FKT SERIES FLAT PANEL SOLAR COLLECTORS ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS 63043966.01-1.
About this manual This installation manual contains important information for the safe and appropriate installation of the roof mounted solar panels. Notes are included with important information for situations in which there is no danger for persons or equipment. These technical documents should be retained in a safe place. These may also be inspected at the manufacturer's premises.
1 General information 2 Specifications . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.2 Notes structure . . . . . . . . . . . . . . . . . . .
General information 1 General information This chapter details which technical rules and regulations apply to this installation. i USER NOTE Observe all standards and guidelines applicable to the installation and operation of this system in your country. UK Installation work on roofs The Health and Safety at Work etc Act 1974 Connection of thermal solar heating systems EN 12976: Thermal solar heating system and their components (prefabricated systems).
Specifications 2 Specifications FKT Solar Panels Certificates 0036 DIN Length Width Height Clearance between collectors Fluid content, portrait version Fluid content, landscape version Gross absorber surface area Net absorber surface area Net weight, portrait version Net weight, landscape version Permissible operating pressure of the collector Tab. 2 Vf Vf AG m m pmax 2,070 mm 1,145 mm 90 mm 25 mm 1.43 l 1.76 l 2.37 m² 2.
Safety 3 Safety This chapter details how the notes for the installation instructions, as well as the general safety instructions, necessary for safe and trouble-free operation, are arranged in this manual. Safety and user notes, which specifically refer to the installation, in the installation manual immediately following the individual installation steps, are found here. Carefully read the safety instructions before commencing the installation.
Safety 3.2 Notes structure Two levels are identified by signal terms: RISK TO LIFE WARNING! Identifies possible dangers emanating from a product, which might lead to serious injury or death if appropriate care is not taken. RISK OF INJURY/ SYSTEM DAMAGE/ BUILDING DAMAGE CAUTION! Identifies potentially hazardous situations, which could lead to medium or slight injuries or to material losses.
Safety 3.3 Please observe these safety instructions RISK TO LIFE through a fall or falling parts. WARNING! B Ensure you have the correct safety equipment for working on roofs. B Take appropriate action to prevent accidents when working on roofs. B Whilst working on the roof, take all necessary precautions against a possible fall. B Always wear your personal protective clothing and safety equipment.
Before installation 4 Before installation 4.1 General notes i USER NOTE It is recommended that the services of a roofing company, who are experienced in working on roofs and will be fully aware of the risks of working at height are considered. Make yourself familiar with the on-site conditions and local regulations before commencing the installation.
Before installation 4.2 Component description 4.2.1 Installation set for the collectors i USER NOTE The installation sets are for mounting and fixing the collectors in place. 8 3 2 1 4 3 5 7 6 63043965.03-1.SD Fig. 2 Installation set for 2 collectors – 1 basic installation set, 1 extended installation set and 2 roof connection installation sets Basic installation set for each collector array and for the first collector (Fig.
Before installation 4.2.2 Hydraulic connection i USER NOTE One connection kit for each collector array will be required. The collectors are connected together by a connection set. 2 1 3 7 6 Fig. 3 5 4 63043966.03-1.SD Connection kit and connection set (illustration shows 2 portrait collectors) Connection kit, per collector array (Fig.
Before installation 4.3 Other equipment – Spirit level – Plumb line – Filling pump – Vest harness with safety rope – Pipe insulation – Scaffolding – Roofing ladder – Crane or mobile hoist i 4.4 USER NOTE When fitting the roof installation set and water connection, the only tool reqiured is the size 5 allen key from the connection kit. Transport and storage Please ensure that the corner protectors are retained. They contain pipework connection pieces which are required for installation.
Before installation 4.5 Technical documentation The solar heating system consists of various components (Fig. 6). Installation, operation and maintenance documentation is provided for each component. Accessories may be accompanied by a separate document. Item 1: Collector: instructions for roof installation are enclosed with the connection kit Item 2: Pump station: instructions enclosed with the complete station Item 3: Solar Controller: instructions are enclosed with the controller.
Before installation 4.6 Determining space required on roof Please note the following minimum space requirements. Dimension A and B Area required for the collector array. H Dimension C At least two tiles to the roof or chimney. Otherwise there is a risk of damaging the tiles, particularly if the tiles are laid in mortar. Dimension D G Roof overhang including gable wall thickness. Dimension E Minimum 30 cm for fitting the connection cables in the attic. 63043965.09-1.SD Fig.
Fitting the roof connection and profile rails 5 Fitting the roof connection and profile rails 5.1 Setting clearances The dimensions given are guide values that should be approximately maintained. i USER NOTE On pan tile roofs the tile troughs determine the true distance between the roof hooks. Distances of roof hooks Every profile rail is fastened using two roof hooks (Fig. 8). See the table for the approximate distance between the roof hooks.
Fitting the roof connection and profile rails 5.2 Pan tile roofs Fit all roof hooks according to the guide values shown in tables 5 and 6 on page 15. i i USER NOTE Do not modify the roof construction and avoid damaging the roof covering. In the case of roof tiles laid in mortar, lift the tiles starting with the 3rd row under the roof. USER NOTE Carefully cut away the base of the tile if necessary to ensure the tile lies correctly over the roof hook. 63043965.13-1.SD Fig.
Fitting the roof connection and profile rails 5.2.2 Fastening roof hooks to joists 1 Alternatively, the roof hook can also be used for fastening to the joist. 2 3 According to the roof hook positions shown in (Tab. 5 and Tab. 6, page 15), sufficiently strong boards must be attached to the joists so that the roof hook can be fitted between the joists. i USER NOTE With some roof coverings it may be necessary to underlay the lower part of the roof hook (Fig.
Fitting the roof connection and profile rails 5.3 Crown tile roofs i USER NOTE 1 Consult a roofer when installing on a roof with crown tiles. During installation, please maintain the required distances (w, x and y) between the roof hooks as detailed in (Tab. 5 and Tab. 6, page 15). According to the roof hook positions shown in (Tab. 5 and Tab. 6, page 15), sufficiently strong boards (Fig.
Fitting the roof connection and profile rails RISK TO LIFE WARNING! Whilst working on the roof, take all necessary precautions against a possible fall. RISK OF INJURY through a fall or falling parts. WARNING! B Take appropriate action to prevent accidents when working on roofs. B Always wear personal protective clothing and safety equipment. i 63043965.10-1.SD USER NOTE Fig.
Fitting the roof connection and profile rails Fitting the roof hook BUILDING DAMAGE caused by leaks. CAUTION! i B Fit each roof hook centrally on a crown tile. 1 USER NOTE If the roof battens are too close together, remove the lower part of the roof hook between the second and third holes. B Push the lower part of the hook down until it lies on the joist or on the board (Fig. 18, Item 1). 63043965.20-1.SD i USER NOTE Fig. 18 The serated washer (Fig.
Fitting the roof connection and profile rails 5.4 Corrugated sheet steel roofs Carriage bolts must be used instead of roof hooks for fastening the profile rails. 1 Standard delivery (Fig. 21): Item 1: Item 2: Item 3: Item 4: Item 5: Item 6: M8 screw Holding bracket M12 nut Washer Sealing disc M12 carriage bolt 2 4× 4× 4× 4× 4× 4× 3 4 5 6 On corrugated roofs, the peaks determine the true distance between the carriage bolts.
Fitting the roof connection and profile rails Fitting the carriage bolts i USER NOTE Using the wood drill, drill precisely at a 90° angle through the roof subframe to obtain a flat, level surface between the holding bracket and profile rail. BUILDING DAMAGE caused by leaks. CAUTION! B Never drill into a tile trough. B Drill through the corrugated metal roof using a metal drill (Ø 13 mm) taking note of the positions of the carriage bolt (see Tab. 5 and Tab. 6).
Fitting the roof connection and profile rails B Tighten the nuts (Fig. 24, Item 2) until the sealing disc (Fig. 24, Item 3) is lying completely flush on the roof. i 1 USER NOTE 2 3 B The holding bracket must be screwed fully onto the carriage bolt. Height of peak, dim. A 35 mm 40 mm 45 mm 50 mm 55 mm 60 mm Dim. B 70 mm 65 mm 60 mm 55 mm 50 mm 45 mm 63043965.25-1.SD Fig.
Fitting the roof connection and profile rails 5.5 i Slate/shingle roofs USER NOTE 1 A roofer must carry out the installation on slates or shingles. 6 Here is an example of the installation of the special roof hooks and the watertight seal with custom flashing (Fig. 26, Item 1 and 2) with a shingle/slate roof. 4 5 4 3 During installation, please maintain the required distances (w, x and y) between the special roof hooks as detailed in (Tab. 5 and Tab. 6, page 15). 2 B Fit special roof hook (Fig.
Fitting the roof connection and profile rails 5.7 Fitting additional rails (accessory) Additional measures are needed for installation heights of 20 to 100 m and/or with standard snow loads of 2.0 to 3.1 kN/m2. i USER NOTE The example here shows an installation on pan tile roofs. The additional rails can also be installed on other types of roof described in this manual. 1 Fitting additional roof hooks Additional roof hooks must be fitted for attaching the snow load profiles.
Fitting the roof connection and profile rails 5.8 Installing profile rails The profile rails must be joined together using rail connectors. Each collector has been provided with an upper and lower profile rail. 5.8.1 Connecting profile rails 1 B Push rail connector (Fig. 31, Item 1) as far as it will go into both profile rails (Fig. 31, Item 2). 2 B To lock, tighten both fitted M10 threaded studs (Fig. 31, Item 3) in the rail connector using a size 5 Allen key. 3 63043965.33-1.SD Fig.
Fitting the roof connection and profile rails 5.8.3 Aligning the profile rails B Align the upper and lower profile rails to the side flush with each other and level them (Fig. 33, use a spirit level).. i 1 USER NOTE 90° Measure the diagonals or place a roof batten (Fig. 33, Item 1), for example, at the ends of the profile rails. The angle between roof batten and profile rail must be 90°. Align the profile rails over the slotted holes. 90° 1 B Tighten the screws. i USER NOTE 63043965.35-1.SD Fig.
Collector installation 6 Collector installation Observe the following safety and user instructions when commencing the collector installation. RISK TO LIFE through a fall or falling parts. WARNING! B Take appropriate action to prevent accidents when working on roofs. B Whilst working on the roof, take all necessary precautions against a possible fall. B Always wear your personal protective clothing and safety equipment.
Collector installation 6.1 1 Preparing to install the collectors Before beginning actual installation on the roof, preassemble the end caps on the ground to make work on the roof easier. 4 To secure the end caps (and later the corrugated pipe connectors and connecting pipes as well), attach brackets to the connections. SYSTEM DAMAGE CAUTION! through leaks in the collector connections.
Collector installation 6.1.2 Fitting the end cap Not all the connections are needed when connecting a collector array. Those that are not used must be closed. 1 B Remove rubber caps (transport protection) from the relevant collector connections. B Push end cap with the O-rings (Fig. 39, Item 1) onto the collector connection. 2 B Push bracket (Fig. 39, Item 2) over the end cap and collector connection to secure the connection. 63043966.12-1.SD Fig. 39 6.
Collector installation Putting the first collector in place Lay the collector on the profile rails in such a way that the sensor bush is at the top to receive the collector sensor. Begin by laying the collectors on the right-hand side of the profile rails. 1 2 RISK OF INJURY CAUTION! 11 Install collectors with at least one assistant. B Place the first collector onto the profile rails and allow it to slide into the anti-slip protectors (Fig. 42).
Collector installation Fitting corrugated pipe connectors to the first collector B Remove the rubber caps from the connections. B Push corrugated pipe connectors (Fig. 45, Item 1) onto the left-hand connections on the first collector. B Push bracket (Fig. 45, Item 2) over the corrugated pipe connector and collector connection to secure the connection. 1 2 63043966.11-1.SD Fig.
Collector installation B Tighten the screw on the double-sided collector clamp using the size 5 Allen key. i USER NOTE When the screw is tightened, the plastic lugs at the pre-determined cut-off points break away. 1 The grip (Fig. 48, Item 1) on the collector clamp now grips the lower collector edges. Repeat the procedure for all the other collectors. 63043965.48-1.SD Fig.
Collector sensor connection 7 Collector sensor connection i USER NOTE B The collector sensor is supplied with the solar controller. A Observe the installation location for single or dual row collector systems (Fig. 50). SYSTEM DAMAGE through faulty sensor cable. CAUTION! 1 2 B Protect the cable from possible damage. Insertion point The collector sensor must be fitted in the collector nearest to the flow connection (Fig. 50, Item 2). – Insertion point (Fig.
Header connection 8 Header connection Information on laying the header pipes can be found in the complete station installation instructions. 1 The pipework connection to the header pipes is made using the long flexible connection pipes. It is not permitted to connect a fixed header pipe directly to the collector. i USER NOTE Use standard ventilation tiles or lead flashing when laying the connection pipes under the roof. 2 Use a specialist company to route the connection pipes under the roof.
Header connection 8.2 De-airing through air vent (accessory) on roof If you intend to vent the solar heating system with an automatic air-vent valve (accessory) at the highest point of the system, run the flow line rising to the air-vent valve (Fig. 54, Item 2) and the return line rising to the collector array (Fig. 54). 2 1 Avoid frequent changes in direction. i User note: For each change of direction downwards and each new rise, install an additional with air vent.
Header connection 8.2.1 Fitting the air vent valve under the roof B Push connection pipe (Fig. 56, Item 3) onto the flow connection on the collector array and fix in place using bracket (Fig. 56, Item 5). B Feed connection pipe together with the sensor cable through the ventilation tile (Fig. 56, Item 4) and through the roof insulation. 5 Perform the same procedure with the return connection. B Remove nut and compression fitting from connection pipe. B Firmly screw connection pipe (Fig.
Header connection 8.2.2 Fitting the air vent valve on the roof 1 To connect the connection pipe to the air vent (flow connection), the elbow must be removed from the connection pipe and the double threaded fitting fitted. 2 B Cut elbow (Fig. 57, Item 1) from connection pipe using pipe cutter. 3 B Push union nut over the connection pipe. 3. 4 Making the sealing face: B Place clamping disc (Fig. 57, Item 2) behind the first rib and press together.
Fitting the connection set for two rows (accessory) 9 Fitting the connection set for two rows (accessory) The connection set (Fig. 59, Item 9) is available as an accessory, and connects two rows of collectors. i 8 7 USER NOTE 6 Fit as many connection parts as possible to the collectors on the ground. This makes installation on the roof easier. 1 5 4 1 Scope of supply (Fig.
Final activities 10 Final activities 10.1 Checking the installation SYSTEM DAMAGE CAUTION! through corrosion if water remains in the solar heating system for an extended period after it has been flushed or after a pressure test. B Start up the solar heating system immediately after flushing/pressure test with solar fluid (for instructions on flushing/pressure test see pump station instructions). Otherwise, carry out flushing/pressure test later.
Final activities 10.2 Insulating the connection and header pipes B Cut enclosed insulation (710 mm long) into 88 mm lengths and place around the corrugated pipe connectors between the collectors. Insulation of the manifolds in internal or external installations – For the insulation of external pipework, use only UV and high temperature resistant insulating materials, rated to 150 °C. – For the insulation of internal pipework, use only high temperature resistant insulating materials, rated to 150 °C.
Quick reference guide for pan tile roof and pressure filling 11 Quick reference guide for pan tile roof and pressure filling These instructions are only intended as an overview of the work to be carried out. You MUST follow the detailed descriptions for the work on the pages mentioned, and all safety and user instructions. 11, 14 6 4 5 8, 10 Fitting roof hooks and profile rails 1. 2. 3. 4. 5. 6. p.
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CONTACT INFORMATION WORCESTER, BOSCH GROUP: TECHNICAL: 08705 266241 SERVICE: 08457 256206 SPARES: 01905 752571 LITERATURE: 01905 752556 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.
