INSTALLATION AND MAINTENANCE INSTRUCTIONS EVACUATED TUBE COLLECTOR SOLAR-LUX 6/ 6 70 646 03-00.0TL ROOF MOUNTING INSTALLATION UK/IE 6 70 647 040 (0/05) GB/IE
TABLE OF CONTENTS TABLE OF CONTENTS Key to symbols and safety instructions....... 3. Explanation of symbols............... 3. General safety information............ 3 Product information...................... 4. Components and instructions.......... 4. Correct use........................ 5.3 EU Declaration of Conformity.......... 5.4 Standard delivery................... 6.4. Mounting bracket................... 6.4. Installation set...................... 6.4.3 Connection set (hydraulic connection)... 7.4.4 Collector.......................... 7.5 Specification....................... 7.6 Data plate......................... 8 3 Regulations............................. 8 4 Before installation....................... 9 4. Determining space requirements....... 9 4. Planning the hydraulic connection...... 9 4.3 Observing general notes............. 0 4.4 Tools and accessories required....... 4.5 Lightning protection................ 4.6 Installation order................... 8 Installing the collectors.................. 8. Installing the first collector........... 8. Installing the second collector......... 3 8.3 Installing the collector sensor......... 3 8.4 Installing the connection cover set (accessory)........................4 9 Hydraulic connections.................... 5 0 Final activities.......................... 7 0. Checking the installation............. 7 0. Pressure filling, purging, venting....... 7 0.3 Adjusting the pre-charge pressure of the expansion vessel..............7 0.4 Determining and setting the operating pressure...............7 0.5 Adjusting the flow rate.............. 7 0.6 Insulating piping................... 7 Replacing individual tubes................ 8 Environmental protection / disposal........ 9 3 Maintenance/inspection.................. 30 5 Handling.............................. 6 Installing the mounting brackets........... 3 6. Determining distances.............. 3 6.. Vertical distances for the mounting brackets............ 4 6.. Horizontal distances for the mounting brackets............ 4 6. Installing mounting brackets pan tile roofs...................... 5 6.3 Installing mounting brackets on plain tile roofs................... 6 6.4 Installing mounting brackets on slate shingle roofs................ 7 7 Installing the rails....................... 8 7. Installing the vertical rails............ 9 7. Installing horizontal rails and retaining clips.................. 0 7.3 Installing the retaining clips to vertical rails..................... 6 70 647 040 (0/05)
KEY TO SYMBOLS AND SAFETY INSTRUCTIONS KEY TO SYMBOLS AND SAFETY INSTRUCTIONS. EXPLANATION OF SYMBOLS WARNING SYMBOLS Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions. NOTICE indicates possible damage to property or equipment, but where there is no risk of injury. CAUTION indicates possible injury. WARNING indicates possible severe injury. DANGER indicates possible risk to life. IMPORTANT INFORMATION ADDITIONAL SYMBOLS Symbol B Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background. Electrical hazards are identified by a lightning symbol surrounded by a warning triangle. Notes contain important information in cases where there is no risk of personal injury or material losses and are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text. Meaning a list entry Tab. a step in an action sequence a reference to a related part in the document or to other related documents a list entry (second level). GENERAL SAFETY INFORMATION DANGER OF FALLING WHEN WORKING ON THE ROOF B If there are not any general anti-fall safety devices, wear personal protective clothing and safety equipment. B Take appropriate action to prevent accidents during all work on roofs. B Observe the health and safety regulations. DANGER OF BROKEN GLASS If the glass tubes are destroyed, there is a risk of injury through falling glass. B Avoid installing in public areas where falling glass could cause injury. RISK OF BECOMING BURNED BY THE COLLECTORS If the collector and its installation material are left exposed to the sunlight for a long period, the parts will become hot. B Care should be taken when working on the collector due to possible high temperatures. INSTALLATION Installation and maintenance may only be carried out by a competent person. Do not alter the components. B Please read these instructions carefully. B Install the installation set only on roofs with sufficient load-bearing capacity. If necessary, consult a structural engineer and/or roofer. B Do not walk on the collectors. Do not subject them to loads from objects at single points or over the entire surface area. B After completing the installation, check that collectors and the installation set are securely positioned. FUNCTION CHECKS The user is responsible for ongoing maintenance and safe upkeep of the system. B Customer recommendation: Arrange a maintenance and inspection contract with a competent person. B Only original spare parts must be used. INSTRUCTING THE CUSTOMER B Notify customers about how the appliance works and provide training on operating the entire system. B Inform customers that they must not carry out any modifications or repairs. B Hand over the installation instructions to the customer and point out that these instructions must be kept and passed on to the next owner/user. 6 70 647 040 (0/05) 3
PRODUCT INFORMATION PRODUCT INFORMATION. COMPONENTS AND INSTRUCTIONS The solar thermal system for DHW heating and/or central heating backup comprises various components ( Fig. ). These have instructions for installation, operation and maintenance. Some accessories have separate instructions. The following topics are described in the instructions for the components: EVACUATED TUBE COLLECTORS ( FIG., []) Installing the mounting brackets. Fastening the collectors. 3 4 Hydraulic connection for the collectors. Maintenance for the collectors. 3 SOLAR PUMP STATION ( FIG., []) Installing the solar pump station. Installing the piping. Commissioning the entire system. Maintenance for the solar pump station. Maintenance for the entire system. CYLINDER ( FIG., [3]) Positioning and installing the cylinder. Commissioning the cylinder. Maintenance for the cylinder. SOLAR CONTROLLER ( FIG., [4]) Installing the controller. Operating the controller and the entire system. 4 3 Fig. 67064603-0.ST Functional diagram of an evacuated tube collector, here: type Solar-Lux 6 = 6 tubes (type Solar-Lux = tubes) Manifold CPC mirror for optimum sunlight utilisation 3 Heat transfer medium tubes 4 Glass-glass evacuated tubes for optimum thermal insulation (It is possible to replace a tube without having to drain the system). REGARDING THESE INSTRUCTIONS The evacuated tube collector is referred to in its short form, collector, on the following pages. Roofing in the form of pantiles, roof tiles etc. is designated uniformly as roof tiles. These instructions describe the installation of evacuated tube collectors (including their hydraulic connection) for the following roofing on pitched roofs: Pan tiles, plain tiles, tiles and slate shingles. 4 67064603-35.ST Fig. Schematic diagram of a solar thermal system 4 6 70 647 040 (0/05)
PRODUCT INFORMATION. CORRECT USE The installation set and the mounting brackets are intended only for the safe attachment of collectors to pitched roofs. The collectors are for DHW heating and can be used to make a contribution to space heating in certain circumstances with specially designed systems. They may only be operated in combination with suitable solar controllers in intrinsically safe, sealed unvented solar thermal systems. These systems must be equipped with a suitable, adequately sized expansion vessel. PERMISSIBLE ROOF PITCH The self-cleaning effect for the glass tubes and CPC mirror will only work if the roof has a pitch of at least 5. The maximum roof pitch is 65. PERMISSIBLE LOADS The installation set is suitable for the following: a standard snow load of.5 kn/m or.0 kn/m ( Tab. 4, page 6) Use an electrical solar filling station to pressure fill with the heat transfer medium Tyfocor LS to purge and fill the system (do not use water because the collectors cannot be drained). This means that there is no need to have an air vent valve up on the roof. For the required expansion vessel pre-charge pressure setting and the operating pressure and flow rate settings for the vacuum tube collector system, please see the chapter entitled "Final activities" ( page 7). In addition to the notes from the solar pump station instructions, please also observe the following: The distance between the solar pump station (Expansion vessel connection) and the bottom edge of the collector array must be at least m ( Fig. 3). The minimum pipe length between the solar pump station (expansion vessel connection) and the collector array must be at least 5 m. For systems utilising more than 8 tubes, a minimum of 0 metres is requires. B To determine the maximum wind speed, take into account the following factors: the location of the solar thermal system, the geographic elevation, the topography the height of the building. If necessary, consult a building structural engineer. HEAT TRANSFER MEDIUM To protect the collectors from frost and corrosion damage, they should be operated with the Tyfocor Glycol LS. Do not add any other heat transfer medium. OTHER APPLICABLE INSTRUCTIONS AND IMPORTANT NOTES The installation and maintenance instructions for the solar pump station contain important information for using evacuated tube collectors in the solar thermal system. Please take particular note of the information on the following topics. Do not carry out brazing close to evacuated tube collectors. If system is used for central heating backup or covers more than 60% of DHW needs, install a pre-cooling vessel before the expansion vessel. Install the expansion vessel (EV) with a tee 0-30 cm above the solar pump station in the return pipework to the panel ( Fig. 3). Do not use any forms of soft soldering with these collectors 67064603-49.ST Fig. 3 > 00 cm 0-30 cm.3 EU DECLARATION OF CONFORMITY This product conforms in design and operation to the European Directives and the supplementary national requirements. Its conformity is demonstrated by the CE designation. The Declaration of Conformity can be requested from the manufacturer (see back cover for address). 6 70 647 040 (0/05) 5
PRODUCT INFORMATION.4 STANDARD DELIVERY B Check that the delivered packages are complete and undamaged..4. MOUNTING BRACKET.4. INSTALLATION SET 5 L 6 4 3 67064603-05.ST 7 67064603-06.ST Fig. 4 Standard delivery for mounting brackets for roof tiles (different mounting brackets subject to roofing) Fig. 5 Standard delivery for installation set Solar-Lux 6 ( x) Solar-Lux 6 (3 x) Item Mounting bracket 4 6 4 ( x) Item Hammer-head bolt (with washer and nut M0) 6 ( x) 6 (3 x) 4 36 6 ( x) Item Hammer-head bolt (with washer and nut M0) 4 6 4 Item 3 Screw 8 x 0 8 Item 4 Tab. Wooden spacer 00 x 50 x 8 mm 8 Standard delivery for mounting brackets for roof tiles subject to number of collectors Item 5 Rail L=300 mm -- -- Item 5 Rail L=953 mm 3 -- Item 5 Rail L=007 mm -- -- Item 5 Rail L=0 mm -- -- Item 6 L-shaped connector 4 6 -- Item 7 Tab. 3 Upper/lower retaining clips 4 6 Installation set subject to number of collectors x Solar-Lux 6 300 3 x Solar-Lux 6 (or x Solar-Lux 6 + x Solar-Lux ) 007 x Solar-Lux or x Solar-Lux 6 953 953 0 Standard snow load: max..5 kn/m Standard snow load: max..5 kn/m Standard snow load: max..0 kn/m Tab. 4 Using the rails (Item 5) and maximum standard snow load (dimensions in mm) 6 6 70 647 040 (0/05)
PRODUCT INFORMATION.4.3 CONNECTION SET (HYDRAULIC CONNECTION).5 SPECIFICATION Solar-Lux 6 Solar-Lux Certificates DIN Width 0.70 m.40 m Depth 0.0 m 0.0 m Length.06 m.06 m Collector connection, flow and return 5 mm 5 mm Absorber capacity 0.97 l. l Aperture area.8 m.57 m 67064603-30.ST 000 Fig. 6 Standard delivery for connection set Absorber area.9 m.58 m Gross area.45 m.86 m Net weight 4 kg 43 kg Item Connection pipe, fully assembled (incl. stainless steel corrugated pipe, insulation and compression fitting for connection to the piping) x Permissible operating pressure for collector (p max ) 0 bar 0 bar Item Tab. 5 Installation and maintenance instructions x Test pressure (p pr ) 3 bar 3 bar Stagnation temperature, max. 30 C 30 C.4.4 COLLECTOR Number of glass tubes 6 Glass tube: Tube length/ ExternalØ / InternalØ 90 mm / 47 mm / 37 mm Tab. 7 mbar Fig. 7 Collector with connection nipple 67064603-3.ST 80 60 40 0 00 80 60 40 0 0 0 3 4 5 6 7 8 Item Connection nipple as connector between collectors x Fig. 8 l/min Pressure drop of collectors 67064655-6.ST Item Collector Solar-Lux 6/ comprising: evacuated tubes, CPC mirror, manifold Tab. 6 x Pressure drop curve for Solar-Lux Pressure drop curve for Solar-Lux 6 6 70 647 040 (0/05) 7
REGULATIONS.6 DATA PLATE The data plate is mounted on the manifold and contains all important information in the form of symbols. Symbol Meaning Explanation A G area gross Gross area A a area aperture Projected mirror area A A area absorber Absorber area V f volume fluid Collector capacity m mass Weight t stg temperature stagnation Stagnation temperature, max. p max pressure maximum Operating pressure, max. p pr pressure proof Test pressure y prod year production Production year Tab. 8 Data plate information 3 REGULATIONS B Comply with all standards and guidelines applicable to the installation and operation of the system in your country and region. These include, but are not limited to: The Health and Safety at Work Act 974. Control of substances hazardous to health regulations (COSHH) 994 The pressure equipment regulations 999 Construction (Design and Management) Regulation (CDM) 007 The Work at Height Regulations 005 Manual Handling Operations Regulations 99 The Lifting Operations and Lifting Equipment Regulations (LOLER) 999 Reporting of injuries, diseases or dangerous occurrences regulations (RIDDOR) 995 Confined spaces regulations 997 Personal protective equipment at work regulations 99 Electricity at work regulations 989 Provision and uses of work equipment regulations (PUWER) 998 BS 6795:986 Code of practice for solar heating systems for swimming pools for swimming pool. BS598: A code of practice for the installation of DSHW systems for domestic hot water BS5546: 000 Specification for installation of hot water supplies for domestic purposes, using gas-fired appliances of rated input not exceeding 70 kw. BS6700: 006 Specification for design, installation, testing and maintenance, of servicing supplying water for domestic use within buildings and their curtilages. EN 976: Thermal solar heating system and their components (prefabricated systems). ENV 977: Thermal solar heating system and their components (bespoke systems). BS 690: Suitability of non-metallic products for use in contact with water intended for human consumption with regards to their effect on the quality of water BSEN 83:003: Heating systems in buildings. Methods for calculation of the design heat load BS 8000-5: 990: Workmanship on building sites. Code of practice for hot and cold water services (domestic scale) 8 6 70 647 040 (0/05)
BEFORE INSTALLATION 4 BEFORE INSTALLATION 4. DETERMINING SPACE REQUIREMENTS These minimum space requirements must be available on the roof. 4. PLANNING THE HYDRAULIC CONNECTION Before installing the collectors, please decide how the collectors will be arranged. a DANGER: Risk of fatal injury from collectors that cannot withstand peak wind and suction values. B Maintain the minimum clearance to the edge of the roof. a = h 0 b C, a a = b 0 The collector sensor [] must be fitted in the collector connected to the flow pipe []. MAXIMUM NUMBER OF COLLECTORS PER ROW: Solar-Lux 6: 6 collectors Solar-Lux : 3 collectors HERE ARE TWO EXAMPLES OF AN HYDRAULIC ARRANGEMENT FOR THE EVACUATED TUBE COLLECTORS: a h 67064603-0.ST Fig. 9 Clearance dimensions for the collector array Dimension a: Use a formula, both are possible Dimensions A and B: Tab. 9 Dimension C: At least 3 rows of tiles to ridge or chimney Dimension D: At least 0.5 m to the right and left of the collector array as well as to the ridge for connection lines below the roof. Fig. 0 3 Connection in a single row, here: flow on the right Collector sensor (always on the flow side) Flow pipe (to the cylinder) 3 Return pipe (from the cylinder) 67064603-3.ST Number of collectors* Solar-Lux 6 Solar-Lux Dimension A Dimension B Dimension Dimension A B 0.70 m.06 m.40 m.06 m.40 m 4.7 m.80 m 4.7 m 3.0 m 6.48 m 4.0 m 6.48 m 4.80 m -- 5.60 m -- 5 3.50 m -- 7.00 m -- 6 4.0 m -- 8.40 m -- Tab. 9 Space requirements (* for dimension B: collectors arranged one above the other) 6 70 647 040 (0/05) 9
BEFORE INSTALLATION 4.3 OBSERVING GENERAL NOTES We recommend that you engage the services of a roofing company, as they are experienced in working on roofs and will be aware of the risk of falling. Familiarise yourself with the on-site conditions and local regulations. Remove and replace broken roof tiles, shingles, etc. Always install collectors with the manifold on the top. 4 Fig. Permissible installation direction 67064603-44.ST Arrange collectors optimally on the roof ( Fig. 3), for example, in such a way that the collector array is aligned with windows and doors. When doing so, maintain the minimum clearances to the edge of the roof ( Fig. 9). 67064603-4.ST 3 N Fig. Three-row connection (with shut-off valve), here: flow on the left Collector sensor (always on the flow side) Flow pipe (to the cylinder) 3 Return pipe (from the cylinder) 4 Shut-off valve (accessory) W S O 67064603-08.ST Fig. 3 Aligning the collector array to the building's shape 0 6 70 647 040 (0/05)
BEFORE INSTALLATION Avoid shade from adjacent building, trees, etc. ( Fig. 4). 4.4 TOOLS AND ACCESSORIES REQUIRED Cordless screwdriver for pre-drilling 6 mm, 9 mm for pre-drilling Spanner, sizes SW3, 7,, 4, 30 Hammer (for roof tiles and connection set) Phillips screwdriver (for connection set) Ventilation tiles to pass piping through the roof (optional) Material for pipe insulation Fig. 4 67064603-09.ST Avoiding shade 4.5 LIGHTNING PROTECTION The need for lightning protection may vary from region to region. B Familiarise yourself with the regional regulations to determine whether a lightning protection system is necessary. The lightning conductor is often a requirement for buildings higher than 0 m. A lightning conductor must be installed by an electrician. Where there is a lightning conductor system installed, have the connection to the solar thermal system checked. 4.6 INSTALLATION ORDER To fasten the collectors to the roof, install in the following order:. Determine distances for mounting brackets. Install mounting brackets. 3. Install rails and retaining clips. 4. Install collectors and collector sensor. 5. Connect piping to collectors. 6 70 647 040 (0/05)
HANDLING 5 HANDLING The collectors and the installation materials are heavy and difficult to handle. Please observe the following notes, since working on the roof can also be dangerous. DANGER: Risk to life through falls or falling parts! B Do not use a ladder to move components to the roof because the installation material and collectors are heavy and can be difficult to handle. B Take appropriate action to prevent accidents during all work on roofs. B Take precautions against a possible fall. B Always wear personal protective clothing and safety equipment. B At least people must carry out installation on the roof. B During transport, secure the collectors and installation material to prevent them falling. B After completing installation, check that the installation set and collectors are securely positioned. B To make it easier to transport the collectors and the installation material, use the following aids with sufficient load-bearing capacity: Mobile hoist or crane Lifting belt Roofing ladder or equipment for sweeping chimneys Scaffolding B Dispose of transportation packaging using the most environmentally friendly method of recycling. NOTE: Collector damage through transport. We recommend transporting the collector to the roof in its transportation packaging. WARNING: Risk of injury from broken glass. B When handling the collectors, always wear protective gloves and goggles. B The belt loops at the top of the collector are for assistance in handling the unit. DANGER: Risk to life through inadequately secured collectors during transport. B Make sure that the collectors are securely fastened during transportation. 6 70 647 040 (0/05)
INSTALLING THE MOUNTING BRACKETS 6 INSTALLING THE MOUNTING BRACKETS The collectors are connected to the supporting surface using mounting brackets. The distances are shown using the example of the mounting bracket for roof tiles. WARNING: Please refer to current health and safety guidelines for working at height. NOTE: Damage to the roofing by stepping on installed mounting brackets and installation set. B To prevent damage to the roofing, do not step on installed components. PREASSEMBLY ON THE GROUND In order make installation on the roof easier for you, we recommend that you preassemble the threaded connections for all mounting brackets on the ground. B Screw on hammer-head bolt with washer and nut M0 to mounting bracket. 6. DETERMINING DISTANCES The mounting bracket for roof tiles is shown as an example in the figures. The distances also apply to other mounting brackets. In order to install the mounting brackets, you must determine the distances for them. Please observe Fig. 6. On pan tile roofs the tile valleys determine the true distance between the mounting brackets. The rafter spacing does not always match the required spacing for the mounting brackets. For larger or smaller rafter spacing, you must install supporting surfaces (braces) on site with adequate load-bearing capacity. For multiple rows of collectors, you must choose the distances for the mounting brackets such that there is a minimum distance of 50 mm between the collectors on the top and bottom. The mounting brackets must be positioned at right angles to each other. Fig. 5 67064603-40.ST Preassembly of hammer-head bolts on the ground NOTE: Collector damage through incorrectly positioned mounting brackets. B Maintain the distance between the mounting brackets ( Fig. 6). B Always choose the largest possible distance between two vertical mounting brackets ( Fig. 6, Dimension b). B A rafter width of at least 88 mm is required to fasten the mounting brackets with 3 screws. Provide for on-site reinforcement in case of narrower rafters. B Define mounting bracket positions ( Fig. 6 to 0 and Tab. 0). 6 70 647 040 (0/05) 3
INSTALLING THE MOUNTING BRACKETS 6.. VERTICAL DISTANCES FOR THE MOUNTING BRACKETS For roof batten spacing of 370 mm (Solar-Lux 6/) and 450/460/470 mm (Solar-Lux 6), the mounting brackets must be installed at a distance from the roof batten. This is the only way to achieve dimension b. Dimension a - Roof batten spacing Dimension b - for Solar-Lux 6 Dimension b - for Solar-Lux 30 mm - 340 mm 50 mm - 75 mm 350, 430 mm 75 mm - 760 mm 370, 470 mm 895 mm 50 mm - 380 mm - 40 mm 50 mm - 840 mm 75 mm 360, 440, 450 mm 760 mm - 80 mm 460 mm 80 mm Tab. 0 Vertical distances for the mounting brackets Fig. 8 x 3 x Solar-Lux 6 (or x Solar-Lux 6 and x Solar-Lux ) for a standard snow load of max..5 kn/m x 0,65-0,8 m 0,65-0,8 m 67064603-03.ST > 0,5 m 90 0,45 m 0,6 m 0,45 m 67064603-46.ST 90 b Fig. 9 x Solar-Lux 6 (and others) for a standard snow load of max..0 kn/m a,395 m Fig. 6 67064603-33.ST Distances to be maintained and rafter width 6.. HORIZONTAL DISTANCES FOR THE MOUNTING BRACKETS Subject to the type of collector and regional standard snow load, you will have to take different distances into account. x x 0,70-,05 m x x 0,70-,05 m 67064603-6.ST Fig. 0 x Solar-Lux (and others) for a standard snow load of max..0 kn/m The Dimension x stands for an identical distance. The maximum difference between these dimensions is 00 mm. x x Fig. 7 0,70-0,93 m 67064603-0.ST x Solar-Lux 6 (or x Solar-Lux ) for a standard snow load of max..5 kn/m 4 6 70 647 040 (0/05)
INSTALLING THE MOUNTING BRACKETS 6. INSTALLING MOUNTING BRACKETS PAN TILE ROOFS B Depending on the distances ( page 4), remove -3 roof tiles from a row in the area of the rafters. Positioning of the mounting brackets: The mounting bracket must be in the tile valley. The mounting bracket must protrude directly above the roof tile below it without touching this tile. B Mark the mounting bracket positions on the roof. B Place mounting bracket [] on rafter and pre-drill using a 6 mm drill bit to fasten with the screws [3]. B If required, use wooden spacer [5] supplied for height compensation (pre-drill 9 mm). B Carefully remove the roof tiles' rain guards and profiles [, 4] in the area of the mounting brackets. B Screw mounting bracket with 3 screws 8 x 0 mm [3] to the rafter. Use a size SW3 spanner. B Put the roof tiles back on. NOTE: Caution, care should be taken to avoid roof leaks from fine, wind-driven snow in the area of the mounting bracket. B If there is a larger gap between the top and the bottom roof tiles, close this gap using UV-resistant sealing tape.. 3 6 9. 3 3. 5 4 67064603-07.ST Fig. Mounting brackets for roof tile roofs Mounting bracket Top roof tile 3 Screws 8 x 0 mm 4 Bottom roof tile 5 Wooden spacer 00 x 50 x 8 mm 6 70 647 040 (0/05) 5
INSTALLING THE MOUNTING BRACKETS 6.3 INSTALLING MOUNTING BRACKETS ON PLAIN TILE ROOFS NOTE: To avoid roof leaks on plain tile roofs, consult a roofer for advice and assistance. B Consult a roofer for advice and assistance. B Depending on the distances determined ( page 4) remove -3 plain tiles from a row in the area of the rafters. Positioning of the mounting brackets: The mounting bracket [] must be in the middle of the plain tile below it. The mounting bracket must protrude directly above the plan tile below it without touching this tile. B To make room for the mounting bracket, shorten the plain tile at the top edge if necessary and/or make a recess in the roof batten lying above. B Mark the mounting bracket positions on the roof. B Pre-drill rafter with 6 mm drill bit. B If required, use wooden spacer [4] supplied for height compensation (pre-drill 9 mm). B Screw mounting bracket with 3 screws 8 x 0 mm [] to the rafter. Use a size SW3 spanner. B Trim adjacent plain tiles [3] and roof them. NOTE: Caution, to avoid roof leaks from fine, wind-driven snow in the area of the mounting bracket. B If there is a larger gap between the top and the bottom roof tiles, close this gap using UV-resistant sealing tape.. 3 6 9 4. 3. 3 67064603-.ST Fig. Mounting brackets for plain tile roofs Mounting bracket Screws 8 x 0 mm 3 Plain tiles, trimmed 4 Wooden spacer 00 x 50 x 8 mm 6 6 70 647 040 (0/05)
INSTALLING THE MOUNTING BRACKETS 6.4 INSTALLING MOUNTING BRACKETS ON SLATE SHINGLE ROOFS NOTE: B To avoid roof leaks on slate or shingle roofs, consult a roofer for advice and assistance. B Because the mounting bracket can rest on the panel below, this panel must be reinforced on-site using a suitable material. B Depending on the distances determined ( page 4), remove several panels in the area of the rafters. Positioning of the mounting brackets: The mounting bracket must protrude directly above the panel below it without touching this panel. B Mark the mounting bracket positions on the roof. B Screw mounting bracket [] with 3 screws 8 x 0 mm [] to the rafter. Use a size SW3 spanner. B Put panels back on. 3 6 67064603-7.ST Fig. 3 Mounting brackets for slate shingle roofs Mounting bracket Screws 8 x 0 mm 6 70 647 040 (0/05) 7
INSTALLING THE RAILS 7 INSTALLING THE RAILS The mounting brackets and the collector are connected by the rails and the retaining clips. EXAMPLES OF HOW THE RAILS CAN BE USED x Solar-Lux 6 x Solar-Lux 6 3 x Solar-Lux 6 300 007 0 953 953 Tab. Dimensions in mm x Solar-Lux x Solar-Lux * x Solar-Lux 6 and x Solar-Lux 300 007 0 953 953 Tab. Dimensions in mm * recommended for the combination x Solar-Lux and x Solar-Lux 6 PREASSEMBLING ON THE GROUND In order make installation on the roof easier for you, we recommend that you preassemble the following parts on the ground using a size SW7 spanner. B Preassemble hammer-head bolts with L-shaped connector: Fig. 8 B Preassemble lower retaining clips with horizontal rail (300 mm or 007 mm): Fig. 8 B Preassemble upper retaining clips with vertical rail (0 mm): Fig. 9 8 6 70 647 040 (0/05)
INSTALLING THE RAILS 7. INSTALLING THE VERTICAL RAILS ALIGNING THE RAILS When installing the rails, make sure that you align them exactly ( Fig. 4): perpendicular to the horizontal (use aid such as roof batten []) same overhang on top and bottom (dimension x). SOLAR-LUX 6: INSTALLING VERTICAL RAILS FOR ROOF BATTEN SPACING OF 350-370 MM AND 430-470 MM For these distances between roof battens, it is necessary to screw together the L-shaped connector and the mounting bracket with the vertical rail. Roof batten spacing Position of L-shaped connector Top, bottom of mounting bracket 350, 430, 440 mm A bottom only 360, 450 mm B bottom only 460 mm A top B bottom 370, 470 mm B top and bottom Tab. 3 Fastening the L-shaped connector to the mounting bracket B Screw rails as specified by Tab. 3 to L-shaped connector and mounting bracket ( Fig. 6). 7 Fig. 4 Aligning the vertical rails SOLAR-LUX : VERTICAL RAILS FOR ALL DISTANCES BETWEEN ROOF BATTENS B Place top and bottom rails on mounting brackets and screw on with hammer-head bolts ( Fig. 5). Use a size SW7 spanner. SOLAR-LUX 6: INSTALLING VERTICAL RAILS FOR ROOF BATTEN SPACING OF 30-340 MM AND 380-40 MM B Place top and bottom rails on mounting brackets and screw on with hammer-head bolts ( Fig. 5). Use a size SW7 spanner. 7 Fig. 6 A B 67064603-45.ST Screwing to L-shaped connector and mounting bracket (here: at position A) CHECKING THE TIGHTNESS OF ALL HAMMER-HEAD BOLTS B Check the tightness of all hammer-head bolts []. 67064603-54.ST Fig. 7 67064603-.ST Fig. 5 Installing rails on mounting brackets 6 70 647 040 (0/05) 9
x INSTALLING THE RAILS 7. INSTALLING HORIZONTAL RAILS AND RETAINING CLIPS Horizontal rails are not always required ( Tab. and, page 8). PREASSEMBLY OF LOWER RETAINING CLIPS ON THE GROUND B Detach upper [] and lower [] retaining clips at the designated breaking point. B Install lower retaining clips [] on the bottom rail at the distances indicated and screw on with a nut and washer. Use a size SW7 spanner. Do not fasten the upper retaining clips [] to the collector and the top rail until after the collector has been installed. INSTALLING THE RAILS When installing the rails, make sure that you align them exactly (dimension x: same overhang on the right and left). Make sure that the hammer-head bolt [4] is fastened tightly. B Using the L-shaped connector [5], 4 hammer-head bolts, 4 washers and 4 nuts, connect the horizontal rail [6] to the vertical rail [7]. 7 7 x 90 90 6 5 953 90 4 0-90 450-550 60-60 300 450-550 0-90 3 0-90 450-550 60-60 450-550 60-450-550 0-90 60 007 67064603-9.ST Fig. 8 Rails and clips, all dimensions in mm Lower retaining clip Upper retaining clip 3 Horizontal rail 007 mm 4 Fastened hammer-head bolt 5 L-shaped connector for connecting the rails 6 Horizontal rail 7 Vertical rail 0 6 70 647 040 (0/05)
INSTALLING THE RAILS 7.3 INSTALLING THE RETAINING CLIPS TO VERTICAL RAILS Horizontal rails are not installed for the 0 mm vertical rail. Therefore, you must install the upper and lower retaining clips on the vertical rails. PREASSEMBLY OF LOWER RETAINING CLIPS ON THE GROUND B Detach upper [] and lower retaining clips [] at the designated breaking point. Make sure that the hammer-head bolt is fastened tightly [3]. B To fasten the lower retaining clips [], push the fastened hammer-head bolt into the rails up to the stop. Tighten with a size SW7 spanner. Do not fasten the upper retaining clips [] to the collector and the rail until after the collector has been installed. 7 0 mm 67064603-7.ST 3 Fig. 9 6 70 647 040 (0/05)
INSTALLING THE COLLECTORS 8 INSTALLING THE COLLECTORS Once the mounting brackets and the rails with the retaining clips have been installed, the collectors can be fastened. DANGER: Risk to life through falling parts! B During installation, secure the collectors to prevent them falling. Wait to tighten the upper retaining clips until the collectors are screwed to each other. B Install the upper retaining clips [ or ] the same way as the lower retaining clips [3]. WARNING: Risk of injury from broken glass. B When handling the collectors, always wear protective gloves and goggles. NOTE: Collector damage from evaporation in the solar circuit. B Leave the sun protection film on the collector until the collector has been purged and filled. However, it must not be exposed to the elements for more than 4 weeks. B Fit a suitable sun protection cover for longer periods of time. B Please observe all guidelines for working at height. 8. INSTALLING THE FIRST COLLECTOR Align the first collector in such a way that during installation all collectors have the same overhang over the rails to the right and left. Fig. 30 Collector fastened to the horizontal rails Upper retaining clip for horizontal rail Upper retaining clip if only vertical rails are available 3 Lower retaining clip 3 67064603-9.ST B Place the packed collector on the rails. B Open the packaging at the bottom. The collector can now slide into the lower retaining clips [3]. This clip must fully grip the collector profile. B For the 300 mm horizontal rail, push the outer edge of the collector to the middle of the rail. Once all the collectors are installed, the overhang on the sides will be the same. 6 70 647 040 (0/05)
INSTALLING THE COLLECTORS 8. INSTALLING THE SECOND COLLECTOR The connection fitting ( Fig. 3) on the right-hand side of the collector connects the two collectors. B Place the second collector on the rails and push it towards the collector that is already installed. B Align the collectors on the rails in such a way that the overhang on the right and left is the same. NOTE: Collector damage through overtightening. B Hold the connection nipple [4] using a size SW spanner. B Tighten the nuts [] using a size SW4 spanner. 4 8.3 INSTALLING THE COLLECTOR SENSOR The collector sensor is supplied with the solar pump station, control or seperately as part of a first fix kit and must be installed in the collector connected to the (hot) flow pipe ( page 9, 0). NOTE: System damage through faulty sensor cable. B Protect the cable from possible damage. The collector sensor must be correctly installed to ensure proper operation of the solar thermal system. B Push the collector sensor [] 90 mm into the sensor well (to the end-stop). 3 4 5 90 mm 67064603-8.ST 67064603-3.ST Fig. 3 Installing the collector sensor Fig. 3 Connecting the collectors with each other hydraulically Left-hand collector Union nut (already assembled) 3 Olive (already assembled) 4 ½ connection nipple 5 Right-hand collector B Install all other connectors the same way. B Tighten upper retaining clips with a size SW7 spanner ( Fig. 30). CAUTION: Risk of scalding from fittings that have not been tightened. B Check that all fittings have been tightened. 6 70 647 040 (0/05) 3
INSTALLING THE COLLECTORS 8.4 INSTALLING THE CONNECTION COVER SET (ACCESSORY) To improve the appearance of the area between two connectors, you can install the connection cover set as an accessory. STANDARD DELIVERY x insulation piece (45 mm wide, 9 mm thick) with self-adhesive closure x cover (70 mm wide) x securing bar (8 x 0 x 80 mm) with screw (4. x 9 mm) x connection plug with metal pin TOOL Screwdriver (Phillips), hammer INSTALLATION The collectors must be exactly aligned prior to installation.. Place the insulation piece over the fitting from below and seal using the self-adhesive tab.. Push the cover onto the insulation. 3. Fasten the cover to the back side of the collector with the securing bar. The new connection plugs hold together the two collector frames, maintaining the correct dimensions.. Remove the original plugs from the collector frame profiles.. Inserting the new connection plugs into the profiles. 3. Drive the metal pin into the plug with the hammer... 67064603-4.ST. 3. Fig. 34 Bottom of collector: exchanging the plugs. 3. 67064603-4.ST Fig. 33 Top of collector at manifold: installing insulation piece and cover 4 6 70 647 040 (0/05)
HYDRAULIC CONNECTIONS 9 HYDRAULIC CONNECTIONS Refer to the "Solar pump station" instructions for information on laying the pipes between the components (collectors, solar pump station, solar cylinder). B Connect piping below the roof to the 5 mm olive fitting of the connection pipe (use size SW30 spanner). NOTE: All roof work should be carried out by qualified personnel to ensure water tightness. Feed sensor cable together with the flow pipe through the roof. CONNECTING PIPEWORK The hydraulic connection to the piping under the roof is made using the m long flexible connection pipes. They can be bent a maximum of 90. NOTE: Collector damage through over tightening. B Hold connection pipe [4] using a size SW4 spanner. B Use a second size SW4 spanner to tighten the nuts []. 67064603-0.ST Fig. 36 Assembled connection pipe and roof outlet 3 4 4 4 67064603-36.ST Fig. 35 Fitting for connection pipe and collector Collector Union nut (already assembled) 3 Olive (already assembled) 4 Connection pipe (already insulated) 6 70 647 040 (0/05) 5
HYDRAULIC CONNECTIONS INSTALLING THE SHUT-OFF VALVE (ACCESSORY) For collector arrays consisting of several rows of collectors connected in parallel, each collector array must be purged and vented separately. In order to do so, each row of collectors requires a shut-off valve in the flow. NOTE: Collector damage from overpressure. The piping between the collector and the expansion vessel (EV) or safety valve must not be shut off. To purge and vent a row of collectors, always open the shut-off valve for this row only. The other shut-off valves remain closed. Open all shut-off valves after purging and venting. Observe the additional notes on pressure filling in the instructions for the solar pump station as well as the filling station. B Install the shut-off valve with the olive fittings ( fittings supplied) in the flow of the collector. 4 67064603-4.ST 3 Fig. 37 Three-row connection (with shut-off ball valve), here: flow on the left Collector sensor Flow pipe (to the cylinder) 3 Return pipe (from the cylinder) 4 Shut-off valve 6 6 70 647 040 (0/05)
FINAL ACTIVITIES 0 FINAL ACTIVITIES 0. CHECKING THE INSTALLATION Checks Once the following checks have been performed, you can carry out the final insulation activities.. Are all connection fittings tightened?. Are all threaded fittings on rails, mounting brackets and retaining clips tightened? 3. Is the collector sensor inserted up to the end-stop? Tab. 4 0. PRESSURE FILLING, PURGING, VENTING The solar thermal system must be filled by means of pressure filling, purged and vented. Observe the notes on pressure filling in the installation instructions for the solar pump station as well as the filling station. NOTE: Collector damage from frost. B Carry out pressure filling using LS heat transfer medium for purging and filling the system. Do not use water because the collectors cannot be drained! 0.3 ADJUSTING THE PRE-CHARGE PRESSURE OF THE EXPANSION VESSEL Before filling the solar thermal system, check the precharge pressure of the expansion vessel. The expansion vessel pre-charge pressure is calculated from the static system head plus.7 bar (static system head = difference in head between the expansion vessel connection and the top edge of the collector; metre difference in head corresponds to 0. bar). Example: 0 m difference in head corresponds to.0 bar plus.7 bar =.7 bar. B Correct the pre-charge pressure of the expansion vessel, if necessary. 0.4 DETERMINING AND SETTING THE OPERATING PRESSURE After carrying out pressure filling and purging as well as a pressure test ( solar pump station instructions), you must determine and set the required operating pressure. For information on how to proceed, please refer to the instructions for the solar pump station. The operating pressure is calculated from the static system head plus.0 bar (static system head = difference in head between the expansion vessel connection and the top edge of the collector; metre difference in head corresponds to 0. bar). Example: 0 m difference in head corresponds to.0 bar plus.0 bar = 3.0 bar. 0.5 ADJUSTING THE FLOW RATE Observe the information in the installation and maintenance instructions for the solar pump station (chapter entitled "Adjusting the flow rate"). Flow rate in l/min (for flow temperature of 0 C) Number of collectors Tab. 5 0.6 INSULATING PIPING Solar-Lux 6 (l/min) Solar-Lux (l/min) --.0.0 4.0 3 3.0 5.5 4 4.0 -- 5 4.5 -- 6 5.5 -- Flow rate to be adjusted for non-variable speed solar controllers subject to the number and type of collectors ON-SITE INSULATION OF PIPING B Use insulation resistant to UV light and high temperatures for outdoor piping. B Use insulation resistant to high temperatures for indoor piping. B Make the insulation bird-proof. 6 70 647 040 (0/05) 7
REPLACING INDIVIDUAL TUBES REPLACING INDIVIDUAL TUBES You can tell when a tube is broken because the silver deposits in the bottom part of the tube will have turned white. WARNING: Risk of injury from broken glass. B When handling the collectors, always wear protective gloves and goggles. B Apply soapsuds or lubricant paste to the top of the tube. B Turning the tube slightly, push it through the silicone ring into the manifold. B Place the tube holder [] on the end of the tube, push it in between the notches in the aluminium profile and engage it in the groove. B Pull down the tube into the tube holder to the endstop. 4 3 67064603-34.ST Fig. 38 Silicone ring Tube holder 3 Release lever 4 Tube REMOVING A MECHANICALLY DESTROYED TUBE B Carefully remove broken glass without damaging the surface of the CPC mirror. B Remove tube holder [] at the bottom. REMOVING A TUBE IS NOT MECHANICALLY DESTROYED B To remove the tube holder [] at the bottom, push up the tube 5 mm into the manifold and push down the two release levers [3] on the right and left using your thumb and pointer finger. B Lift the tube holder toward the manifold to release it. B Lift the tube somewhat and turn it about the longitudinal axis to pull it straight down and out. INSTALLING THE TUBE Install the new tube [4] the same way that you removed the old tube. Make sure that the silicone ring [] fits tightly in the manifold. 8 6 70 647 040 (0/05)
ENVIRONMENTAL PROTECTION / DISPOSAL ENVIRONMENTAL PROTECTION / DISPOSAL Environmental protection is our principal policy. Quality of performance, efficiency and environmental protection are equally important objectives for us. All legislation and regulations pertaining to the environment are strictly observed. To protect the environment, we use the best possible technology and materials. DISPOSAL At the end of their service life, materials should be recycled in the most environmentally compatible method of recycling. 6 70 647 040 (0/05) 9
MAINTENANCE/INSPECTION 3 MAINTENANCE/INSPECTION DANGER: Risk to life through falls and falling parts! B Take appropriate action to prevent accidents during all work on roofs. B Take precautions against a possible fall. B Always wear personal protective clothing and safety equipment. The collector array must be inspected at regular intervals (inspection). Defects must be remedied immediately (maintenance). We recommend conducting the first maintenance/inspection after about 500 operating hours, and then at intervals of - years. Use the table to make copies to ensure that activities are documented after the third time maintenance is conducted. B Fill out the report and tick off the tasks performed. Owner: Site location: Maintenance and inspection work Page Maintenance/inspection Date. Visual inspection of the collectors carried out (glass tubes fit tightly, appearance)?. Collector sensor is positioned correctly and is inserted into the sensor well to the end-stop? 3 3. Visual inspection of the installation system carried out? 4. Visual inspection for leaks carried out at points where installation system meets the roof? 5. Visual inspection of pipe insulation carried out? Notes The collector array has been serviced as specified by these instructions. Date, stamp, signature Date, stamp, signature Date, stamp, signature Tab. 6 30 6 70 647 040 (0/05)
NOTES 6 70 647 040 (0/05) 3
WORCESTER, BOSCH GROUP: TECHNICAL SUPPORT: 0844 89 3366 APPOINTMENTS: 0844 89 3000 SPARES: 0905 7557 LITERATURE: 0844 89 9800 TRAINING: 0905 7556 SALES: 0905 75640 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 89 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 70 647 040