FK240 FLAT SOLAR COLLECTORS ROOF-TOP INSTALLATION FOR WORCESTER SOLAR SYSTEMS G INSTALLATION INSTRUCTIONS
About ths manual Ths nstallaton manual contans mportant nformaton for the safe and approprate nstallaton of the roof mounted solar panels. Notes are ncluded wth mportant nformaton for stuatons n whch there s no danger for persons or equpment. These techncal documents should be retaned n a safe place. These may also be nspected at the manufacturer's premses. The actvtes descrbed n the nstallaton manual assume expertse based on completed vocatonal tranng n gas or water-related nstallaton. Only carry out these nstallaton steps, f you possess these sklls. Hand these nstallaton nstructons to the customer. Explan to the customer the functon and operaton of the related devces. RECYCLING At the end of ther servce lfe, collectors may be returned to the manufacturer. Materals wll be recycled n an envronmentally approprate manner. 2 6 720 62 202 (05.03)
Contents General nformaton..........................................4 2 Specfcatons...............................................5 3 Safety.....................................................6 3. Correct use...............................................6 3.2 Notes structure.............................................6 3.3 Please observe these safety nstructons.............................7 4 efore the nstallaton.........................................9 4. General notes..............................................9 4.2 Component descrpton....................................... 0 4.3 Takng measurements........................................ 4 5 Preassemblng profle rals.................................... 6 5. Connectng profle rals....................................... 6 5.2 Installaton of the collector holder brdge............................ 7 5.3 Installaton of the lateral collector holder............................. 8 5.4 Installaton of antslp protecton.................................. 8 6 Installaton of profle rals and roof hooks........................ 9 6. Settng clearances.......................................... 20 6.2 Pantle or brck tle rdge...................................... 2 6.3 Crown tle rdges........................................... 24 6.4 Slate/shngle rdges......................................... 26 7 Collector nstallaton......................................... 27 7. Placng and connectng collectors n the collector holders................. 28 7.2 Securng collectors......................................... 30 8 Header connecton.......................................... 32 8. Water connecton acc. to the Tchelmann prncple...................... 32 8.2 Always ensure the system s properly vented......................... 33 8.3 Connecton flow and return lnes................................. 34 8.4 Connecton of ar trap and ventng valve (accessory).................... 36 8.5 Dummy plug nstallaton....................................... 37 9 Collector sensor connecton................................... 38 0 Insulatng the connecton and header ppes....................... 39 6 720 62 202 (05.03) 3
General nformaton General nformaton Ths chapter detals whch techncal rules and regulatons apply to ths nstallaton. Observe all standards and gudelnes applcable to the nstallaton and operaton of ths system n your country. Installaton work on roofs The Health and Safety at Work etc Act 974 The Management of Health and Safety at Work Regulatons 999 The Constructon (Health Safety and Welfare) Regulatons 996 The Constructon (Desgn and Management) Regulatons 994 The Lftng Operatons and Lftng Equpment Regulatons 998 Tab. UK Connecton of thermal solar heatng systems EN 2976: Thermal solar heatng system and ther components (prefabrcated systems). ENV 2977: Thermal solar heatng system and ther components (bespoke systems). S 598: Latest verson: Solar heatng systems for domestc hot water. Techncal rules for the nstallaton of thermal solar heatng systems (selecton) n UK Installaton and equpment of DHW cylnders S5546: 2000 Specfcaton for nstallaton of hot water supples for domestc purposes, usng gas-fred applances of rated nput not exceedng 70 kw. S6700:997 Specfcaton for desgn, nstallaton, testng and mantenance, of servcng supplyng water for domestc use wthn buldngs and ther curtlages. VO: Contract procedures for constructon work, part C: General techncal condtons of contract for constructon servces (ATV). 2 Terms of nvtatons to tender for constructon servces gvng specal consderaton to the constructon of lvng accommodaton. The nstallaton of the Worcester Solar System must be carred out n accordance wth the relevant requrements for safety, current IEE wrng regulatons, local buldng regulatons, buldng standards (Scotland) (Consoldaton) regulatons and by-laws of the local water company and health and safety document No 635 (Electrcty at Work Regulatons 989). S 598: Latest verson 4 6 720 62 202 (05.03)
Specfcatons 2 Specfcatons FK240 Length 25 mm Wdth 35 mm Heght 2 mm Clearance between collectors 40 mm Absorber lqud content.5 l Gross absorber surface area 2.4 m² Net absorber surface area 2. m² Net weght approx. 43 kg Permssble collector operatng pressure 3 bar Type approval code 08-228-762 Tab. 2 FK240 Specfcatons 6 720 62 202 (05.03) 5
Safety 3 Safety Ths chapter detals the safety nstructons n general and the meanng of user notes. You wll fnd the safety and user notes, whch specfcally refer to the nstallaton, n ths chapter and n the nstallaton manual,.e. mmedately followng the ndvdual nstallaton steps. Carefully read the safety nstructons before commencng the nstallaton on the roof. Severe njury as well as materal losses and envronmental damage, may follow f you gnore safety nstructons. 3. Correct use Ths nstallaton set holds the thermal solar collectors, whch are nstalled on slopng roofs wth a slope of 25 to 60. Operatng condtons Only erect the nstallaton set on roofs whose constructon can support the weght. If necessary, consult a structural engneer or a roofer. The nstallaton set s sutable for a standard snow load of 2.24 kn/m². If the nstallaton set s nstalled n a roof wth a slope of 45, the approved snow load s 3. kn/m². The mountng kt must not be used for fxng any other objects to the roof. The kt s ntended exclusvely for the safe fxng of solar collectors. 3.2 Notes structure Two levels are dentfed by sgnal terms: RISK TO LIFE WARNING! Identfes possble dangers whch mght lead to serous njury or death f approprate care s not taken. 6 6 720 62 202 (05.03)
Safety RISK OF INJURY/SYSTEM DAMAGE CAUTION! Identfes potentally dangerous stuatons, whch mght lead to mld or slght njures or to materal losses. Further symbols dentfyng dangers and user notes: RISK TO LIFE from electrc shock. WARNING! Tp for the optmum utlsaton and settng of the products plus other useful nformaton. 3.3 Please observe these safety nstructons RISK TO LIFE WARNING! through a fall or fallng parts. Ensure you have the correct safety equpment for workng on roofs. Take approprate acton to prevent accdents when workng on roofs. Whlst workng on the roof, take all necessary precautons aganst a possble fall. Always wear your personal protectve clothng and safety equpment. After completng the nstallaton, always check the secure postonng of the nstalled set and that of the collectors. RISK OF INJURY CAUTION! Injury and operatng faults can result from makng changes to the system constructon. Never change the system constructon. 6 720 62 202 (05.03) 7
Safety RISK OF INJURY CAUTION! Some parts may cause burns, f the collector and nstallaton materals are exposed to solar radaton for longer perods of tme. Always wear your personal protectve clothng and safety equpment. Cover the collector (e.g. wth a sheat) and the nstallaton materal durng the nstallaton as protecton aganst hgh temperatures resultng from solar rradaton. 8 6 720 62 202 (05.03)
efore the nstallaton 4 efore the nstallaton 4. General notes Make yourself famlar wth the on-ste condtons and local regulatons before commencng the nstallaton. RISK OF INJURY CAUTION! Some parts may cause burns, f the collector and nstallaton materals are exposed to solar radaton for longer perods of tme. Always wear your personal protectve clothng and safety equpment. Cover the collector (e.g. wth a sheet) and the nstallaton materal durng the nstallaton as protecton aganst hgh temperatures resultng from solar rradaton. Check the delvery for completeness and perfect condton. the optmum arrangement of the solar collectors. Take account of the drecton of the sunlght (angle of nclnaton, southerly drecton). Avod the shade of hgh trees or structures and locate the collectors accordng to the shape of the buldng (e.g. algned wth wndows, doors, etc.). Only use OEM components and replace any damaged or faulty parts mmedately. Fg. General overvew of collector par roof mountng Remove broken roof tles, shngles or plates n the area of the collectors and have them replaced. 6 720 62 202 (05.03) 9
efore the nstallaton 4.2 Component descrpton You wll need an extenson set for the second and every subsequent collector and a basc ppework set for every collector array. 4.2. asc set (per collector array for the frst collector) Fg. 2 Item : Profle rals 2 Item 2: Antslp devce Item 3: Standard collector clps, ncl. spacers 4 Item 4: Collector holders 4 Others: Varous small components 4 3 2 4.2.2 Extenson kt (for each addtonal collector) Fg. 3 Fg. 2 asc set Item : Ral connector 2 Item 2: Profle rals 2 Item 3: Collector holder lnk, ncl. spacers 2 Item 4: Double clps, ncludng protectve caps 2 Item 5: Antslp devce Others: Varous small components 5 4 3 2 Fg. 3 Extenson set 0 6 720 62 202 (05.03)
efore the nstallaton 4.2.3 asc ppe set (per collector array) Fg. 4 Item : Cable clamp for collector sensor Item 2: SW 5 Allen key Item 3: solar hoses, length 000 mm 2 Item 4: solar hoses, length 60 mm (spare) 2 Item 5: Hose couplngs 2 Item 6: Hose clps (ncludng x spare) 7 Item 7: Dummy plug 2 Others: Varous small components 3 2 4 6 5 7 4.2.4 Roof hook nstallaton set (for pantle and brck rdges) Fg. 5 Fg. 4 asc ppework set Item : Roof hook 4 Varous small components Fg. 5 Roof hook nstallaton set 6 720 62 202 (05.03)
efore the nstallaton 4.2.5 Roof hook addtonal nstallaton set (for pantle and brck rdges; accessores, per collector) Fg. 6 Item : Addtonal roof hooks 4 4.2.6 Specal roof hook nstallaton set (for slate, shngle and crown tle rdges; accessores; per collector) Fg. 7 Fg. 6 Roof hook addtonal nstallaton set accessores Item : Specal roof hooks 4 Others: Varous small components Fg. 7 Specal roof hook nstallaton set accessores 2 6 720 62 202 (05.03)
efore the nstallaton 4.2.7 Specal roof hook nstallaton set (for crown tle rdges; accessores, per collector) Fg. 8 Item : Specal roof hook accessores 4 Others: Varous small components 4.2.8 Other requred tools and equpment SW 3, 27 spanners Sprt level Sucton pump (recommended but not requred) Vest harness wth safety rope Ppe nsulaton Scaffoldng (where requred by law) Roofng ladder Fg. 8 Specal roof hook nstallaton set accessores 6 720 62 202 (05.03) 3
efore the nstallaton 4.3 Takng measurements Carefully select the locaton of the collector array on the roof, and note the correct collector orentaton. 4.3. Estmate your space requrements Plan suffcent roof area for vertcal nstallaton. These dmensons relate to the roof surface area, whch must be avalable. The dmensons stated relatng to space requrements are smply the wdth of the collector array. In addton, allow at least 0.5 m on ether sde of the collector array for ppework (Fg. 9). If you nstall a vent, suffcent space around the flow ext must be planned durng nstallaton. Fg. 9 Space requred for collector array 4 6 720 62 202 (05.03)
efore the nstallaton 4.3.2 Please observe these dmensons Dmenson A and Dmenson A and (Fg. 0) correspond to the area requred for the selected number and layout of the collectors. Dmenson C Dmenson C represents at least two tles to the rdge. There s a rsk of damagng the tles at the roof rdge, partcularly f the tles are lad n mortar. Dmenson D Dmenson D corresponds to the roof heght ncludng the gable wall. The adjacent 50 cm clearance to the collector array s requred under the roof on the rght or left dependng on the type of connecton. Dmenson E Dmenson E corresponds to at least 30 cm, whch s requred n the attc for nstallaton of the connecton ppes. Dmenson F Dmenson F corresponds to at least 40 cm, whch s requred n the attc for nstallaton of the connecton ppes. Fg. 0 Space requred for collector array Space requrement Number of collectors Dmenson A Dm. 2 2,34 m 2,20 m 3 3,5 m 2,20 m 4 4,68 m 2,20 m 5 5,85 m 2,20 m 6 7,02 m 2,20 m 7 8,9 m 2,20 m 8 9,36 m 2,20 m 9 0,53 m 2,20 m Tab. 3 Space requrement for vertcally nstalled collectors 6 720 62 202 (05.03) 5
Preassemblng profle rals 5 Preassemblng profle rals efore startng the nstallaton on the roof, the profle rals for a maxmum of three collectors can be preassembled on the ground. Fg. Preassembled profle rals for two adjacent collectors 5. Connectng profle rals If you wsh to preassemble multple collectors (at least two), the ndvdual profle rals (top and bottom) must be connected wth ral connectors (Fg. 2, Item and 2). Slde the ral connectors (Fg. 2, Item ) untl they lock (Fg. 2, Item 3) n the profle rals. 4 3 2 Fg. 2 Item : Item 2: Item 3: Item 4: Pluggng profle rals together Plug connector Ral connector (back) Lock Drlled hole 6 6 720 62 202 (05.03)
Preassemblng profle rals 5.2 Installaton of the collector holder brdge The threaded plates (Fg. 3, Item ) are preassembled at the factory wth the panhead screws (Fg. 3, Item 2) to the collector holder lnk (Fg. 3, Item 4). The threaded plates have a self-lockng, tght thread. 2 3 4 Poston the two collector holder lnks centrally Fg. 3 on the two profle rals (above the ral connector). A drlled hole (Fg. 2, Item 4, page 6) s present n the ral connector to check that the collector holder lnk s centrally postoned. Make sure that the spacer block (Fg. 3, Item 3 and Fg. 4, Item ) s at rght angles to the profle rals on the frame. Now fasten the collector holder lnk to the underlyng profle rals and ral connectors wth the preassembled threaded plates and pan-head screws. Fg. 3 Item : Item 2: Item 3: Item 4: Installaton of the collector holder brdge Threaded plate (preassembled) Pan-head screw (preassembled) Spacer block Collector holder lnk (preassembled) Pay partcular attenton to the orentaton of the threaded plates n Fg. 3. Fg. 4 Vew of the exact poston of the spacer block 6 720 62 202 (05.03) 7
Preassemblng profle rals 5.3 Installaton of the lateral collector holder The lateral collector holders act as lateral ends or lmts of the collector array. Install the collector holder Fg. 5 so the edge of the threaded plate s flush wth the end of the profle ral. The threaded plate must not protrude under any crcumstances. Attach the collector holders wth the preassembled threaded plates (self-lockng, tght thread; Fg. 5, Item 2) and pan-head screws (Fg. 5, Item ). 2 Fg. 5 Item : Item 2: Securng the collector holder flush wth the profle ral Pan-head screw (M8 x 6, preassembled) Threaded plate (preassembled) 5.4 Installaton of antslp protecton To be able to nstall the collectors safely, the antslp devce (Fg. 6, Item ) must be attached and secured to the bottom profle rals. Attach the preassembled antslp devce centrally between the collector holders Fg. 6 wth the threaded plates (self-lockng, tght thread; Fg. 6, Item 3) and pan-head screws (Fg. 6, Item 2). Tghten the screws. 2 3 Fg. 6 Item : Item 2: Item 3: Attachng antslp devce Antslp devce Pan-head screw (preassembled) Threaded plate (preassembled) 8 6 720 62 202 (05.03)
Installaton of profle rals and roof hooks 6 Installaton of profle rals and roof hooks RISK TO LIFE WARNING! Whlst workng on the roof, take all necessary precautons aganst a possble fall. RISK OF INJURY CAUTION! When workng on a roof fallng parts may cause serous njury. Take approprate acton to prevent accdents when workng on roofs. Always wear your personal protectve clothng and safety equpment. For better access to the roof use a scaffold tower. Fg. 7 Profle rals wth roof hooks nstalled on a tle roof for two adjacent collectors 6 720 62 202 (05.03) 9
Installaton of profle rals and roof hooks 6. Settng clearances The dmensons gven are gude values that should be approxmately mantaned. On pantle and brck tle roofs the tle troughs determne the true dstance between the roof hooks. Dstances of roof hooks Every profle ral s fastened wth two roof hooks (and f requred addtonal roof hooks) (Fg. 8). See the table for the approxmate dstance between the roof hooks. Dstance w Dstance x Dstance z approx. 70 mm approx. 700 mm approx. 470 mm Tab. 4 Dstance of the roof hooks from one another Dstances x and z should always be approxmately equal to dstance w. Fg. 8 Dstance of the roof hooks from one another Dstances of profle rals Set the dstance (Fg. 9) between the top and bottom profle rals. Use the table values. from Dstance y to 650 mm 690 mm Tab. 5 Dstance (centre-centre) between bottom and top profle ral The top profle ral must be between the sensor pocket and the collector connecton. Fg. 9 Dstance of the profle rals from one another 20 6 720 62 202 (05.03)
Installaton of profle rals and roof hooks 6.2 Pantle or brck tle rdge Always nstall all roof hooks (and addtonal roof hooks f requred) followng the reference values specfed n the tables on page 20. Do not modfy the roof constructon and avod damagng the roof coverng. In the case of rdge tles lad n mortar, lft the tles startng wth the 3rd row under the rdge. Fg. 20 Vew of attached roof hooks and addtonal roof hooks 6.2. Attachng roof hooks Lft the correspondng pantle or brck tle (Fg. 2). Attach the roof hook to the roof battens and poston t wth the bottom n a tle trough. If necessary, knock off the base of the tle so t wll le correctly back on top of the roof hook. Mark the dstance of the profle rals on the roof hook. If the tles overlap more than 95 mm, they must be notched n the area of the roof hook. Fg. 2 Attachng roof hooks 6 720 62 202 (05.03) 2
Installaton of profle rals and roof hooks 6.2.2 Attachng addtonal roof hooks (accessores) Addtonal roof hooks are requred as well as the roof hook f: the roof slope s less than 30. the dstance to the edge of the roof or rdge s greater than three pantles or brck tles. wnd forces are expected. Lft the correspondng pantle or brck tle (Fg. 22). Take the addtonal roof hook and gude t dagonally under the pantle or brck tle. The addtonal roof hook must be attached to the roof batten and be n contact wth the roof hook above. 6.2.3 Installng profle rals Always start wth the bottom profle ral. Fg. 22 Attachng addtonal roof hooks Place the profle rals that were preassembled on the nstalled roof hooks (Fg. 23). As specfed n Table 5, page 20 the profle ral should be postoned as far down the hook as possble (the collector later covers the addtonal roof hook as far as possble). We recommend a batten gauge to mantan the correct dstance of the profle rals. Algn the profle rals horzontally. Connect the profle rals and roof hooks wth nuts, shms and pan-head screws. Fg. 23 Screw preassembled profle ral to roof hook and addtonal roof hook 22 6 720 62 202 (05.03)
Installaton of profle rals and roof hooks 6.2.4 Algnng profle rals Algn the top profle rals to the sde flush wth the bottom profle rals (Fg. 24). Measure the dagonals or place a roof batten on the collector holders of the profle rals. The angle between roof batten and profle ral must be 90. Fg. 24 Algnng profle rals 6 720 62 202 (05.03) 23
Installaton of profle rals and roof hooks 6.3 Crown tle rdges Consult a roofer when nstallng on a roof wth crown tles. Durng nstallaton mantan the requred dstances (w, x and y) between the specal roof hooks and addtonal roof hooks (Table 4 and 5, page 20). UILDING DAMAGE CAUTION! caused by leaks. Install every specal roof hook and addtonal roof hook on the centre of a crown tle. Install the specal addtonal roof hooks (accessores: condtons of use see Chapter 6.2.2 "Attachng addtonal roof hooks (accessores)", page 22) centrally on the crown tles wth the ncluded screws (Fg. 25). Cut the adjacent crown tle (Fg. 25, dashed lne). Attach the crown tle to the roof batten (Fg. 26). Fasten the specal addtonal roof hooks to the roof batten f necessary, addtonal roof hooks must be nstalled or the roof battens cut out so the crown tles le flat agan. Fg. 25 Cut crown tle and nstall specal addtonal roof hooks (accessores) Fg. 26 Fastenng crown tles 24 6 720 62 202 (05.03)
Installaton of profle rals and roof hooks Place the second row of crown tles (Fg. 27) and fasten them n place. Install the specal roof hooks (Fg. 28) wth the ncluded screws. Fg. 27 Installng second row of crown tles Cut the adjacent crown tles (Fg. 29) and fasten them to the buldng. Fnsh the roof. Install the profle rals (see Chapter 6.2.3 "Installng profle rals", page 22). Fg. 28 Installng specal roof hooks Fg. 29 Cuttng and nstallng crown tles 6 720 62 202 (05.03) 25
Installaton of profle rals and roof hooks 6.4 Slate/shngle rdges A roofer should carry out the nstallaton wth slates or shngles. Here s an example of the nstallaton of the specal roof hooks and the watertght seal wth on-ste flashng (Fg. 3, Item 4 and 6) wth a slate/shngle rdge. Ft the slate/shngle rdge accordng to the condtons on ste. Durng nstallaton mantan the requred dstances (w, x and y) between the specal roof hooks and addtonal roof hooks (Table 4 and 5, page 20). Install the specal roof hook (Fg. 3, Item 5) and the seal (Fg. 3, Item 2 and 7) on the slate/shngle rdge wth the ncluded screw (Fg. 3, Item 3). To ensure that the nstallaton s watertght, flashng must be nstalled or postoned on the buldng above and below the specal roof hooks (Fg. 3, Item 4 and 6). Fg. 30 Specal roof hook fully nstalled 4 The specal roof hooks must be postoned on the front of a multple rdge (Fg. 3, Item ). 3 5 2 6 7 Fg. 3 Item : Item 2: Item 3: Item 4: Item 5: Item 6: Item 7: Installng specal roof hooks on a multple rdge Vew of the multple rdge Seal (on buldng) Screw Flashng (on buldng) Specal roof hooks Flashng (on buldng) Seal (on buldng) 26 6 720 62 202 (05.03)
Collector nstallaton 7 Collector nstallaton Observe the followng safety and user nstructons when commencng the collector nstallaton. RISK TO LIFE through a fall or fallng parts. WARNING! Take approprate acton to prevent accdents when workng on roofs. Whlst workng on the roof, take all necessary precautons aganst a possble fall. Always wear your personal protectve clothng and safety equpment. After completng the nstallaton, always check the secure postonng of the nstalled set and that of the collectors. Ensure that the correct equpment s used for workng on roofs. Fg. 32 Vew of nstallaton on roof Use lftng equpment as used by roofng contractors or suffcent sucton handles for the nstallaton (for easer lftng). SYSTEM DAMAGE CAUTION! Unsecured collectors may fall durng handlng and nstallaton. 6 720 62 202 (05.03) 27
Collector nstallaton 7. Placng and connectng collectors n the collector holders CAUTION! RISK OF INJURY Install collectors wth at least one assstant. Always commence wth the rght hand collector. Poston the frst collector centrally nto the trough of the preassembled collector holders. Slde the collector (Fg. 33, Item und 2) down n front of the antslp devce (Fg. 33, Item 4). Slde the antslp devce up untl the edge of the antslp devce locks nto the groove (Fg. 33, Item 3) n the collector frame. 2 4 3 Fg. 33 Item : Item 2: Item 3: Item 4: Insertng the frst collector Collector trough Collector frame Groove on collector frame Antslp devce As standard, the hose clp s ftted to (Fg. 34, Item 2) the solar hose (Fg. 34, Item ). efore nsertng the next collectors, push the hose clps (Fg. 34, Item 2) over the pre-assembled solar hoses (Fg. 34, Item ). Ensure that the second hose clp (Fg. 34, Item 2) s located on the solar hose. 2 Fg. 34 Item : Item 2: Return Flow Pull the hose clp over the solar hose. Pre-assembled solar hose Hose clp 28 6 720 62 202 (05.03)
Collector nstallaton Whlst nsertng the next collector, push the preassembled solar hoses onto the connectons of the prevously nstalled collector (Fg. 35). Then place the collector nto the collector holders. SYSTEM DAMAGE CAUTION! It s only possble to adjust the locaton of the hose clp wth the blue clampng rng stll n place and the clp n the open state. The clp should not be slackened wth plers, to avod damage to the corroson resstant coatng on the hose clp. RISK OF INJURY CAUTION! Only pull the blue rng from the clp when the solar hose s n the correctly nstalled poston. Fg. 35 Insertng the second collector and tghtenng the hose clp The blue clampng rng must be removed from the hose clp to close or secure the solar hose. 6 720 62 202 (05.03) 29
Collector nstallaton 7.2 Securng collectors Secure the collectors wth the collector clamps suppled. Poston the edge of the double clamp onto the glass panes of the collectors (Fg. 36). Hold the collector clamps tghtly when securng the clamps to ensure that they st n proper algnment. Ensure that the protectve caps (Fg. 36, Item ) of the double clamps are present. Secure the double clamps on the collector holders usng the pan-head screws suppled. Use the Allen key SW5 to secure the collector clamps. Fg. 36 Securng collectors centrally 30 6 720 62 202 (05.03)
Collector nstallaton Make sure that the plastc top parts (Fg. 38, Item 4) of the two-part spacer blocks are located on the plastc bottom parts (Fg. 38, Item 5). The plastc top parts support the collector frame. Tp the collector clps slghtly forward and nsert them nto the groove n the collector frame. Secure the collector clps on the sde collector holders usng the pan-head screws suppled. Fg. 37 Securng collectors to the sde 3 4 2 5 6 Fg. 38 Item : Item 2: Item 3: Item 4: Item 5: Item 6: Dagram of nserted collector clps Collector trough Collector frame Collector clps Top spacer plastc ottom spacer plastc Collector holder 6 720 62 202 (05.03) 3
Header connecton 8 Header connecton 8. Water connecton acc. to the Tchelmann prncple Always connect the collectors accordng to the Tchelmann prncple (Fg. 39). Install the ppework so that the same volume flow s channelled to each collector. 2 3 Return 4 Flow Fg. 39 Item : Item 2: Item 3: Water connecton acc. to the Tchelmann prncple Dummy plug Automatc ar-vent valve (accessory) Temperature sensor 32 6 720 62 202 (05.03)
Header connecton 8.2 Always ensure the system s properly vented If you ntend ventng a solar heatng system wth automatc ar-vent valves at the hghest pont of the system, run your ppework rsng to the ar-vent valve. Avod frequent changes n drecton. For each change of drecton downwards and each new rse, nstall an addtonal ar trap wth ar vent. 2 3 4 If you cannot provde an automatc ar-vent valve due to space restrctons, nstall a manual ar-vent valve. 7 5 Functon of the grub screw and the weather protecton cap The solar heatng system s vented through the opened grub screw (Fg. 40, Item ). The weather protecton cap must always be postoned over the grub screw to prevent mosture enterng through the opened shut-off screw nto the solar heatng system (Fg. 40, Item 2). For solar heatng systems always use allmetal ar vents. Automatc vents wth plastc floats wll be destroyed as the lqud and steam temperatures can be n excess of 0 C. Plastc ppes (e.g. those made from polyethylene) are also unsutable for solar heatng systems. Open the ar-vent valve by unscrewng the grub screw one full revoluton. Fg. 40 Item : Item 2: Item 3: Item 4: Item 5: Item 6: Item 7: Vew ar trap wth vent valve for flow connecton (accessory) Grub screw Weather protecton cap Automatc ar-vent valve (accessory) all valve, 3/8", I/A wth wnged handle (accessory) Ar trap (accessory) Solar heatng staton header Header from the solar collectors 6 6 720 62 202 (05.03) 33
Header connecton 8.3 Connecton flow and return lnes The manfold termnates as ppelne under the roof. The connecton wth the collector array s acheved va ¾nch solar hoses (part of the basc ppework set). 8.3. Connect flow lne Remove the preassembled short solar hose (f the flow ppe s on the r.h. sde) and replace t wth the long solar hose (Fg. 4, Item 4) at the top connecton of the collector that s the last hydraulcally. 5 Fasten the long solar hose to the collector wth a new hose clp (Fg. 4, Item 5). Slde the second hose clp (Fg. 4, Item 3) over the long solar hose. 4 3 2 Do not nstall the ar vent (accessory) and the bleeder (accessory) yet. You wll need a converson kt to nstall the bleeder above the roof. It must be ordered separately. Fg. 4 Item : Return Flow Connectng flow lne and ar vent wth bleeder Ar trap and ventng valve (accessory) Item 2: Hose couplng Item 3: Hose clp Item 4: long solar hose Item 5: Hose clp On pantle or brck tle roofs feed the flow lne and the sensor cable (Fg. 42, Item and 2) nto the attc through an ar pantle (Fg. 42, Item 3) or an antenna barrel. Use a roofng company for a sheet steel roof. Use a specally shaped nsert on corrugated roofs. Connect the ar vent wth bleeder (accessores) (Fg. 4, Item ) to the hose couplng (Fg. 4, Item 2) on the long solar hose n the attc f possble. The hose couplng s ncluded wth the basc ppng set. Return Flow 2 3 Fg. 42 Layng out flow ppe and sensor cable Item : Sensor cable Item 2: Flow lne Item 3: Ar pantle 34 6 720 62 202 (05.03)
Header connecton 8.3.2 Connecton of the return ppe Durng the nstallaton ensure that the return ppe s run below the collector array rsng to the array (Fg. 43). Fasten the long solar hose (Fg. 43, Item 2) to the collector wth the hose clp. Slde the second hose clp over the long solar hose. Gude the return lne nto the attc through a sutable roof openng (e.g. sol vent cover) (Fg. 43, Item ). Slde the suppled hose couplng onto the ppe. 2 Return Flow Fg. 43 Item : Item 2: Connectng return lne sol vent cover long solar hose 6 720 62 202 (05.03) 35
Header connecton 8.4 Connecton of ar trap and ventng valve (accessory) Connect the system to the ar vent (Fg. 44, Item 4) n the flow (Fg. 44, Item 3) at the hghest pont of the system wth the suppled hose couplng. Slde the hose clp up to the ar vent. SYSTEM DAMAGE 3 4 CAUTION! It s only possble to adjust the locaton of the hose clp wth the blue clampng rng stll n place and the clp n the open state. The clp should not be slackened wth plers, to avod damage to the corroson resstant coatng on the hose clp. 2 RISK OF INJURY CAUTION! Only pull the blue rng from the clp when the solar hose s n the correctly nstalled poston. Fg. 44 Poston of ar vent wth bleeder Return Flow The blue clampng rng must be removed from the hose clp to close or secure the solar hose. Item : Item 2: sol vent cover Return lne Pull the serrated washers of the hose clps. Item 3: Flow lne Item 4: Ar trap and ventng valve (accessory) 36 6 720 62 202 (05.03)
Header connecton 8.5 Dummy plug nstallaton Seal the collector connectons, whch are not requred, usng the dummy plugs suppled wth the basc ppelne kt. To do ths, nsert the dummy plug (Fg. 45, Item ) head frst nto the short solar hose. Push the hose clp (Fg. 45, Item 2) up to the head of the dummy plug (Fg. 45, Item ). 2 Fg. 45 Item : Item 2: Return Flow Dummy plug nstallaton Dummy plug Hose clp 6 720 62 202 (05.03) 37
Collector sensor connecton 9 Collector sensor connecton Observe the nstallaton locaton for sngle or dual row collector systems. Locaton Inserton pont (Fg. 46, Item A) for sngle row collector systems. Inserton pont (Fg. 46, Item ) for dual row collector systems. Collector sensor connecton The collector sensor s part of the control unt package. A Insert the collector sensor (Fg. 46, Item ) through the compresson fttng (Fg. 46, Item 2 and 3) and push the collector sensor approx. 70 mm untl t reaches the end of the sensor pocket (Fg. 46, Item 4). 4 Return Flow Thread the bottom part of the compresson fttng (Fg. 46, Item 3) nto the sensor pocket thread (Fg. 46, Item 4). 3 2 Tghten the compresson fttng (Fg. 46, Item 2 and 3). Flow Return Fg. 46 Item : Item 2: Item 3: Item 4: Collector sensor connecton Collector sensor Upper part - compresson fttng Lower part compresson fttng Sensor pocket for collector sensor 38 6 720 62 202 (05.03)
Insulatng the connecton and header ppes 0 Insulatng the connecton and header ppes Carry out the followng nsulatng work only after completon of the pressure test and when all connectons are tght. Fnally, check the secure postonng of the nstalled set and that of the collectors. Insulaton of nternal and external manfolds For the nsulaton of external ppework, use only UV and hgh temperature resstant nsulatng materals. For the nsulaton of nternal ppework, use only hgh temperature resstant nsulatng materals, e.g. Armaflex HT for solar nstallatons. Also nsulate the connectons between the collectors. 6 720 62 202 (05.03) 39
INSTALLATION INSTRUCTIONS EXCELLENCE COMES AS STANDARD Worcester, osch Group Cotswold Way, Warndon, Worcester WR4 9SW Telephone: (0905) 754624 Fax: (0905) 75469 Worcester, osch Group s a tradng name of T Thermotechnology UK Ltd. www.worcester-bosch.co.uk 6 720 62 202 (05.03) SD