []) on the collector tensioner now grips the lower collector edge. When the screw is tightened, the plastic lugs at the pre-determined cut-off points break away (00/06)

37 GR Collector installation Installing the single sided collector tensioner on the left B Push the single sided collector tensioner (Fig. 68, []) into the ends of the profile rail. B Push collector tensioner up against the collector frame and secure in place with size 5 spanner. The hold-down retainer (Fig. 68, []) on the collector tensioner now grips the lower collector edge RS When the screw is tightened, the plastic guide at the pre-determined cut-off points breaks away. Fig. 66 Solar hose with secured hose clips SD RS Fig. 67 Double sided collector tensioner between collectors SD RS Fig. 68 Single sided collector tensioner on the left Once all the collectors have been fitted, the remaining single sided collector tensioners can be secured (00/06)