Solar Thermal Flat Plate Collectors FKT-1 Rack System for Flat Roof and Wall Installation

Transcription

1 SD Solar Thermal Flat Plate Collectors FKT- Rack System for Flat Roof and Wall Installaton US/CA Installaton Manual for Contractors

2 2 Contents US General Specfcatons Safety Intended use Gudelne of Notces Please observe these safety nstructons efore nstallaton General notes Component descrpton Other equpment needed for the nstallaton Transport and storage Techncal documentaton Determnng the nclnaton for the collectors Determnng space requrements Installng racks on flat roofs and walls Dstances between collector trangles Clearances between the collector trangles when usng ballast trays (accessory) Stablzng the flat roof rack Wall mountng racks - nstallaton Installng the profle rals Collector nstallaton Preparng to nstall the collectors FKT Water connectons Installng the plug Attachng the collectors Collector sensor connecton FKT Hydraulc connecton FKT Ppe bracket Hydraulc collector connecton wthout an ar vent Hydraulc collector connecton wth an ar vent (accessory) Connectng two arrays Fnal actvtes Checkng the nstallaton Insulatng the ppes Quck reference gude for mountng and pressure fllng Spare parts Certfcaton osch Solar Collectors - Specfcatons subject to change wthout notce.

3 US General 3 General Ths chapter detals whch techncal rules and regulatons apply to ths nstallaton. Lghtnng protecton Observe all standards and gudelnes applcable to the nstallaton and operaton of ths system n your country. Installatons must be made n accordance wth all codes and regulatons applcable to the nstallaton ste. If the solar equpment protrudes above the roof rdge or the buldng heght (nstallaton heght) exceeds 66 ft (20 m), t s recommended to have lghtnng arrestors nstalled on the tallest equpment ncludng the solar collectors. osch Solar Collectors - Specfcatons subject to change wthout notce.

4 4 Specfcatons US 2 Specfcatons FKT- Certfcates 0036 DIN Length Wdth Depth Clearance between collectors Absorber contents, portrat verson Absorber contents, landscape verson V f V f 8-/2 n (2,070 mm) 45-/8 n (,45 mm) 3-/2 n (90 mm) n (25 mm) 0.38 gal (.43 l ) 0.46 gal (.76 l) Gross absorber surface area A G 25.5 ft² (2.37 m²) Net absorber surface area Net weght, portrat verson Net weght, landscape verson Permssble operatng pressure of the collector m m p max 24.0 ft² (2.23 m²) 97 lbs (44 kg) 99 lbs (45 kg) 45 ps (0 bar) Tab. Specfcatons osch Solar Collectors - Specfcatons subject to change wthout notce.

5 US Safety 5 3 Safety Ths chapter explans the meanng of the notes you wll fnd n ths manual and provdes general safety nstructons for safe and trouble-free operaton. You wll fnd the nstallaton-specfc safety and user notes next to the approprate nstallaton steps. Carefully read the safety nstructons before commencng the nstallaton. Severe njury and even death, as well as property damage and envronmental damage, may follow f you gnore safety nstructons. About ths manual Ths nstallaton manual contans mportant nformaton for the safe and ntended nstallaton of sloped roof mountng systems as well as plumbng connectons. The llustratons n ths manual show portrat collectors. Instructons for landscape collectors are the same as for portrat unless stated otherwse. These techncal documents should be retaned n a safe place. The actvtes descrbed n the nstallaton manual assume expertse based on completed vocatonal tranng n plumbng. Only carry out these nstallaton steps f you possess these sklls. Hand these nstallaton nstructons to the buldng owner. Explan to the customer the functon and operaton of the related devces. 3. Intended use Install components only on roofs wth suffcent strength and capacty. Take the addtonal roof load per flat roof support, ncludng solar collector, nto consderaton. If necessary, ask a structural engneer for assstance. Only nstall ths system on flat roofs or roofs wth a shallow ptch ( 25, less than a 2/6 ptch). If there s a rsk that larger quanttes of snow accumulate behnd the collectors (towards the roof rdge), prevent ths by fttng a sutable protectve grlle. Applcaton condtons for flat roof supports The mountng system set s sutable for a max. standard snow load of 42 lbs/sqft (2.0 kn/m²), a buldng heght of max. 66 ft (20 m), and a max. wnd speed of 8mph (29 km/h). Usng approprate accessores, the nstallaton set can be used for a max. standard snow load of 79 lbs.sqft (3.8 kn/m²), a max. buldng heght of 328 ft (00 m), and a max. wnd speed of 94 mph (5 km/h). Do not attach any other devces, e.g. antennas, to collector racks. Wall mountng Landscape collectors can be nstalled on vertcal walls usng the same mountng racks. Wall nstallaton of portrat collectors s not permtted. Ensure that the wall s structurally sound and capable of bearng the load. It s recommended to consult a structural engneer. Wall mounted collectors are sutable for wnd speeds up to of 8mph (29 km/h), a maxmum nstallaton heght of 66 ft (20 m) and a maxmum snow load of 42 lbs/sqft (2.0 kn/m²). Ensure that fallng ran water, snow, and ce do not cause a nusance or hazard below. osch Solar Collectors - Specfcatons subject to change wthout notce.

6 6 Safety US 3.2 Gudelne of Notces Two levels of danger are dentfed by the followng symbols: WARNING! CAUTION! DANGER Denotes a possble severely dangerous stuaton where, wthout proper cauton, bodly njury or loss of lfe may result. DANGER OF INJURY/SYSTEM DAMAGE Denotes a possble dangerous stuaton that can lead to mld to moderate bodly njury or property damage. Addtonal symbol for desgnatng user notes: 3.3 Please observe these safety nstructons WARNING! RISK OF LIFE from a fall or fallng parts. Take approprate safety measures to prevent accdents when workng on roofs. Whle workng on the roof, take all necessary precautons aganst a possble fall. Always wear protectve clothng and safety equpment. After completng an nstallaton always verfy that all components are nstalled accordng to the nstructons and are securely attached. Applcaton comment for optmum use of equpment and adjustment as well as useful nformaton. CAUTION! RISK OF INJURY Personal njury and system faults can result from altered constructon. Never modfy structural elements. Never drll addtonal holes. Never attach non-system related components (e.g. antennas) RISK OF INJURY CAUTION! Solar system components can become very hot even when a system s decommssoned. Always wear protectve clothng and safety equpment. Cover the collector (collector covers are avalable as an accessory) durng nstallaton to prevent aganst hgh temperatures resultng from solar radaton. CAUTION! Observe maxmum load and dstance from edges before nstallng the substructure supports to the roof. If necessary, consult a structural engneer to determne f the structure s sutable for nstallng solar collectors ncludng expected snow and wnd loads. CAUTION! Solar ppes and solar flud can cause severe burns. Extreme cauton must be taken when a system s n stagnaton. osch Solar Collectors - Specfcatons subject to change wthout notce.

7 US Safety 7 SYSTEM DAMAGE CAUTION! Avod scratchng or sudden shocks to the glass of a solar panel. Never step or walk on collectors. CAUTION! Never braze or solder n close proxmty of a solar panel. CAUTION! Install a heat exchanger to separate pool water or potable water from the collector system. CAUTION! The use of heat transfer flud Tyfocor L, Tyfocor LS and Tyfocor L "G" s strongly recommended. For more detaled nformaton about sutable solar heat transfer fluds refer to the nstallaton nstructon of the KS pump statons. CAUTION! Ths system s not sutable for dran back nstallatons. Only closed loop pressurzed systems are permtted. osch Solar Collectors - Specfcatons subject to change wthout notce.

8 8 efore nstallaton US 4 efore nstallaton 4. General notes It s recommended to consult a roofng company, as they are experenced n workng on roofs and are equpped wth the necessary personal safety equpment. Roofers also are experenced wth attachng equpment to the roof and makng proper penetratons. Make yourself famlar wth the on-ste condtons and local regulatons before commencng the nstallaton. Check the delvery for completeness and perfect condton. the roof structure for suffcent strength and possble damage (e.g. leaks). the buldng heght and determne the type of fxngs requred for the flat roof supports (see secton 5.3 "Stablzng the flat roof rack", page 23). the optmal arrangement of the solar collectors. Take nto consderaton the orentaton of the buldng toward the sun, any tall trees, adjacent buldngs, buldng features, etc. Fg. Flat roof mounted collectors SD where the penetraton(s) nto the buldng envelope are located and arrange the collector array accordngly. f the collector array can be arranged symmetrcally wth the buldng and buldng features. the stablty of the support surface. Remove gravel or smlar materal. Only use OEM components and replace any defectve or damaged parts mmedately. It s recommended to consult a professonal roofer f roof repars are necessary. Have the work completed before nstallng the solar equpment. Fg. 2 Wall mounted collectors SD osch Solar Collectors - Specfcatons subject to change wthout notce.

9 US efore nstallaton Component descrpton 4.2. Collector racks The collectors are attached to horzontal rals that are mounted on trangular racks. The nclnaton of the racks s adjustable to match the desred angle of nsolaton Fg. 3 Rack set for 2 collectors - basc rack, extenson rack SD asc rack for each collector array ncludng the frst collector (Fg. 3): Extenson rack for each addtonal collector (Fg. 3): Horzontal ral 2 Horzontal ral 2 3 M8 screw Ral connector 2 5 Sngle-sded collector clamp 4 3 M8 screw M8 nut 4 4 Double-sded collector clamp 2 7 ottom ral 2 6 M8 nut 2 8 Collector hanger 2 7 ottom ral 8 Collector hanger 2 For hgher snow and wnd loads, auxlary braces and addtonal horzontal rals are needed. osch Solar Collectors - Specfcatons subject to change wthout notce.

10 0 efore nstallaton US Hydraulc connecton For the hydraulc connectons the connecton kt s needed. The parts used to connect two collectors are ncluded n two of the corner protectors of each collector's packagng Fg Connecton kt and connecton set SD Connecton kt, per collector array (Fg. 4) 2 Clp (ncl. spare) 2 7 racket for routng the supply ppe 2 3 Elbow 2 8 Compresson fttng for collector sensor 4 Compresson rng 2 9 Sze 5 Allen wrench 5 Compresson nut 2 0 Dummy plug 2 6 Insulaton for flex-ppe connector 28 n (70 mm) Connecton set between the collectors, for each collector (n two carryng angles, Fg. 5) Flexble collector connector 2 2 Clp 4 2 Fg. 5 Two of the collector's protectve corners SD osch Solar Collectors - Specfcatons subject to change wthout notce.

11 US efore nstallaton 4.3 Other equpment needed for the nstallaton Level Rope Hgh head fllng pump Personal protectve equpment for on the roof Ppe nsulaton wth UV protectve coatng Scaffoldng Ladder ucket truck or scssor lft Equpment for attachng the racks to the roof or substructure 4.4 Transport and storage All components are protected by transport packagng. Dspose of the transport packagng n an envronmentally frendly manner. Transport protecton for collector connectons The collector connectons are protected aganst damage by rubber caps. SYSTEM DAMAGE CAUTION! Storage from damaged gaskets. Do not remove the rubber caps (Fg. 6, []) untl mmedately pror to nstallaton. The collectors must be stored n dry condtons. Do not store collectors outsde wthout protecton from the weather. The packagng s not desgned to be all weather proof. Fg SD Rubber caps on collector connectons Protect the collectors usng a tarp durng transport n wet weather n an open truck. osch Solar Collectors - Specfcatons subject to change wthout notce.

12 2 efore nstallaton US 4.5 Techncal documentaton The solar heatng system conssts of varous components (Fg. 7). Installaton, operaton and mantenance documentaton s provded for each component. If needed accessores are accompaned by a separate document. Collector: nstructons for flat roof mountng are enclosed wth the connecton kt 2 Pump staton: nstructons enclosed wth the thermal staton 3 DHW storage tank: nstructons enclosed wth the DHW storage tank 3 2 Fg SD Solar thermal system components and techncal documentaton 4.6 Determnng the nclnaton for the collectors The collectors' nclnaton depends on the applcaton. It can be adjusted usng the telescopc rals (Fg. 8) Determnng the applcaton Dependng on the applcaton dfferent collector nclnatons are chosen. See Tab. 2 for recommendatons. Applcatons Inclnaton DHW Domestc hot water + central heatng Domestc hot water + swmmng pool Fg. 8 Inclnaton of the collector on a flat roof SD Domestc hot water + central heatng + swmmng pool Tab. 2 Area of applcaton, nclnaton range Above Tab. 2 s vald for areas at Lattude. For areas further north steeper angles, and further south shallower angles are recommended. osch Solar Collectors - Specfcatons subject to change wthout notce.

13 US efore nstallaton Sloped roofs On roofs that slghtly sloped n a southerly drecton, the ptch angle s deducted from the nclnaton. On roofs slghtly sloped n a northerly drecton, the ptch angle s added to the nclnaton (Fg. 9). WARNING! CAUTION! RISK TO LIFE If there s a rsk that larger quanttes of snow accumulate underneath the collectors nstall a sutable protectve grlle on ste. SYSTEM DAMAGE from strong wnds. On sloped roofs racks must be permanently secured to the roof. allast trays are only permtted as addtonal means. It s recommended to consult a professonal roofer when nstallng collector racks on a sloped roof SD Fg. 9 Inclnaton of the collector on a flat roof Angle of ncdence (absolute angle to the horzontal plane) 2 Collector nclnaton 3 Roof ptch Walls The collector racks can also be used for wallmountng. RISK TO LIFE WARNING! from fallng collectors, due to mproper attachement. The collector nclnaton (Fg. 0, []) to the horzontal must be between 45 and 60 (Fg. 0, [2] of the collectors to the wall must be between 30 and 45 ) SD Fg. 0 Permtted nclnaton of the collector on a wall Inclnaton to the horzontal plane 2 Inclnaton to the wall osch Solar Collectors - Specfcatons subject to change wthout notce.

14 4 efore nstallaton US Telescopc rals The nclnaton s set usng the telescopc rals. Select holes on the upper and lower telescopc rals as shown n Fg. 2 and Fg. 3. Insert telescopc rals nto each other and fasten wth an M8 20 screw (Fg. ).. For portrat nstallaton of a collector wth an nclnaton of 30 to 60, use the uppermost hole on the lower telescopc ral (Fg. 2, []). For an nclnaton of 25, shorten the top of the lower ral by 5-/2 n (40 mm) and use the lower hole (Fg. 2, [2]). Fg. Connectng telescopc rals SD 2 Fg. 2 Adjust nclnaton for portrat collectors osch Solar Collectors - Specfcatons subject to change wthout notce.

15 US efore nstallaton 5 For nstallaton of landscape collectors wth an nclnaton of 35 to 60, use the uppermost hole on the lower telescopc ral (Fg. 3, [3]). For an nclnaton of 25 and 30, shorten the top of the lower ral by 5-/2 n (40 mm) and use the lower hole (Fg. 3, [2]). RISK TO LIFE WARNING! from fallng collectors, due to mproper attachement. 3 For wall-mounted nstallaton, use only the postons for 30, 35, 40 and 45 (Fg. 3, []) Determnng space requrements 4.7. Clearance between collector arrays The mnmum spacng between the collector arrays s determned by the nclnaton of the collector. Fg. 3 Adjustng the nclnaton of landscape collectors When usng mult-row arrays, note that the clearance X (Fg. 4) between the arrays must be large enough to avod shadows fallng over adjacent collectors. Mantan the clearance stated n the tables or calculate the requre clearance (Techncal Gude). X Inclnaton collector Portrat Collectors Clearance X Landscape Collectors Fg. 4 Shadow clearance X SD n (4.74 m) 03-3/6 n (2.63 m) n (5.8 m) 2-7/8 n (2.87 m) /8 n (5.58 m) 2 /2 n (3.09 m) n (5.94 m) 29-5/8 n (3.29 m) n (6.26 m) 36-3/6 n (3.46 m) /8 n (6.52 m) 4-5/8 n (3.6 m) n (6.74 m) 46-7/6 n (3.73 m) n (6.90 m) 50-7/0 n (3.82 m) Tab. 3 Requred clearance between two collector arrays to avod shadng osch Solar Collectors - Specfcatons subject to change wthout notce.

16 6 efore nstallaton US The above angles are vald for 50 Lattude. Greater dstances are needed further North, and lesser dstances further South Estmatng your space requrements SYSTEM DAMAGE CAUTION! from wnd and pressure peaks around the roof edges. efore commencng the nstallaton, ensure that at least the dstances shown n Fg. 5 are clear between the racks and the edge of the roof. Fg. 5 Dstance from the edge of the roof Allow suffcent space for the dfferent forms of nstallaton (Portrat, Landscape). These dmensons (Tab. 4 and Tab. 5) relate to the roof surface area whch must be avalable. The quoted dmensons are smply the wdth of the collector array. In addton, allow at least -/2 ft (0.5 m) on ether sde of the collector array for ppework. A Fg SD Space requrements collector array portrat verson osch Solar Collectors - Specfcatons subject to change wthout notce.

17 US efore nstallaton 7 Space requrements for portrat collectors: Space requrements for landscape collectors: Number Dmenson A ton of collectors son A ton Inclna- Number Dmen- Inclna- Dmenson of collectors Dmenson 2 7' 8-/4" 3' 8-/2" 25 6' /2" (.84 m) 2 (2.34 m) (4.8 m) 25 3' 5-3/4" (.06 m) 3 ' 6-/4" 20' 7-/4" 30 5' 9" (.75 m) 3 (3.5 m) (6.28 m) 30 3' 4-/4" (.02 m) 4 5' 4-/4" 27' 6" 35 5' 6-/4" (.68 m) 4 (4.68 m) (8.38 m) 35 3' -3/4" (0.96 m) 5 9' 2-/4" 34' 4-/2" 40 5' 2-/4" (.58 m) 5 (5.85 m) (0.48 m) 40 3' (0.9 m) 6 23' /2" 4' 0-/4" 4' 3-/4" 45 6 (7.02 m) (.48 m) (2.58 m) 45 2' 9-/2" (0.85 m) 7 26' 0-/2" 4' 0-/4" 48' 2" 50 7 (8.9 m) (.48 m) (4.68 m) 50 2' 9-/2" (0.85 m) 8 30' 8-/2" 4' 0-/4" 55' 3/4" 55 8 (9.36 m) (.48 m) (6.78 m) 55 2' 9-/2" (0.85 m) 9 34' 6-/2" 4' 0-/4" 6 -/4" 60 9 (0.53 m) (.48 m) (8.88 m) 60 2' 9-/2" (0.85 m) 0 38' 4-3/4" 68' 0" 0 (.70 m) (20.98 m) Tab. 4 Space requrement for portrat collectors Tab. 5 Space requrements for landscape collectors osch Solar Collectors - Specfcatons subject to change wthout notce.

18 8 Installng racks on flat roofs and walls US 5 Installng racks on flat roofs and walls RISK TO LIFE WARNING! Use approprate personal protectve equpment whenever on a ladder, lft, or the roof. RISK OF INJURY WARNING! from a fall or fallng parts. Take approprate measures to prevent accdents when workng on roofs. Always wear your personal protectve clothng and safety equpment. Observe all natonal and local safety regulatons, as well as the safety nstructons n ths manual when workng on roofs. Fg. 7 Flat roof rack for 2 portrat collectors SD Ensure suffcent stablty of the nstallaton surface, and remove any gravel and smlar materal. Take measures to protect the roof membrane when workng on the roof. It s recommended to consult a professonal roofer to ensure the membrane s not damaged. Ths nstallaton method also apples to landscape collectors. The followng descrbes the nstallaton of portrat collectors. The landscape verson s nstalled n the same way. Notes dentfy any varatons. Fg. 8 Landscape flat roof racks for 2 collectors SD osch Solar Collectors - Specfcatons subject to change wthout notce.

19 US Installng racks on flat roofs and walls 9 5. Dstances between collector trangles The dstances between the collector trangles (center to center) depend on: the collector verson (Portrat, Landscape) and the maxmum desred snow and wnd loads. You must strctly observe the clearances as ndcated n Fg. 9 so that the profle rals can stll be nstalled at a later stage. 5.. asc verson Two collector trangles are requred for the frst collector. For every addtonal portrat collector, another collector trangle s requred (Fg. 9). For every addtonal landscape collector, two collector trangles are requred (Fg. 2). The basc verson can be used for the followng loads: Installaton heght max. 66 ft (20 m) max. 42 lbs/sqft (2.0 kn/m²) snow load max. 8 mph (29 km/h) wnd speeds Fg. 9 asc verson for 2 portrat collectors last collector x collectors frst collector Fg. 20 asc verson for 3 0 portrat landscape collectors Fg. 2 asc verson for 2 landscape collectors osch Solar Collectors - Specfcatons subject to change wthout notce.

20 20 Installng racks on flat roofs and walls US 5..2 Addtonal supports for tall buldngs and hgh wnd and snow loads (accessory) For greater loads, addtonal supports (and addtonal profle rals, page 28) are requred for portrat collectors (Fg. 22) and acheves the followng loads: uldng heght max. 328 ft (00 m) (nstallaton heght) max. 79 lbs/sqft (3.8 kn/m²) snow load max. wnd speed of 94 mph (5 km/h) Landscape collectors acheve the same loads usng the basc verson (Fg. 2), provded that a thrd profle ral s nstalled, (page 28). 38 5/8 n (980 mm) (90 mm) 38 5/8 n (980 mm) (90 mm) 38 5/8 n (980 mm) Fg. 22 Auxlary supports for 3 portrat collectors osch Solar Collectors - Specfcatons subject to change wthout notce.

21 US Installng racks on flat roofs and walls Clearances between the collector trangles when usng ballast trays (accessory) The dstances between the collector trangles (center to center, n nches) depend on: the collector verson (Portrat, Landscape) the maxmum snow and wnd loads f ballast trays are beng used. For portrat collectors, an addtonal trangle must be nstalled for the 4th, 7th and 0th collector n order for the ballast trays to ft. (Fg. 23, []). See Tab. 7 for mnmum ballast tray weghts asc verson The basc verson can be used for the followng loads: buldng heght max. 66 ft (20 m) (nstallaton heght) max. 42 lbs/sqft (2.0 kn/m²) snow load max. wnd speed of 8 mph (29 km/h) Number of collectors Tab efore consderng the use of ballast trays verfy that the buldng substructure s capable of supportng the load. Due to the sze of the ballast trays, the collector trangles must be spaced exactly 38-5/8" (980 mm) apart. Four trays are ftted underneath each collector. Ensure exact placement of the trangles so that the profle rals can be nstalled. Dmenson A 5 n (38 mm) 5 n (38 mm) 22 /2 n (57 mm) 22 /2 n (57 mm) 22 /2 n (57 mm) 22 /2 n (57 mm) 22 /2 n (57 mm) Dmenson Dmenson C n (38 mm) 5 n (38 mm) 22 /2 n (57 mm) 22 /2 n (57 mm) Dstances between auxlary trangles n (38 mm) osch Solar Collectors - Specfcatons subject to change wthout notce.

22 22 Installng racks on flat roofs and walls US Fg. 23 asc verson for up to 0 portrat collectors Landscape collectors must use only the auxlary trangle (accessory). For landscape collectors, 3 collector braces must be ftted for each collector (Fg. 24) Verson for hgher loads (accessory, Fg. 25) For hgher loads, ropes (page 24) and addtonal horzontal profle rals (page 28) are requred. Ths verson can be used for the followng loads: uldng heght max. 328 ft (00 m) (nstallaton heght) max. 79 lbs/sqft (3.8 kn/m²) snow load max. wnd speed of 94 mph (5 km/h) Fg. 24 asc verson for 2 landscape collectors For dstances between the landscape collector trangles, refer to Fg. 24. Fg SD Verson for maxmum loads, 3 portrat collectors osch Solar Collectors - Specfcatons subject to change wthout notce.

23 US Installng racks on flat roofs and walls Stablzng the flat roof rack The followng detals refer to a sngle collector. Flat roof racks must be secured n one or more of the followng ways to prevent movng or tppng of the structure: Secure the racks to the buldng's substructure usng suffcent anchor bolts (on-ste). Use ballast trays (accessory) and load up wth concrete blocks or smlar materal. Te down the racks usng guy lnes as necessary. For all methods, please consder the structural ntegrty of the roof. Usng concrete blocks or smlar materal n the ballast trays, a maxmum load of 705 lbs (320 kg) s possble per collector (Tab. 7). For the followng table, please also consder the clearances and number of addtonal collector trangles (Secton 5. "Dstances between collector trangles"). Installaton heght 0-26 ft (0 to 8 m) ft (8 to 20 m) ft (20 to 00 m ) Tab. 7 Wnd speed 64 mph (02 km/h) 8 mph (29 km/h) 94 mph (5 km/h) ase anchor Number and type of screws 2, 3 Mnmum measures to stablze one collector Wth addtonal profle ral only 2 Per collector trangle Stablzng a collector Weghtng Weght (e.g. concrete blocks) Securng aganst tppng Weght (e.g. concrete blocks) Ropes Securng aganst movng Maxmum guy wre tenson 2 M8/ lbs (270 kg) 397 lbs (80 kg) 360 lbs-ft (.6 kn) 2 M8/ lbs (450 kg) 705 lbs (320 kg) 562 lbs-ft (2.5 kn) 3 M8/ lbs (450 kg) 742 lbs-ft (3.3 kn) 3 Or equvalent osch Solar Collectors - Specfcatons subject to change wthout notce.

24 24 Installng racks on flat roofs and walls US 5.3. Securng flat roof supports on ste Fasten the flat roof supports wth anchor bolts. As an example, see mountng on I-beams (Fg. 26, [3]). Desgn the substructure so that the collectors and rack system wthstand the snow loads and wnd forces they are desgned for. Addtonal measures may be requred on ste Addtonal measures may be requred the structure and prevent damage to the roof. SYSTEM DAMAGE 2 3 CAUTION! from modfcatons to the flat roof racks. For example, never drll addtonal holes n rals and profles. Fg. 26 Flat roof support on grders, dmensons n mm (value n brackets = landscape verson) Transfer the lower profle hole clearances (Fg. 26, [2]) onto the I-beams, and drll correspondng holes. Insert screws (see Tab. 7 and Fg. 26, []) through the profles and I-beams and tghten wth nuts and washers Securng flat roof supports wth ballasts 2 3 Install collector racks (see Secton 5. "Dstances between collector trangles"). Place ballast trays (Fg. 27, [2]) nto lower profles (Fg. 27, []) and nto each other (Fg. 27, [3]). Place concrete blocks or smlar nto loadng trays (for requred weght, see Tab. 7). locks are stacked to acheve the requred weght Provdng extra support for the flat roof racks usng guy wre If needed, nstall guy wres accordng to the followng descrpton: Fg loadng trays per collector SD Select the type of guy wres dependng on the expected loads (see Tab. 7). Attach each collector on ste to the bolt on the lower profle and a sutable pont on the roof, usng at least 2 guy wres (Fg. 28, []). Fg. 28 Flat roof support wth guy wres SD osch Solar Collectors - Specfcatons subject to change wthout notce.

25 US Installng racks on flat roofs and walls Wall mountng racks - nstallaton The landscape collector racks are used for wall nstallaton. Do not wall mount collectors where fallng ran water, snow, and ce can created nusance or hazard below. RISK TO LIFE WARNING! from fallng collectors, due to ncorrect nstallaton. Only landscape collectors are sutable for wall nstallaton. Collectors may only be nstalled at a maxmum heght of66 ft (20 m), a maxmum expected wnd velocty of 8 mph (29 km/h) and snow load of 42 lbs/sqft (2.0 kn/m²). Each collector brace must be attached usng holes provded, usng 3 sutable screws or bolts dependng on the wall structure. Install only on a structurally sound outsde wall. Fg. 29 Wall mountng support SD efore nstallng the wall mountng racks, check the load-bearng capablty of the wall and ts base. If necessary, ask a structural engneer for assstance. Never modfy the rackng system. Never place or mount objects n the space underneath the collector racks, or mount non-related equpment to the racks. Do not close off the sdes and bottom of the racks. osch Solar Collectors - Specfcatons subject to change wthout notce.

26 26 Installng racks on flat roofs and walls US Use 3 screws to fasten each collector brace to the wall (see Tab. 8, Fg. 30, []). Fg. 30 Attachng the collector rack to the wall (for 2 collectors) osch Solar Collectors - Specfcatons subject to change wthout notce.

27 US Installng racks on flat roofs and walls Installng the profle rals The profle rals must be joned together usng the provded connectors. Each collector s attached usng an upper and a lower profle ral Connectng profle rals Push connector (Fg. 3, []) as far as t wll go nto both profle rals (Fg. 3, [2]). To lock, tghten both nstalled M0 threaded studs (Fg. 3, [3]) n the connector usng a sze 5 Allen wrench SD Installng profle rals Fg. 3 Connectng profle rals 2 3 Postonng the profle rals depends on whether portrat or landscape collectors are beng nstalled and on the clearances between the collector trangles. If the racks are bolted to the substructure, begn fastenng the profle rals as follows: portrat: landscape: Tab. 8 asc verson Algn wth mddle hole on connector (Fg. 32, []) Algn wth thrd slotted hole from rght (Fg. 32, [2]) ase anchorng Auxlary brace Algn wth second slotted hole from rght (Fg. 32, [3]) Algnng the lower and upper profle rals when usng base anchorng -- Fg SD Algnng the profle rals for on-ste base anchorng 2 3 If usng ballast trays, begn fastenng the profle rals as follows: portrat: landscape: Tab. 9 Loadng trays 2 collectors 3 to 0 collectors Algn wth mddle hole on connector (Fg. 33, []) Algn wth second slotted hole from rght (Fg. 33, [3]) Algn wth sxth slotted hole from rght (Fg. 33, [2]) Algn wth second slotted hole from rght (Fg. 33, [3]) Algnng the lower and upper profle rals when usng ballast trays Fg. 33 Algnng the profle rals for loadng trays SD osch Solar Collectors - Specfcatons subject to change wthout notce.

28 28 Installng racks on flat roofs and walls US Lghtly tghten the pre-assembled profle rals (Fg. 34, [2]) wth M8 x 20 bolts (Fg. 34, []) so that the profle rals can stll be shfted. Algn the sdes of the upper and lower profle rals symmetrcally. Tghten bolts Installng addtonal profle rals (accessory) If the collector array s exposed to greater loads (nstallaton heght over 66 ft (20 m), snow load over 42 lbs/sqft (2.0 kn/m²)) and/or wnd load up to 9 mph (5km/h), addtonal rals must be nstalled. Fasten addtonal profle rals as descrbed n Secton "Installng profle rals", usng the mddle hole on the trangle (Fg. 35, []). Algn the profle rals symmetrcally. Tghten bolts. Fg SD Installng profle rals (for two portrat collectors n ths example) Installaton of collector hangers Two collector hangers are nstalled on the lower profle ral to hold the weght of the collector. Push each hanger (Fg. 36, [3]) nto the nnermost slots (Fg. 36, []) of the profle rals untl t clcks nto place (Fg. 36, [2]). Fg Installng addtonal profle rals SD Fg. 36 Attachng collector hanger Slots for collector hangers 2 Snap the collector hangers n place 3 Collector hangers SD osch Solar Collectors - Specfcatons subject to change wthout notce.

29 US Collector nstallaton 29 6 Collector nstallaton Observe the followng safety and user nstructons when commencng the collector nstallaton. RISK TO LIFE WARNING! from a fall or fallng parts. Take approprate safety measures to prevent accdents when workng on roofs. Whle workng on the roof, take all necessary precautons aganst a possble fall. Always wear protectve clothng and safety equpment. After completng an nstallaton always verfy that all components are nstalled accordng to the nstructons and are securely attached. Fg. 37 Flat roof nstallaton: 2 collectors SD RISK OF INJURY CAUTION! durng nterrupton of work. Secure the collectors and racks from fallng. Stablse the collector array. SYSTEM DAMAGE CAUTION! from damaged gaskets and contamnaton. Do not remove the rubber caps on the collector connectons untl mmedately pror to nstallaton. Use lftng equpment used by roofng contractors, suffcently strong 3-pont sucton handles or specal carryng handles (avalable as accessores) for easer lftng. Fg. 38 Wall nstallaton SD Unsecured collectors may fall durng handlng and nstallaton. osch Solar Collectors - Specfcatons subject to change wthout notce.

30 30 Collector nstallaton US 6. Preparng to nstall the collectors FKT- efore begnnng actual nstallaton on the roof, preassemble the plugs on the ground to make work on the roof easer. 4 To secure the plugs (and later the flexble ppe connectors and connectng ppes as well), nstall a clp each. CAUTION! SYSTEM DAMAGE from leaks n the collector connectons. The flexble ppes and collector connectons must be free of damage and contamnaton. The collector connectons have specal grease appled at the factory to make nstallaton easer. Do not use any other grease. 4 Fg. 39 Water connecton (rght) up to max. 5 collectors Flexble ppe 2 Supply ppe 3 Return ppe 4 Lockng cap SD 6.2 Water connectons The collectors must be nstalled wth the collector sensor well (Fg. 40, []) at the top. The water connectons can be made on the rght (Fg. 39) or left (Fg. 40). In ths manual, the connecton ppes are shown on the rght. The ppework n the collector s arranged as a double meander, whch allows two dfferent types of water connectons: Sngle-sded connecton of up to 5 collectors Up to 5 collectors can be connected to one sde of a collector array (Fg. 39 and Fg. 40). Dagonal connecton of up to 0 collectors If there are more than 5 collectors nstalled n one collector array, the water connecton must be dagonally (reverse-return prncple, Fg. 4). Dagonal connecton also apples f there are fewer than 6 collectors (Fg. 4). Fg SD Water connecton (left) up to max. 5 collectors Fg. 4 Dagonal water connectons SD osch Solar Collectors - Specfcatons subject to change wthout notce.

31 US Collector nstallaton Installng the plug At ths stage t s advsable to check the complete rack wth a level to be square and plumb. Verfy that all screws and bolts are tght. Not all the connecton ponts are needed n an nstallaton, so those that are not used must be plugged. Remove rubber caps (transport protecton) from the relevant collector connectons. Push plug wth the O-rngs (Fg. 42, [3]) onto the collector connecton. Ensure t hts the stop. Push clp (Fg. 42, [2]) over the plug and collector grove to secure the connecton. 3 CAUTION! SYSTEM DAMAGE from mproperly nstalled lockng clps. Secure each plug wth a clp (Fg. 42, []). Fg SD Securng plug wth a clp 6.4 Attachng the collectors The collectors are attached to the profle rals usng the sngle-sded collector clamps (Fg. 43, [2]) at the begnnng and end of a collector array, and doublesded clamps (Fg. 43, []) between each collector. In addton, the collector hangers (Fg. 43, [3]) hold the weght of the collectors. 2 The plastc parts of the collector clamps do not have any support functon. They are smply ntended to make nstallaton easer. Fg Fasteners for the collector SD osch Solar Collectors - Specfcatons subject to change wthout notce.

32 32 Collector nstallaton US Installng the sngle collector clamp on the rght Push sngle-sded collector clamps (Fg. 44, []) 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 nstall sngle-sded collector clamps on the opposte sde of the collector array untl the last collector has been nstalled. Layng the frst collector n place Lay the collector down on the profle rals n such a way that the sensor well to receve the collector sensor s at the top. egn by layng the collectors on the rght-hand sde of the profle rals. Fg. 44 Pushng on the sngle-sded collector clamp SD CAUTION! RISK OF INJURY It takes at least two people to nstall the collectors. Place the frst collector onto the profle rals and allow t to slde nto the collector hangers (Fg. 45, [2]) (Fg. 45). The lower collector edge must le evenly n the openng of both collector hangers (Fg. 45, []). Carefully push collector (Fg. 46, []) up aganst the sngle-sded collector clamp and algn horzontally. Verfy that the collector sts square on the rack and that both collector hangers and both collector clamps grp the edges of the collector. Tghten sngle-sded collector clamp usng sze 5 Allen wrench (Fg. 46, [2]). Fg SD Layng the frst collector on the profle rals 2 When the screw s tghtened, the plastc gude breaks away at the pre-determned cut-off ponts SD The top (Fg. 46, [2]) of the collector clamp now grps the lower edge of the collector. Fg. 46 Sngle-sded collector clamp screwed n place osch Solar Collectors - Specfcatons subject to change wthout notce.

33 US Collector nstallaton 33 Insertng a double-sded collector clamp Insert the double-sded collector clamp, nut frst, nto the openng made by the profle ral and connector so that the plastc spacer (Fg. 47, []) covers 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 Installng flexble connectors to the frst collector Fg. 47 Installng a double-sded collector clamp SD Remove the rubber caps from the connectons. Push flexble connectors (Fg. 48, []) onto the left-hand connectons on the frst collector. Ensure each one s pushed n untl t hts the stop. Push clp (Fg. 48, [2]) over the flexble connector to secure t n place. 2 Fg SD Installng flexble connectors on the frst collector Puttng the second collector n place Slde the second collector nto the collector hangers. CAUTION! SYSTEM DAMAGE from damaged flexble connectors. Do not use any tools, e.g. plers (Fg. 49, [2]). These could render the corrugated ppe connector unusable. Push the second collector toward the frst wth the collector connectons algned wth the preassembled flexble connectors (Fg. 49, []) on the frst collector. Once the connectors are pushed all the way to the stop, place second clp (Fg. 49, [3]) over the flexble connector and collector connecton. Fg Pushng second collector toward the frst SD osch Solar Collectors - Specfcatons subject to change wthout notce.

34 34 Collector nstallaton US SYSTEM DAMAGE CAUTION! from unsecured connectors and plugs. Secure each plug wth one clp and each flexble connector wth two clps (Fg. 50, []) SD Fg. 50 Flexble connector secured wth clps Tghten the screw on the double-sded collector clamp usng the sze 5 Allen wrench. When the screw s tghtened, the plastc gudes lugs break away at the predetermned cutoff ponts. The top (Fg. 5, []) of the collector clamp now grps the lower edge of both collectors. Repeat the procedure for all the other profle rals nstalled, and all other collectors. Installng the sngle-sded collector clamp on the opposte end Once all collectors are nstalled, the two remanng sngle-sded collector clamps can be attached. Push the sngle-sded collector clamp (Fg. 52, []) nto the profle rals. Push collector clamp up aganst the collector frame and tghten usng sze 5 Allen wrench (Fg. 52, [2]). The top (Fg. 52, [2]) of the collector clamp now grps the lower edge of the collector. Fg SD Double-sded collector clamp between two collectors 2 When the screw s tghtened, the plastc gude breaks away at the pre-determned cut-off ponts. Fg. 52 Sngle-sded collector clamp (left) SD osch Solar Collectors - Specfcatons subject to change wthout notce.

35 US Collector sensor connecton FKT Collector sensor connecton FKT- The collector sensor s part of the pump staton or the solar controller. Ensure the correct sensor placement n sngle and mult-array solar systems (Fg. 53). A SYSTEM DAMAGE from faulty sensor cable. CAUTION! Protect the cable from possble damage from the weather, rhodents, and brds. 2 Inserton pont The collector sensor must be nstalled n the collector that the supply ppe s connected to (Fg. 53, [2]). Fg SD Collector sensor well locaton (schematc) 2 Locaton (Fg. 53, [A]) for sngle array collector systems. Locaton (Fg. 53, []) for dual array collector systems. Return lne 2 Supply ppe Always nstall the sensor where the hottest flud temperature of the array s to be expected, or where the supply ppe run connects to the pump staton. Installng the collector sensor For a contnuously troublefree readng of the absorber temperature, the collector sensor (Fg. 54, []) must be completely nserted nto the sensor well as far as t wll go (0 n (250 mm)). Usng the collector sensor or screwdrver, puncture the membrane of the sensor well (Fg. 54, [3]). Screw stran relef (Fg. 54, [2]) nto sensor bushng. Insert collector sensor approx. 0 n (250 mm) nto the sensor well (as far as t wll go). Tghten the stran relef (Fg. 54, [2]), to secure the sensor n place. Use cable tes or smlar to route the sensor cable securely untl t meet up wth the twn tube. If the membrane (Fg. 54, [3]) on the wrong collector was accdentally punctured, t can be resealed usng the plug from the connecton kt. Frst remove the nut n the sensor well usng the stran relef (Fg. 54, [2]). 3 2 Fg. 54 Insertng the collector sensor nto the collector Collector sensor 2 Stran relef 3 Sensor well osch Solar Collectors - Specfcatons subject to change wthout notce.

36 36 Hydraulc connecton FKT- US 8 Hydraulc connecton FKT- Informaton on routng the ppes can be found n the pump staton nstallaton nstructons. SYSTEM DAMAGE CAUTION! from leaks n the collector connecton, due to movements caused by expanson and contracton of the ppework. Route the supply ppe (Fg. 55, []) alongsde the collector, rather than vertcally downward. 2 Fg. 55 Feedng header ppes to the collector array Supply ppe 2 Return lne SD 8. Ppe bracket When routng the supply ppe alongsde the collector, use the suppled bracket to attach t securely. We recommend commercally avalable hose clamps (Fg. 56, []) attached to the M8 thread on the bracket (Fg. 56, [2]). Select a hose clamp accordng to the outsde dameter of the supply ppe, ncl. nsulaton. 2 Place bracket (Fg. 56, [3]) onto collector frame and tghten wth sze 5 Allen wrench. Install supply ppe n the hose clamp. Fg. 56 Fastenng holder to the collector frame Hose clamp (not suppled) 2 M8 thread 3 racket SD osch Solar Collectors - Specfcatons subject to change wthout notce.

37 US Hydraulc connecton FKT Hydraulc collector connecton wthout an ar vent If fllng a solar system usng a hgh volume and hgh pressure fllng staton, an ar vent on the roof s not requred unless corrugated ppng s used for large portons of the ppework. Follow these steps to make the connecton: Remove rubber caps (transport protecton) from the relevant collector connectons. Push elbow (Fg. 57, [2]) wth compresson rng and compresson nut onto collector connecton. Secure elbow wth clp (Fg. 57, []). Perform the same procedure wth the return connecton Fg. 57 Installng supply ppe (wth no vent on roof) Clp 2 Elbow 3 Compresson rng /2" 4 Compresson rng SD osch Solar Collectors - Specfcatons subject to change wthout notce.

38 38 Hydraulc connecton FKT- US 8.3 Hydraulc collector connecton wth an ar vent (accessory) If a hgh volume and hgh pressure fllng staton s not avalable for fllng, f corrugated ppe s used for large portons of the ppe runs, or f the ppes are routed n a way that may prevent ar from beng bled easly, nstall an ar vent (Fg. 58, [2]) and route all ppes sloped toward the collector array (Fg. 58). 2 Avod frequent changes n drecton. For each change of drecton downwards and each new rse, an addtonal ar vent may be necessary SD Fg. 58 Ar vent wth ppes sloped upward Collector sensor 2 Automatc ar vent above the collector supply ppe Ensure the ar vent s rated for Propylene Glycol and the temperatures of the solar thermal system. Functonalty of the automatc ar-vent valve The solar thermal system s vented through the opened bleeder screw. When n operaton, the weather protecton cap (Fg. 59, []) must always be postoned over the bleeder screw to prevent drt from enterng the system Open the ar-vent by unscrewng the bleeder screw one full turn SD Fg. 59 Unversal ar-vent set Weather protecton cap (grub screw) 2 Automatc ar vent 3 all valve 4 Gasket 5 Vent body 6 Double npple wth O-rng 7 Npple R¾ 8 Unon nut (not needed here) 2 9 Gasket (not needed here) 0 Large dameter washer (not needed here) Compresson washer (not needed here) 6 osch Solar Collectors - Specfcatons subject to change wthout notce.

39 US Hydraulc connecton FKT- 39 Installng the ar vent Frmly screw npple (Fg. 60, [6]) and double npple (Fg. 60, [4]) nto ar vent body (O-rng gasket). Push ar vent (Fg. 60, [5]) and npple onto collector connecton untl t hts the stop, and secure wth ar vent body. Connect supply ppe to the compresson fttng /2" (Fg. 60, [2]). Ensure the ar vent s postoned vertcally otherwse the float wll not work properly SD Fg. 60 Connectng the ar vent Clp 2 Unon nut for /2" compresson fttng 3 Compresson rng 4 Double npple wth O-rng 5 Vent body 6 Npple 8.4 Connectng two arrays Use a second connecton kt for connectng two collector arrays (Fg. 6, []). Install ndvdual parts as descrbed n Secton 8.2 "Hydraulc collector connecton wthout an ar vent". Make on-ste connecton between collector arrays. Fg. 6 Two collector arrays, one behnd the other SD osch Solar Collectors - Specfcatons subject to change wthout notce.

40 40 Fnal actvtes US 9 Fnal actvtes 9. Checkng the nstallaton 9.2 Insulatng the ppes CAUTION! SYSTEM DAMAGE from corroson f water remans n the solar system for an extended perod after flusng 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. Cut enclosed nsulaton (28 n (70 mm) long) nto 3.5 n (88 mm) lengths and place around the corrugated ppe connectors between the collectors. For the nsulaton of external ppework, use only UV and hgh temperature resstant materals. For the nsulaton of nternal ppework, use only hgh temperature resstant materals. Ensure the nsulaton s weather, rhodent and brd proof. Do not nsulate any ppes before a thorough leak test has been performed. Checks Corrugated ppe connector, plugs and connectng ppe bends secured wth brackets? All collector braces connected to profle rals? Ant-slp protecton nstalled and clcked nto place n profle rals? Sensor nserted as far as t wll go and secured wth compresson fttng? Pressure test carred out and all connectons leak-proof (see complete staton nstructons)? If an automatc ar-vent valve (accessory) s nstalled, the ball valve must be closed after the ventng procedure (see complete staton nstallaton nstructons) has been completed. In larger systems and where corrugated ppes are beng used, t may be necessary to bleed addtonal ar after -2 weeks of operaton. osch Solar Collectors - Specfcatons subject to change wthout notce.

41 US Quck reference gude for mountng and pressure fllng 4 0 Quck reference gude for mountng 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 obey all safety and user nstructons. Installng trangles and profle rals. Insert telescopc rals nto each other accordng to page 4 the selected angle of nclnaton, and secure. 2. Drll holes n I-beams (or smlar), and secure page 24 collector trangles wth screws. 3. Connect profle rals together usng plug connectors. page Attach profle rals to collector trangles. page Algn sdes of the profle rals symmetrcally. page Install collector hangers on the two nner slots on the lower profle rals. page 28 Preparng to nstall the collectors Fg. 62 Installng on a flat roof SD 7. Push plugs onto those connectons that are not requred and secure usng clps. page 32 Fastenng the collectors 8. Push sngle-sded collector clamp nto profle rals. page Place frst collector onto profle rals and push onto collector clamp. page 3 0. Tghten collector clamp. page 3. Place double-sded collector clamp nto profle ral page 32 and push onto frst collector. 2. Push flexble connectors onto the connectons on page 32 the frst collector and secure wth clps. 3. Push second collector toward the frst and fx n page 33 place wth clps. 4. Tghten screws on the double-sded collector clamp. page Repeat the procedure for all other collectors. page Install sngle-sded collector clamps on other sde. page 34 Fg. 63 Water connectons SD Ppng connecton 7. Insert collector sensor as far as t wll go nto the page 35 collector that wll be connected to the supply ppe, and secure. 8. Install bracket for supply ppe on collector frame page 36 and tghten. 9. Attach elbow to supply and return ppes. page Secure the elbows wth clps. page Perform nstallaton checks. page Insulate supply and return ppes wth UV and hgh page 40 temperature resstant materal. Fg SD Installng the collector sensor and connecton parts osch Solar Collectors - Specfcatons subject to change wthout notce.

42 42 Collector US Spare parts osch Solar Collectors - Specfcatons subject to change wthout notce.