FKT SERIES FLAT PANEL SOLAR COLLECTORS ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS

Transcription

1 FKT SERIES FLAT PANEL SOLAR COLLECTORS ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS SD G Installaton nstructons

2 About ths manual Ths nstallaton manual contans mportant nformaton for the safe and approprate nstallaton of the roof mounted solar panels. Notes are ncluded wth mportant nformaton for stuatons n whch there s no danger for persons or equpment. These techncal documents should be retaned n a safe place. These may also be nspected at the manufacturer's premses. The actvtes descrbed n the nstallaton manual assume expertse based on completed vocatonal tranng n gas or water-related nstallaton. Only carry out these nstallaton steps, f you possess these sklls. Hand these nstallaton nstructons to the customer. Explan to the customer the functon and operaton of the related devces (006/0)

3 General nformaton Specfcatons Safety Correct use Notes structure Please observe these safety nstructons efore nstallaton General notes Component descrpton Other equpment Transport and storage Techncal documentaton Determnng space requred on roof Fttng the roof connecton and profle rals Settng clearances Pan tle roofs Crown tle roofs Corrugated sheet steel roofs Slate/shngle roofs Sheet roofs Fttng addtonal rals (accessory) Installng profle rals Collector nstallaton Preparng to nstall the collectors Fastenng the collectors Collector sensor connecton Header connecton De-arng through pressure fllng De-arng through ar vent (accessory) on roof Fttng the connecton set for two rows (accessory) Fnal actvtes Checkng the nstallaton Insulatng the connecton and header ppes Quck reference gude for pan tle roof and pressure fllng (006/0)

4 General nformaton General nformaton Ths chapter detals whch techncal rules and regulatons apply to ths nstallaton. Observe all standards and gudelnes applcable to the nstallaton and operaton of ths system n your country. Installaton work on roofs The Health and Safety at Work etc Act 97 The Management of Health and Safety at Work Regulatons 999 The Constructon (Health Safety and Welfare) Regulatons 996 The Constructon (Desgn and Management) Regulatons 99 The Lftng Operatons and Lftng Equpment Regulatons 998 UK Connecton of thermal solar heatng systems EN 976: Thermal solar heatng system and ther components (prefabrcated systems). ENV 977: Thermal solar heatng system and ther components (bespoke systems). S 6795: Code of practce for solar heatng systems for swmmng pools. Installaton and equpment of DHW cylnders S556: 000 Specfcaton for nstallaton of hot water supples for domestc purposes, usng gas-fred applances of rated nput not exceedng 70 kw. S6700:997 Specfcaton for desgn, nstallaton, testng and mantenance, of servcng supplyng water for domestc use wthn buldngs and ther curtlages. Tab. Techncal rules for the nstallaton of thermal solar heatng systems (selecton) n UK Lghtnng protecton If the buldng heght (nstallaton heght) exceeds 0 m, and there s no lghtnng conductor nstalled, ask your local electrcal contractor to connect the components on the roof whch conduct electrcty wth an electrcal earth cable of at least 6 mm to the earth bondng. Specal measures regardng lghtnng protecton are not requred for buldng heghts (nstallaton heghts) of less than 0 m. Where there s a lghtnng conductor system nstalled, ask your local electrcal contractor to check the ncluson of the solar heatng system nto the lghtnng protecton system. The nstallaton of the Worcester Solar System must be carred out n accordance wth the relevant requrements for safety, current IEE wrng regulatons, local buldng regulatons, buldng standards (Scotland) (Consoldaton) regulatons and by-laws of the local water company and health and safety document No 65 (Electrcty at Work Regulatons 989). S 6795: Latest verson (006/0)

5 Specfcatons Specfcatons FKT Solar Panels Certfcates 006 DIN Length,070 mm Wdth,5 mm Heght 90 mm Clearance between collectors 5 mm Flud content, portrat verson V f. l Flud content, landscape verson V f.76 l Gross absorber surface area A G.7 m² Net absorber surface area. m² Net weght, portrat verson m 6 kg Net weght, landscape verson m 7 kg Permssble operatng pressure of the collector p max 0 bar Tab. Specfcatons (006/0) 5

6 Safety Safety Ths chapter detals how the notes for the nstallaton nstructons, as well as the general safety nstructons, necessary for safe and trouble-free operaton, are arranged n ths manual. Safety and user notes, whch specfcally refer to the nstallaton, n the nstallaton manual mmedately followng the ndvdual nstallaton steps, are found here. Carefully read the safety nstructons before commencng the nstallaton. Severe njury and even death, as well as materal losses and envronmental damage, may follow f you gnore safety nstructons.. Correct use Ths nstallaton set holds the thermal solar collectors (portrat and landscape), whch are nstalled on slopng roofs wth a slope of 5 to 65. The collectors can be nstalled on corrugated and sheet steel roofs wth slopes of between 5 and 65. Operatng condtons Only erect the nstallaton set on roofs whose constructon can support the weght. If necessary, consult a structural engneer or a roofer. The nstallaton set s sutable for a max. standard snow load of.0 kn/m² and an nstallaton heght of max. 0 m. Usng approprate accessores, the nstallaton set can be used for a max. standard snow load of. kn/m² and a max. nstallaton heght of 00 m. See Chapter 5.7 "Fttng addtonal rals (accessory)". The roof nstallaton set must not be used for fxng any other objects to the roof. The kt s ntended exclusvely for the safe fxng of solar collectors (006/0)

7 Safety. Notes structure Two levels are dentfed by sgnal terms: RISK TO LIFE WARNING! Identfes possble dangers emanatng from a product, whch mght lead to serous njury or death f approprate care s not taken. CAUTION! RISK OF INJURY/ SYSTEM DAMAGE/ UILDING DAMAGE Identfes potentally hazardous stuatons, whch could lead to medum or slght njures or to materal losses. Addtonal symbol for desgnatng user notes: Tp for the optmum utlsaton and settng of the control(s) plus other useful nformaton (006/0) 7

8 Safety. Please observe these safety nstructons RISK TO LIFE WARNING! through a fall or fallng parts. Ensure you have the correct safety equpment for workng on roofs. Take approprate acton to prevent accdents when workng on roofs. Whlst workng on the roof, take all necessary precautons aganst a possble fall. Always wear your personal protectve clothng and safety equpment. After completng the nstallaton, always check the secure postonng of the nstalled set and that of the collectors. RISK OF INJURY CAUTION! Injury and operatng faults can result from makng changes to the system constructon. Never change the system constructon. RISK OF INJURY CAUTION! Some parts may cause burns, f the collector and nstallaton materals are exposed to solar radaton for longer perods of tme. Always wear your personal protectve clothng and safety equpment. Cover the collector (e.g. wth a coverng sheet avalable as an accessory ) and the nstallaton materal durng the nstallaton as protecton aganst hgh temperatures resultng from solar rradaton (006/0)

9 efore nstallaton efore nstallaton. General notes It s recommended that the servces of a roofng company, who are experenced n workng on roofs and wll be fully aware of the rsks of workng at heght are consdered. Make yourself famlar wth the on-ste condtons and local regulatons before commencng the nstallaton. RISK OF INJURY CAUTION! If the collector and ts nstallaton materal s left exposed to the sunlght for a long perod, the parts wll become hot and may cause burns. Wear protectve clothng. Cover the collector (e.g. wth a coverng sheet avalable as an accessory ) and the nstallaton materal durng the nstallaton as protecton aganst hgh temperatures resultng from solar rradaton. Fg SD General overvew of collector par roof mountng Check the delvery for completeness and perfect condton. the optmum arrangement of the solar collectors. Take account of the drecton of the sunlght (angle of nclnaton, southerly drecton). Avod the shade of hgh trees or structures and match the collector array to the shape of the buldng (e.g. flush wth wndows, doors, etc.). Only use OEM components and replace any faulty parts mmedately. Remove broken pan tles, shngles or plates n the area of the collectors and replace them (006/0) 9

10 efore nstallaton. Component descrpton.. Installaton set for the collectors The nstallaton sets are for mountng and fxng the collectors n place. 8 5 Fg SD Installaton set for collectors basc nstallaton set, extended nstallaton set and roof connecton nstallaton sets asc nstallaton set for each collector array and for the frst collector (Fg. ): Extended nstallaton set for each addtonal collector (Fg. ): Item : Profle ral Item : Profle ral Item : Sngle-sded collector clamp Item : Double-sded collector clamp Item 7: Ant-slp protecton Item 7: Ant-slp protecton Item 8: M8 screw Item 6: Ral connector wth threaded studs Item 8: M8 screw Roof connecton, pan tle roofs, per collector (Fg. ): Item Roof hook, adjustable Item 5 Sldng nut (006/0)

11 efore nstallaton.. Hydraulc connecton One connecton kt for each collector array wll be requred. The collectors are connected together by a connecton set SD Fg. Connecton kt and connecton set (llustraton shows portrat collectors) Connecton kt, per collector array (Fg. ) Item : Connector clp Item 6: Sze 5 Allen key Item : Connectng ppe (nsulaton not shown) Item 7: End cap Item : Insulaton for corrugated ppe connector 70 mm Item 8: Sensor bush plug, not shown Item 5: Clamped jont for collector sensor Connecton set between the collectors, for each collector (n two corner protectors, Fg. ) Item : Corrugated ppe connector Item : Connector clp Fg. Corner protectors wth one connecton set SD (006/0)

12 efore nstallaton. Other equpment Sprt level Plumb lne Fllng pump Vest harness wth safety rope Ppe nsulaton Scaffoldng Roofng ladder Crane or moble host When fttng the roof nstallaton set and water connecton, the only tool requred s the sze 5 allen key from the connecton kt.. Transport and storage Please ensure that the corner protectors are retaned. They contan ppework connecton peces whch are requred for nstallaton. All components are protected by transport packagng. Dspose of the transport packagng n an envronmentally frendly recyclng system. Transport protecton for collector connectons The collector connectons are protected aganst damage by rubber caps. SYSTEM DAMAGE CAUTION! Storage through damaged sealng faces. Do not remove the rubber caps (Fg. 5, Item ) untl mmedately pror to nstallaton. The collectors must be stored n dry condtons. Do not store collectors outsde wthout protecton from the ran SD Fg. 5 Plastc caps on collector connectons (006/0)

13 efore nstallaton.5 Techncal documentaton The solar heatng system conssts of varous components (Fg. 6). Installaton, operaton and mantenance documentaton s provded for each component. Accessores may be accompaned by a separate document. Item : Collector: nstructons for roof nstallaton are enclosed wth the connecton kt Item : Item : Item : Pump staton: nstructons enclosed wth the complete staton Solar Controller: nstructons are enclosed wth the controller. DHW Cylnder: nstructons enclosed wth the DHW cylnder. Fg SD Solar heatng system components and techncal documentaton (006/0)

14 efore nstallaton.6 Determnng space requred on roof Please note the followng mnmum space requrements. Dmenson A and Area requred for the collector array. Dmenson C H At least two tles to the roof or chmney. Otherwse there s a rsk of damagng the tles, partcularly f the tles are lad n mortar. Dmenson D Roof overhang ncludng gable wall thckness. G Dmenson E Mnmum 0 cm for fttng the connecton cables n the attc. Fg. 7 Clearances to be observed SD Dmenson F Mnmum 0 cm for nstallng the connecton cables n the attc (f nstallng a vent, suffcent space must also be allowed for n the vcnty of the flow outlet). Please note that the ar vent must be the hghest pont of the system. Dmenson G Mnmum 50 cm left and rght of the collector array for the ppework under the roof. Dmenson H Dmenson H s.900 mm (.000 mm for landscape collectors) and s the mnmum dstance from the upper edge of the collector to the lower profle ral, whch s nstalled frst. Space requrements for portrat collectors: Space requrements for landscape collectors: Number of collectors Dmenson A Dm. Number of collectors Dmenson A Dm.. m.07 m.7 m.5 m.9 m.07 m 6.6 m.5 m.66 m.07 m 8.6 m.5 m m.07 m m.5 m m.07 m 6.55 m.5 m m.07 m 7.6 m.5 m 8 9. m.07 m m.5 m m.07 m m.5 m 0.68 m.07 m m.5 m Tab. Space requrement for portrat collectors Tab. Space requrement for landscape collectors (006/0)

15 Fttng the roof connecton and profle rals 5 Fttng the roof connecton and profle rals 5. Settng clearances The dmensons gven are gude values that should be approxmately mantaned. On pan tle roofs the tle troughs determne the true dstance between the roof hooks. Dstances of roof hooks Every profle ral s fastened usng two roof hooks (Fg. 8). See the table for the approxmate dstance between the roof hooks. Installaton Dstance w Dstance x Dstance z type portrat approx mm 70 mm 00 mm landscape approx. 090 mm mm 950 mm Tab. 5 Dstance of the roof hooks from one another Dstances x and z should always be approxmately equal to dstance w. Fg. 8 z Dstance of the roof hooks from one another x SD Dstances of profle rals Set the dstance between the top and bottom profle rals (Fg. 9). Use the table values. Installaton Dstance y type from to portrat 0 mm 70 mm landscape 600 mm 80 mm Tab. 6 Dstance (centre-centre) between bottom and top profle ral y Landscape nstallaton s only possble f roof battens are max. 0 mm apart. Fg. 9 Dstance between the profle rals SD (006/0) 5

16 Fttng the roof connecton and profle rals 5. Pan tle roofs Ft all roof hooks accordng to the gude values shown n tables 5 and 6 on page 5. Do not modfy the roof constructon and avod damagng the roof coverng. In the case of roof tles lad n mortar, lft the tles startng wth the rd row under the roof. Carefully cut away the base of the tle f necessary to ensure the tle les correctly over the roof hook. Fg. 0 Ftted roof hooks for two collectors SD CAUTION! SYSTEM DAMAGE through subsequent loosenng of the long hexagon nut on the roof hook. When the nut s tghtened, adhesve s actvated whch bonds the jont securely after one hour. If the nut becomes loose after ths tme, t must be tghtened on-ste (e.g. lock washer). 5.. Attachng the roof hooks over the roof batten In ts packaged state, the lower part of the roof hook s folded. Loosen the long hexagon nut (Fg., Item ) on the roof hook and move the lower part of the roof hook (Fg., Item ) to the correct poston. Push the tle upwards accordng to the roof hook postons shown n (Tab. 5 and Tab. 6, page 5). Attach n the roof hook n such a way that the front brace les n a tle trough (Fg., Item ). Push the lower part of roof hook (Fg., Item ) upwards untl t touches the roof batten (Fg., Item ). Tghten the long hexagon nut (Fg., Item ). To do ths, nsert the sze 5 Allen key nto one of the holes n the hexagon nut and turn. The serated washer (Fg., Item 5) must grp the teeth on the lower part of the roof hook. Fg. Fg. Turnng the lower part of the roof hook SD SD Roof hook located n place (some tles have been removed to show the example n more detal) (006/0)

17 Fttng the roof connecton and profle rals 5.. Fastenng roof hooks to josts Alternatvely, the roof hook can also be used for fastenng to the jost. Accordng to the roof hook postons shown n (Tab. 5 and Tab. 6, page 5), suffcently strong boards must be attached to the josts so that the roof hook can be ftted between the josts. Wth some roof coverngs t may be necessary to underlay the lower part of the roof hook (Fg., Item ) wth boards so that the upper part of the roof hook les on top of the tle. Loosen the long hexagon nut (Fg., Item ). Insert bolt nto upper hole (Fg., Item ). Loosely fasten lower part of roof hook (Fg., Item ). Do not tghten the connecton yet. SYSTEM DAMAGE Fg. Item : Item : Item : Item : Item 5: Fastenng roof hooks to josts Lower part of roof hook Long hexagon nut Upper hole for fastenng the lower part Underlay f necessary Cut off f necessary SD CAUTION! through breakage of the roof hook f the bolt s not postoned n the upper hole, resultng n uneven load dstrbuton. Lay front brace onto the tle so that when subjected to a load t les n a tle trough (Fg., Item ). The roof hook must have some clearance along the upper edge of the tle (Fg., Item ). Adjust the top of the tle f necessary. 6 5 Push the lower part of the roof hook down untl t les on the jost or on the boards (Fg., Item 6). The serated washer (Fg., Item 5) must grp the teeth on the lower part of the roof hook. Tghten the long hexagon nut (Fg., Item ). To do ths, nsert the sze 5 Allen key nto the hole n the hexagon nut and turn. Usng sutable screws, fasten the lower part of the roof hook nto the frst (Fg., Item ) and second holes (at least) of the jost. Fg. Item : Item : Item : Roof hook ftted (some tles have been removed for a better vew) Long hexagon nut Screw for fastenng roof hook Front brace SD Item : Adjust the tle as necessary to ft the roof hook Item 5: Serated washer Item 6: oard (006/0) 7

18 Fttng the roof connecton and profle rals 5. Crown tle roofs Consult a roofer when nstallng on a roof wth crown tles. Durng nstallaton, please mantan the requred dstances (w, x and y) between the roof hooks as detaled n (Tab. 5 and Tab. 6, page 5). Accordng to the roof hook postons shown n (Tab. 5 and Tab. 6, page 5), suffcently strong boards (Fg. 5, Item ) must be attached to the josts (cut out counterbattens) so that the roof hook can be ftted between the josts. Fg. 5 Ft boards/planks f necessary SD If the roof has been ftted wth boards, the same roof hook as wth pan tle roofs can be used (page 6). It may be possble to ft the roof hooks over battens. Preparng roof hook efore nstallng, the lower part must be moved to the correct poston. Loosen the long hexagon nut (Fg. 6, Item ). Insert bolt nto upper hole (Fg. 6, Item ). Loosely fasten lower part of roof hook (Fg. 6, Item ). Do not tghten the connecton yet. CAUTION! SYSTEM DAMAGE through breakage of the roof hook f the bolt s not postoned n the upper hole, resultng n uneven load dstrbuton. Fg. 6 Repostonng lower part of roof hook SD Item : Lower part of roof hook Item : Long hexagon nut Item : Upper hole for fastenng the lower part Item : Cut off f necessary (006/0)

19 Fttng the roof connecton and profle rals RISK TO LIFE WARNING! Whlst workng on the roof, take all necessary precautons aganst a possble fall. RISK OF INJURY through a fall or fallng parts. WARNING! Take approprate acton to prevent accdents when workng on roofs. Always wear personal protectve clothng and safety equpment. For better access to the roof use a roofng ladder or slde the tles at the edge of the collector array up. Fg. 7 Ftted profle rals for two collectors SD (006/0) 9

20 Fttng the roof connecton and profle rals Fttng the roof hook UILDING DAMAGE CAUTION! caused by leaks. Ft each roof hook centrally on a crown tle. If the roof battens are too close together, remove the lower part of the roof hook between the second and thrd holes. Push the lower part of the hook down untl t les on the jost or on the board (Fg. 8, Item ). The serated washer (Fg. 9, Item ) must grp the teeth on the lower part of the roof hook. Fg. 8 5 Ftted roof hook SD Tghten the long hexagon nut (Fg. 9, Item ). To do ths, nsert the sze 5 Allen key nto the hole n the hexagon nut and turn. Usng sutable screws, fasten the lower part of the roof hook nto the frst (Fg. 9, Item ) and second holes (at least) of the jost or board SD Fg. 9 Ftted roof hook cross secton showng shortened lower part of roof hook Item : Long hexagon nut Item : Serated washer Item : Screw for fastenng roof hook Cut the adjacent crown tles (Fg. 0, Item ) to sze (dashed lne, Fg. 0, Item ). Fg. 0 Roof hook wth covered roof SD (006/0)

21 Fttng the roof connecton and profle rals 5. Corrugated sheet steel roofs Carrage bolts must be used nstead of roof hooks for fastenng the profle rals. Standard delvery (Fg. ): Item : M8 screw Item : Holdng bracket Item : M nut Item : Washer Item 5: Sealng dsc Item 6: M carrage bolt On corrugated roofs, the peaks determne the true dstance between the carrage bolts. Durng nstallaton, please mantan the requred dstances (w, x and y) between carrage bolts as detaled n (Tab. 5 and Tab. 6, page 5). CAUTION! SYSTEM DAMAGE due to an nsuffcently strong subframe. Check that the subframe s strong enough. To fasten the carrage bolts, tmber supports of at least 0 0 mm thckness are requred. If necessary, ft addtonal tmber supports to mantan the measurements shown n Tab. 5 and Tab. 6. Fg. Roof connector for corrugated steel sheets Addtonal tools requred Cordless screwdrver Tape measure Wood drll, Ø 6 mm (drll bt length see Chapter "Fttng the carrage bolts", page ) Metal drll, Ø mm Spanner sze 5 and SD (006/0)

22 Fttng the roof connecton and profle rals Fttng the carrage bolts Usng the wood drll, drll precsely at a 90 angle through the roof subframe to obtan a flat, level surface between the holdng bracket and profle ral. UILDING DAMAGE CAUTION! caused by leaks. Never drll nto a tle trough. Drll through the corrugated metal roof usng a metal drll (Ø mm) takng note of the postons of the carrage bolt (see Tab. 5 and Tab. 6). Do not drll nto the wood beneath! Fg. Creatng a drllng template SD Feed wood drll (Ø 6 mm) through the hole and drll vertcally nto the subframe (tmber support). When fttng the carrage bolts, note the sequence of the ndvdual parts (Fg. ). Turn holdng bracket (Fg., Item ) untl t touches the carrage bolt (Fg., Item 5). Screw the pre-assembled carrage bolt nto the roof usng a sze 5 spanner untl dstance s reached. 5 When screwng n Carrage bolts, ensure that the dstance (Fg. ) s the same for all carrage bolts SD Fg. Item : Item : Item : Item : Item 5: Fttng the carrage bolts sequence Holdng bracket M nut Washer Sealng dsc M carrage bolt (006/0)

23 Fttng the roof connecton and profle rals Tghten the nuts (Fg., Item ) untl the sealng dsc (Fg., Item ) s lyng completely flush on the roof. The holdng bracket must be screwed fully onto the carrage bolt. Heght of peak, dm. A Dm. 5 mm 70 mm 0 mm 65 mm 5 mm 60 mm 50 mm 55 mm 55 mm 50 mm 60 mm 5 mm Fg. Item : Item : Item : Carrage bolt ftted to corrugated roof Holdng bracket Nut, M Sealng dsc SD Fastenng the profle ral Please also note Chapter 5.8. "Connectng profle rals". Fasten each profle ral (Fg. 5, Item ) wth two bolts (Fg. 5, Item ). The profle rals must not sag due to dfferences n level of the josts. Use a plumb lne to check. If necessary, pack the profle rals at the holdng bracket SD Fg. 5 Item : Item : Item : Fastenng the profle ral to the holdng bracket Screw Profle ral Holdng bracket (006/0)

24 Fttng the roof connecton and profle rals 5.5 Slate/shngle roofs A roofer must carry out the nstallaton on slates or shngles. 6 Here s an example of the nstallaton of the specal roof hooks and the watertght seal wth custom flashng (Fg. 6, Item and ) wth a shngle/slate roof. Durng nstallaton, please mantan the requred dstances (w, x and y) between the specal roof hooks as detaled n (Tab. 5 and Tab. 6, page 5). 5 Ft specal roof hook (Fg. 6, Item 5) and gasket (Fg. 6, Item ) to the slate/shngle roofs usng screw (Fg. 6, Item 6). To ensure that the nstallaton s watertght, flashng (Fg. 6, Item, ) must be nstalled on the buldng above and below the specal roof hooks. Fg. 6 Item : Item : Mountng on slate/shngle roof Flashng (on buldng) Flashng (on buldng) SD User note: The specal roof hooks must be postoned on the front of a multple roof (Fg. 6, Item ). Item : Item : Item 5: Item 6: Multple ttes Gasket (on buldng) Specal roof hooks Screw 5.6 Sheet roofs A roofer must carry out the nstallaton on a sheet steel roof. Carrage bolts (Fg. 7, Item 5) must be used nstead of roof hooks for fastenng the profle rals. Durng nstallaton, please observe the dstances (w, x and y) between Carrage bolts as detaled n (Tab. 5 and Tab. 6, page 5) To ensure the roof s water tght, sleeves for the carrage bolts (Fg. 7, Item 5) must be soldered onto the sheet steel roof. For the fttng sequence for carrage bolts and profle rals, and the relevant nstructons, see Chapter 5. "Corrugated sheet steel roofs". Fg. 7 Item : Item : Item : Mountng on sheet steel roof Holdng bracket M nut Washer SD Item : Sealng dsc Item 5: M carrage bolt Item 6: Sleeve (not suppled) (006/0)

25 Fttng the roof connecton and profle rals 5.7 Fttng addtonal rals (accessory) Addtonal measures are needed for nstallaton heghts of 0 to 00 m and/or wth standard snow loads of.0 to. kn/m. The example here shows an nstallaton on pan tle roofs. The addtonal rals can also be nstalled on other types of roof descrbed n ths manual. Fttng addtonal roof hooks Addtonal roof hooks must be ftted for attachng the snow load profles. Fasten addtonal roof hooks (Fg. 8, Item ) as centrally as possble between the upper and lower roof hooks already ftted. Fg SD Addtonal roof hooks for the snow load profle (here: for two collectors) There must be at least one free row of tles between the upper, mddle and lower roof hooks. Fastenng the snow load profle to the roof hooks Push sldng nut (Fg. 9, Item ) onto the roof hook n the drecton of the arrow. Place the snow load profle (Fg. 9, Item ) onto the roof hooks and tghten usng an M8 bolt (Fg. 9, Item ). Make sure snow load profles are level and flush (use strng lne). Installng the profle rals Fg. 9 Fastenng the snow load profle SD The profle rals must be joned before they are fastened. Please see Chapter 5.8. "Connectng profle rals". Place the profle rals (Fg. 0, Item ) nto the ndentatons (Fg. 0, Item ) on the snow load profles and loosely fasten usng bolt and sldng nut (Fg. 0, Item ) so that the profle rals can stll be algned. Carry out the same procedure for the other profle rals. To contnue wth the nstallaton, see Chapter 5.8. "Algnng the profle rals". Fg. 0 Fttng landscape profle rals SD (006/0) 5

26 Fttng the roof connecton and profle rals 5.8 Installng profle rals The profle rals must be joned together usng ral connectors. Each collector has been provded wth an upper and lower profle ral Connectng profle rals Push ral connector (Fg., Item ) as far as t wll go nto both profle rals (Fg., Item ). To lock, tghten both ftted M0 threaded studs (Fg., Item ) n the ral connector usng a sze 5 Allen key Installng profle rals Push sldng nut (Fg., Item ) onto the roof hook n the drecton of the arrow. Place the lower profle rals (Fg., Item ) onto the roof hooks and loosely fasten M8 bolt (Fg., Item ) so that the profle rals can stll be algned. Carry out the same procedure for the upper profle rals. Care should be taken not to over-tghten the stud n the ral connector to avod deformng the materal. Fg. Item : Item : Item : Fg. Item : Item : Item : Connectng profle rals Ral connector Profle ral M0 threaded stud Fastenng profle rals to the roof hook Sldng nut Profle ral olt SD SD (006/0)

27 Fttng the roof connecton and profle rals 5.8. Algnng the profle rals Algn the upper and lower profle rals to the sde flush wth each other and level them (Fg., use a sprt level).. Measure the dagonals or place a roof batten (Fg., Item ), for example, at the ends of the profle rals. The angle between roof batten and profle ral must be 90. Algn the profle rals over the slotted holes Tghten the screws. The profle rals must not sag due to dfferences n level of the josts. Fg. Algnng the profle rals SD Check usng a plumb lne Installaton of ant-slp protecton To prevent the collectors from slppng, you must fasten two ant-slp protectors to the lower profle rals for each collector. Push each ant-slp protector (Fg., Item ) nto the nnermost slotted holes (Fg., Item ) over the profle rals untl t clcks nto place (Fg., Item ). Fg. Item : Item : Item : Attachng ant-slp protecton Fxng holes for the ant-slp protecton Clckng the ant-slp protecton nto place Ant-slp protecton (006/0) 7

28 Collector nstallaton 6 Collector nstallaton Observe the followng safety and user nstructons when commencng the collector nstallaton. RISK TO LIFE through a fall or fallng parts. WARNING! Take approprate acton to prevent accdents when workng on roofs. Whlst workng on the roof, take all necessary precautons aganst a possble fall. Always wear your personal protectve clothng and safety equpment. After completng the nstallaton, always check the secure postonng of the nstalled set and that of the collectors. Fg. 5 Vew of roof mountng wth collectors SD Ensure that the correct equpment s used for workng on roofs. SYSTEM DAMAGE through nterrupton of work. CAUTION! Secure the collectors aganst fallng. Stablse the collector array. Use lftng equpment as used by roofng contractors or suffcent sucton handles for the nstallaton. Unsecured collectors may fall durng handlng and nstallaton (006/0)

29 Collector nstallaton 6. Preparng to nstall the collectors efore begnnng actual nstallaton on the roof, preassemble the end caps on the ground to make work on the roof easer. To secure the end caps (and later the corrugated ppe connectors and connectng ppes as well), attach brackets to the connectons. CAUTION! SYSTEM DAMAGE through leaks n the collector connectons. The corrugated ppe connectors, connectng ppes and collector connectons must not dsplay any sgns of damage or contamnaton. 6.. Ppework connectons The collector connectons have had specal grease appled n the factory to make nstallaton easer. Do not use any other grease. Fg. 6 Item : Item : Item : Item : Water connecton (rght) up to max. 5 collectors Corrugated ppe connector Flow lne Return lne End cap SD The collectors must be nstalled n such a way that the sensor bushs that receve the collector sensor (Fg. 7, Item ) are at the top. The water connecton ppes can be connected on the rght (Fg. 6) or left (Fg. 7). In ths manual, the connecton ppes are shown on the rght. The ppework n the collector s desgned as a double meander, whch enables you to carry out two dfferent water connectons: sngle-sded connecton of up to 5 collectors Up to 5 collectors can be connected one sde of a collector array (Fg. 6 and Fg. 7). Two-way connecton of up to 9 collectors If there are more than 5 collectors nstalled n one collector array, the water connecton must be two-way (Tchelmann prncple, Fg. 8). The two-way connecton can also be made f there are fewer than 6 collectors (Fg. 8). Fg SD Water connecton (left) up to max. 5 collectors If more than 9 collectors are requred then a further AGS pump staton s requred. Fg. 8 Two-way ppework connectons SD (006/0) 9

30 Collector nstallaton 6.. Fttng the end cap Not all the connectons are needed when connectng a collector array. Those that are not used must be closed. Remove rubber caps (transport protecton) from the relevant collector connectons. Push end cap wth the O-rngs (Fg. 9, Item ) onto the collector connecton. Push bracket (Fg. 9, Item ) over the end cap and collector connecton to secure the connecton. Fg. 9 Securng end cap wth bracket SD 6. Fastenng the collectors The collectors are fastened to the profle rals usng the sngle-sded collector clamps (Fg. 0, Item ) at the begnnng and end of a collector array, and double-sded clamps (Fg. 0, Item ) between each collector. In addton, the ant-slp protectors prevent the collector from slppng. The plastc parts on the collector clamps do not have any support functon. They are smply ntended to make nstallaton easer. Fg. 0 Fasteners for the collector SD Pushng on the sngle-sded collector clamp on the rght Push sngle-sded collector clamps (Fg., Item ) nto the profle rals at the rght-hand end of the collector array untl they clck nto place n the frst slotted hole on the profle rals. Do not ft the sngle-sded collector clamps to the left-hand sde of the collector array untl the last collector has been nstalled. Fg. Pushng on the sngle-sded collector clamp SD (006/0)

31 Collector nstallaton Puttng the frst collector n place Lay the collector on the profle rals n such a way that the sensor bush s at the top to receve the collector sensor. egn by layng the collectors on the rght-hand sde of the profle rals. CAUTION! RISK OF INJURY Install collectors wth at least one assstant. Place the frst collector onto the profle rals and allow t to slde nto the ant-slp protectors (Fg. ). The lower collector edge must le n the openng of the ant-slp protector (Fg., Item ). Carefully push collector (Fg., Item ) up aganst the sngle-sded collector clamp and algn horzontally. Screw n sngle-sded collector clamp (Fg., Item ) usng sze 5 Allen key. When the screw s tghtened, the plastc lugs at the pre-determned cut-off ponts break away and can be dscarded. Fg. Layng the frst collector on the profle rals SD The grp on the collector clamp (Fg., Item ) now grps the lower collector edge. Insertng a double-sded collector clamp Insert the double-sded collector clamp, nut frst, nto the openng made by the profle ral and plug connector so that the plastc spacer (Fg., Item ) surrounds the profle ral. Push double-sded collector clamp up aganst the collector frame. Do not tghten the screw untl the second collector has been pushed up aganst the double-sded collector clamp. Fg SD sngle-sded collector clamp screwed n place Fg. Fttng a double-sded collector clamp SD (006/0)

32 Collector nstallaton Fttng corrugated ppe connectors to the frst collector Remove the rubber caps from the connectons. Push corrugated ppe connectors (Fg. 5, Item ) onto the left-hand connectons on the frst collector. Push bracket (Fg. 5, Item ) over the corrugated ppe connector and collector connecton to secure the connecton. Fg SD Fttng corrugated ppe connectors to the frst collector Puttng the second collector n place Place the second collector onto the profle rals and allow t to slde nto the ant-slp protectors. CAUTION! SYSTEM DAMAGE through damaged corrugated ppe connectors. Do not use any tools, e.g. plers (Fg. 6, Item ). These could render the corrugated ppe connector unusable. Push the second collector on to the frst n such a way that the collector connectons are pushed nto the preassembled corrugated ppe connectors (Fg. 6, Item ) on the frst collector. Fg. 6 Pushng second collector towards the frst SD Place second bracket (Fg. 6, Item ) over the corrugated ppe connector and collector connecton. SYSTEM DAMAGE CAUTION! through unsecured corrugated ppe connectors and end caps. Secure each end cap wth one bracket and each corrugated ppe connector wth two brackets (Fg. 7, Item ) SD Fg. 7 Corrugated ppe connector secured wth brackets (006/0)

33 Collector nstallaton Tghten the screw on the double-sded collector clamp usng the sze 5 Allen key. When the screw s tghtened, the plastc lugs at the pre-determned cut-off ponts break away. The grp (Fg. 8, Item ) on the collector clamp now grps the lower collector edges. Repeat the procedure for all the other collectors. Fttng the sngle-sded collector clamp on the left Fg SD Double-sded collector clamp between two collectors Once all collectors are ftted, the two remanng snglesded collector clamps can be attached. Push sngle-sded collector clamp (Fg. 9, Item ) nto upper and lower profle rals. Push collector clamp up aganst the collector frame and screw n place usng sze 5 Allen key (Fg. 9, Item ). When the screw s tghtened, the plastc lugs at the pre-determned cut-off ponts break away and can be dscarded SD Fg. 9 sngle-sded collector clamp (left) (006/0)

34 Collector sensor connecton 7 Collector sensor connecton The collector sensor s suppled wth the solar controller. A Observe the nstallaton locaton for sngle or dual row collector systems (Fg. 50). SYSTEM DAMAGE CAUTION! through faulty sensor cable. Protect the cable from possble damage. Inserton pont The collector sensor must be ftted n the collector nearest to the flow connecton (Fg. 50, Item ). Inserton pont (Fg. 50, Item A) for sngle row collector systems. Inserton pont (Fg. 50, Item ) for dual row collector systems. Installng the collector sensor For perfect functonng of the solar heatng system, the collector sensor (Fg. 5, Item ) needs to be nserted nto the sensor gude tube as far as t wll go (approx. 50 mm). Usng the collector sensor or screwdrver, push through the sealng membrane on the sensor bush (Fg. 5, Item ). Screw clamped jont (Fg. 5, Item ) nto sensor bush. Insert collector sensor approx. 50 mm nto the sensor gude tube (as far as t wll go). Tghten clamped jont (Fg. 5, Item ), counterhold f necessary. If you accdentally push through the sensor bush (Fg. 5, Item ) on the wrong collector, t can be resealed usng the plug from the connecton kt. You must frst remove the nut n the sensor bush usng the cable gland (Fg. 5, Item ). Fg. 50 Item : Item : Fg. 5 Item : Item : Item : Collector sensor nstallaton locaton (schematc) Return lne Flow lne SD Pushng the collector sensor nto the collector Collector sensor Clamped jont Sensor bush 50 mm Kollektor SD (006/0)

35 Header connecton 8 Header connecton Informaton on layng the header ppes can be found n the complete staton nstallaton nstructons. The ppework connecton to the header ppes s made usng the long flexble connecton ppes. It s not permtted to connect a fxed header ppe drectly to the collector. Use standard ventlaton tles or lead flashng when layng the connecton ppes under the roof. Use a specalst company to route the connecton ppes under the roof SD Feed the sensor cable together wth the flow lne through the ventlaton tle under the roof. Fg. 5 Item : Item : Item : Routng connecton ppes under the roof Flow lne (shown wthout nsulaton) Return lne (shown wthout nsulaton) Sensor cable If you ntend to vent the solar heatng system wth an automatc ar-vent valve (accessory) at the hghest pont of the system, run the flow lne rsng to the arvent valve and the return lne rsng to the collector array. 8. De-arng through pressure fllng If ventng of the solar heatng system s carred out usng a pressure fllng pump, no vent s requred on the roof. Push connecton ppe (.000 mm, Fg. 5, Item ) onto the flow connecton on the collector array and fx n place usng bracket (Fg. 5, Item ). Feed connecton ppe together wth the sensor cable through the ventlaton tle (Fg. 5, Item ) and through the roof nsulaton. Connect header ppe to the compresson fttng (Fg. 5, Item ). Perform the same procedure wth the return connecton. Fg SD Fttng flow lne (wth no vent at hghest pont n the system) (006/0) 5

36 Header connecton 8. De-arng through ar vent (accessory) on roof If you ntend to vent the solar heatng system wth an automatc ar-vent valve (accessory) at the hghest pont of the system, run the flow lne rsng to the ar-vent valve (Fg. 5, Item ) and the return lne rsng to the collector array (Fg. 5). Avod frequent changes n drecton. User note: For each change of drecton downwards and each new rse, nstall an addtonal wth ar vent. If you cannot provde an automatc ar vent valve due to space restrctons, nstall a manual ar vent valve. Fg. 5 Item : Item : Vew wth vent valve for flow connecton Collector sensor Automatc ar vent valve on roof SD Functon of the weather protecton cap and weather protecton cap on the automatc ar vent valve The solar heatng system s vented through the opened weather protecton cap. When n operaton, the weather protecton cap (Fg. 55, Item ) must always be postoned over the weather protecton cap to prevent mosture enterng through the opened weather protecton cap nto the solar heatng system). Open the ar vent valve by unscrewng the weather protecton cap one full revoluton. Unversal ar vent set (Fg. 55): Item : Weather protecton cap Item : Automatc ar vent Item : all valve Item : Gasket Item 5: Vent pot Item 6: Double threaded fttng wth O-rng Item 7: Threaded fttng R¾ Item 8: Unon nut Item 9: Gasket Item 0: Large dameter washer Item : Clampng dsc Fg SD Unversal ar vent set (006/0)

37 Header connecton 8.. Fttng the ar vent valve under the roof Push connecton ppe (Fg. 56, Item ) onto the flow connecton on the collector array and fx n place usng bracket (Fg. 56, Item 5). Feed connecton ppe together wth the sensor cable through the ventlaton tle (Fg. 56, Item ) and through the roof nsulaton. 5 Perform the same procedure wth the return connecton. Remove nut and compresson fttng from connecton ppe. Frmly screw connecton ppe (Fg. 56, Item ) and double threaded fttng (Fg. 56, Item ) nto ar pot (O-rng gasket). Connect header ppe to double threaded fttng wth compresson fttng (Fg. 56, Item ). Fg. 56 Fttng the ar vent valve under the roof SD Item : Item : Item : Item : Item 5: Double threaded fttng wth O-rng Ar pot Connecton ppe Ventlaton tle racket (006/0) 7

38 Header connecton 8.. Fttng the ar vent valve on the roof To connect the connecton ppe to the ar vent (flow connecton), the elbow must be removed from the connecton ppe and the double threaded fttng ftted. Cut elbow (Fg. 57, Item ) from connecton ppe usng ppe cutter. Push unon nut over the connecton ppe. Makng the sealng face: Place clampng dsc (Fg. 57, Item ) behnd the frst rb and press together. The clampng dsc must le evenly on the collar of the nut. Put large dameter washer (Fg. 57, Item ) nto the unon nut n front of the cut surface of the connecton ppe. Frmly screw double threaded fttng (Fg. 57, Item ) nto unon nut, so that a flat sealng surface s created on the connecton ppe. Remove double threaded fttng and large dameter washer and check that a flat sealng surface has been created. Remove any burrs as requred. Insert gasket (Fg. 57, Item 5) and screw n double threaded fttng. Connecton to the collector: Frmly screw threaded fttng (Fg. 58, Item 5) and connecton ppe (Fg. 58, Item ) nto ar pot (O-rng gasket). Push ar pot (Fg. 58, Item ) and threaded fttng onto collector connecton and secure wth bracket (Fg. 58, Item 6). Feed connecton ppe together wth the sensor cable through the ventlaton tle (Fg. 58, Item ) and through the roof nsulaton. Connect header ppe to the compresson fttng (Fg. 58, Item ). Install return connecton as descrbed n Chapter 8. "De-arng through pressure fllng". Fg. 57 Item : Item : Item : Item : Item 5: 6 Fg. 58 Item : Item : Item : Item : Item 5: Item 6:.. Preparng the connecton ppe racket Clampng dsc Large dameter washer (for makng sealng face) Double threaded fttng Gasket 5 Fttng the ar vent Ar pot Connecton ppe Compresson fttng mm Ventlaton tle Threaded fttng R¾ racket SD SD (006/0)

39 Fttng the connecton set for two rows (accessory) 9 Fttng the connecton set for two rows (accessory) The connecton set (Fg. 59, Item 9) s avalable as an accessory, and connects two rows of collectors. Ft as many connecton parts as possble to the collectors on the ground. Ths makes nstallaton on the roof easer. Scope of supply (Fg. 59) Item : End cap Item : Connecton ppe Item : racket Item : Gasket Item 5: Large dameter washer Item 6: Clampng dsc Item 7: Olve Item 8: Nut 5 Fg Schematc dagram and scope of supply SD Fttng addtonal end caps Use the end caps to close up any collector connectons not n use (Fg. 59, Item, see Chapter 6.. "Fttng the end cap", page 0). Installng the connecton set Remove double threaded fttng and compresson fttng from connecton ppe. If you need to shorten the connecton ppe (Fg. 60, Item ), observe the nstallaton steps descrbed n "Makng the sealng face:", page 8. Insert gasket (Fg. 60, Item ) nto nut. Insert bracket (Fg. 60, Item ) nto nut, algn and screw tght. Push connecton ppe (Fg. 60, Item ) onto the collector connectons and fx n place usng brackets (Fg. 60, Item ) from the connecton kt. Extendng the connecton set Ft olve (Fg. 6, Item ) and nut to bracket (Fg. 6, Item ). Push copper ppe (cut to approprate length) ( mm, Fg. 6, Item ) nto compresson fttngs. Tghten the fttngs. Fg. 60 Fg. 6 Connecton set between two collector rows Lengthenng the connecton ppe SD SD (006/0) 9

40 Fnal actvtes 0 Fnal actvtes 0. Checkng the nstallaton SYSTEM DAMAGE CAUTION! through corroson f water remans n the solar heatng system for an extended perod after t has been flushed or after a pressure test. Start up the solar heatng system mmedately after flushng/pressure test wth solar flud (for nstructons on flushng/pressure test see pump staton nstructons). Otherwse, carry out flushng/pressure test later. Carry out the fnal nsulatng work only once the approprate checks have been performed. Checks Corrugated ppe connector, end caps and connecton ppes secured wth clps? Profle rals connected to roof hook and sldng nut? Ant-slp protecton nstalled and clcked nto place n profle rals? Sensor nserted as far as t wll go and secured wth clamped jont? Pressure test carred out and all connectons leak-proof (see pump staton nstructons)? If you are ventng the solar heatng system wth an automatc ar vent valve (accessory), you must close the ball valve after the ventng procedure (see pump staton nstallaton nstructons) (006/0)

41 Fnal actvtes 0. Insulatng the connecton and header ppes Cut enclosed nsulaton (70 mm long) nto 88 mm lengths and place around the corrugated ppe connectors between the collectors. Insulaton of the manfolds n nternal or external nstallatons For the nsulaton of external ppework, use only UV and hgh temperature resstant nsulatng materals, rated to 50 C. For the nsulaton of nternal ppework, use only hgh temperature resstant nsulatng materals, rated to 50 C. Make the nsulaton brd-proof (006/0)

42 Quck reference gude for pan tle roof and pressure fllng Quck reference gude for pan tle roof and pressure fllng These nstructons are only ntended as an overvew of the work to be carred out. You MUST follow the detaled descrptons for the work on the pages mentoned, and all safety and user nstructons. Fttng roof hooks and profle rals. Turn lower part of roof hook and hook complete roof hook nto a tle trough, observng the dstances gven n (Chapter 5. "Settng clearances", page 5). p. 6. Lft lower part of roof hook and tghten fttng. p. 6. Connect profle rals together usng plug connectors. p. 6. Fasten profle rals to roof hook p Algn profle rals horzontally and laterally flush wth p. 7 each other. 6. Install ant-slp protectors nto the two nner slotted holes on the lower profle rals. p. 7 Preparng to nstall the collectors 7. Push end caps onto those connectons that are not requred and secure usng brackets. p. 0 Fg. 6, 6 Roof mountng 5 7 9, 8, SD 8 Fastenng the collectors 8. Push sngle-sded collector clamp (rght) nto profle rals. p Place frst collector (rght) onto profle rals and push onto collector clamp. p. 0. Screw up collector clamp on the rght. p.. Place double-sded collector clamp nto profle ral and p. push onto frst collector.. Push corrugated ppe connectors onto the connectons p. on the frst collector and secure wth brackets.. Push second collector towards the frst and ft second p. bracket.. Tghten screws on the double-sded collector clamp. p. 5. Repeat the procedure for all other collectors. p. 6. Ft sngle-sded collector clamps on the left p. 7 7 Fg. 6 Water connectons SD Header connecton 7. Insert collector sensor as far as t wll go nto the collector wth the flow lne to be connected, and screw tght. p. 8. Push connecton ppes onto flow and return connectons and secure wth brackets. p Feed flow connecton ppe together wth sensor cable p. 5 through ventlaton tle or lead flashng and roof nsulaton. 0. Perform nstallaton checks. p. 0. Insulate header ppes and corrugated ppe connectors p. wth UV and hgh temperature resstant materal ,9 8 Fg. 6 Fttng the collector sensor and header ppes SD (006/0)

43 (006/0)

44 CONTACT INFORMATION WORCESTER, OSCH GROUP: TECHNICAL: SERVICE: SPARES: LITERATURE: TRAINING: SALES: WESITE: EXCELLENCE COMES AS STANDARD Worcester, osch Group Cotswold Way, Warndon, Worcester WR 9SW. Tel Fax Worcester, osch Group s a brand name of T Thermotechnology UK Ltd a (006/0)