FKT SERIES FLAT PANEL SOLAR COLLECTORS FLAT ROOF AND WALL MOUNTED INSTALLATION FOR WORCESTER SOLAR HEATING SYSTEMS 63043970.01-1.
About this manual This installation manual contains important information for the safe and appropriate installation of the roof mounted solar collectors. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 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 roof The Health and Safety at Work etc Act 1974 Connection of thermal solar heating systems Installation and equipment of DHW cylinders EN 12976: Thermal solar heating system and their components (prefabricated systems).
Specifications 2 Specifications FKT Solar collectors 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 3.1 Correct use Install components only on roofs with sufficient strength. Please take the additional roof load per flat roof support, including solar collector, into consideration. If necessary, ask a structural engineer for assistance. Only install this system on flat roofs or roofs with a shallow pitch (≤ 25°). If there is a risk that larger quantities of snow might accumulate behind the collectors (towards the roof ridge), prevent this by fitting a suitable protective grille.
Safety 3.2 Notes structure Two levels are identified by signal terms: RISK TO LIFE WARNING! Identifies possible dangers which might lead to serious injury or death if appropriate care is not taken. RISK OF INJURY/SYSTEM DAMAGE CAUTION! Identifies potentially dangerous situations, which might lead to mild or slight injuries or to material losses. Further symbols identifying dangers and user notes: RISK TO LIFE from electric shock.
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 fully experienced in working on roofs and will be aware of the risk of working at height, are considered. Make yourself familiar with the on-site conditions and local regulations before commencing the installation. Check B the delivery for completeness and perfect condition. B the roof structure for sufficient strength and possible damage (e.g. leaks).
Before installation 4.2 Component description 4.2.1 Installation set for the collectors The installation sets are for mounting and fixing the collectors in place. 23 1 4 5 6 5 3 7 8 63043970.03-1.SD Fig. 3 Installation set for 2 collectors - 1 basic installation set, 1 extended installation set Basic installation set for each collector array and for the first collector (Fig.
Before installation 4.2.2 Pipework connection One connection kit for each collector array is required. The collectors are connected together by a connection set. 2 1 10 3 4 5 9 Fig. 4 8 7 6 63043969.03-1.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. 7). 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 4.6.2 Sloping roofs On roofs that slope slightly in a southerly direction, the pitch angles are deducted from the angle of incidence. On roofs that slope slightly in a northerly direction, the pitch angles are added to the angle of incidence (Fig. 9). 1 RISK TO LIFE WARNING! SYSTEM DAMAGE CAUTION! 45° If there is a risk that larger quantities of snow might accumulate behind the collectors (towards the roof ridge), prevent this by fitting a suitable protective grille on site.
Before installation 4.6.4 Fitting telescopic rails Different angles of incidence can be set using the telescopic rails. B Select holes on the upper and lower telescopic rails as shown in Fig. 12 and Fig. 13. B Insert telescopic rails into each other and fasten with M8 × 20 screw (Fig. 11). 1. 63043970.08-1.SD Fig.
Before installation i USER NOTE 35° 40° For landscape installation of a collector with an angle of inclination of 35° to 60°, use the uppermost hole on the lower telescopic rail (Fig. 13, Item 3). 45° 50° 55° 60° For an angle of inclination of 25° and 30°, you must shorten the top of the lower rail by 140 mm and use the lower hole (Fig. 13, Item 2). 1 1 1 25° 30° 1 140 mm RISK TO LIFE WARNING! 3 from falling collectors, due to incorrect use.
Before installation 4.7.2 Estimating your space requirements SYSTEM DAMAGE CAUTION! through wind, eddies and pressure peaks around the roof edges. B Before commencing the installation, ensure that at least one metre is allowed between the flat roof supports and the edge of the roof (Fig. 15). >1 m >1 m 63043970.41-1.SD Fig. 15 Distance from the edge of the roof Allow sufficient installation space for the different forms of installation (landscape, portrait). These dimensions (Tab. 5 and Tab.
Installing flat roof and wall mounting supports 5 Installing flat roof and wall mounting supports 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 your personal protective clothing and safety equipment. i 63043970.11-1.SD USER NOTE Fig.
Installing flat roof and wall mounting supports 5.1 Distances between collector braces for on-site base anchoring The distances between the collector braces (middle/middle, in mm) depend on: – the collector version (portrait, landscape) – and the maximum snow and wind loads i USER NOTE You must strictly observe the clearances between the collector braces so that the profile rails can still be installed at a later stage. 980 980 5.1.1 Basic version 63043970.44-1.
Installing flat roof and wall mounting supports 5.1.2 Version with auxiliary brace (accessory) For greater loads, an auxiliary brace (and additional profile rails, page 29) is required for portrait installation for the second and all further collectors (Fig. 22). This version can be used for the following loads: – Building height max. 100 m (installation height) – max. 3.8 kN/m² snow load i USER NOTE For landscape installation, a max. building height of 100 m and a max. snow load of 3.
Installing flat roof and wall mounting supports 5.2 Clearances between the collector braces when using loading trays (accessory) The distances between the collector braces (middle/middle, in mm) depend on: – the collector version (portrait, landscape) – and the maximum snow and wind loads. For portrait installation, an auxiliary brace must be erected for the 4th, 7th and 10th collectors (Fig. 23, Item 1).
Installing flat roof and wall mounting supports i USER NOTE Landscape installation can be carried out using only the auxiliary brace (accessory). For landscape installation, 3 collector braces must be fitted for each collector (Fig. 24). 980 980 135 980 980 63043970.16-1.SD Fig. 24 Basic version for 2 landscape collectors 5.2.2 Version for maximum loads (accessory, Fig. 25) For greater loads, ropes (page 25) and additional rails (page 29) are also required.
Installing flat roof and wall mounting supports 5.3 Stabilising the flat roof supports The following details refer to a single collector. These details are based on DIN 1055, part 4 "Design loads for buildings". Individual flat roof supports may be secured in the following three ways to prevent slippage or tipping of the structure due to the effect of the wind: – Securing flat roof supports with anchor bolts (onsite).
Installing flat roof and wall mounting supports 5.3.1 Securing flat roof supports on site with base anchoring 1 You can fasten the flat roof supports with anchor bolts. As an example, we describe fastening onto girders (Fig. 26, Item 3). Design the substructure so that the collectors can withstand the snow loads and wind forces placed upon them. 2 In addition, a means of fixing should be provided on site that stabilises the structure and prevents damage to the roof. 3 SYSTEM DAMAGE 63043970.46-1.
Installing flat roof and wall mounting supports 5.4 Wall mounting supports - installation The landscape collector braces can also be used for wall-mounted installation. RISK TO LIFE WARNING! from falling collectors, due to incorrect use. B Only landscape collector braces are allowed for wall-mounted installation. B Collectors may only be installed on walls of buildings with a height up to 20 m (wind velocity = 129 km/h) and a snow load of up to 2.0 kN/m².
Installing flat roof and wall mounting supports 980 980 135 980 980 1 63043970.30-1.SD Fig.
Installing flat roof and wall mounting supports 5.5 Installing the profile rails The profile rails must be joined together using plug connectors. Each collector is provided with an upper and lower profile rail. 1 2 5.5.1 Connecting profile rails B Push plug connector (Fig. 31, Item 1) as far as it will go into both profile rails (Fig. 31, Item 2). B To lock, tighten both fitted M10 threaded studs (Fig. 31, Item 3) in the plug connector using a size 5 spanner. 3 63043965.33-1.SD Fig. 31 5.5.
Installing flat roof and wall mounting supports B Lightly tighten the pre-assembled profile rails (Fig. 34, Item 2) with M8 x 20 bolts (Fig. 34, Item 1) so that the profile rails can still be aligned. B Align the sides of the upper and lower profile rails. B Tighten bolts. 1 2 63043970.21-1.SD Fig. 34 Fitting profile rails (for two portrait collectors in this example) 5.5.
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 locking caps on the ground to make work on the roof easier. 4 To secure the locking 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, so those that are not used must be closed. B Remove rubber caps (transport protection) from the relevant collector connections. B Push end cap with the O-rings (Fig. 42, Item 3) onto the collector connection. 3 1 B Push bracket (Fig. 42, Item 2) over the end cap and collector connection to secure the connection. SYSTEM DAMAGE 2 from unsecured end caps. CAUTION! 6.
Collector installation Putting the first collector in place Lay the collector on the profile rails in such a way that the sensor bush to receive the collector sensor is at the top. Begin by laying the collectors on the right-hand side of the profile rails. 1 RISK OF INJURY CAUTION! 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. 45, Item 2) (Fig. 45).
Collector installation Fitting corrugated pipe connectors to the first collector B Remove the rubber caps from the connections. B Push corrugated pipe connectors (Fig. 48, Item 1) onto the left-hand connections on the first collector. B Push bracket (Fig. 48, 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 spanner. i USER NOTE When the screw is tightened, the plastic lugs at the pre-determined cut-off points break away. 1 The grip (Fig. 51, Item 1) on the collector clamp now grips the lower collector edge. 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. 53). 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. 53, 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. SYSTEM DAMAGE CAUTION! from leaks in the collector connection, due to movements caused by heat. B Feed the on-site flow line (Fig. 55, Item 1) alongside the collector, rather than vertically downwards. 1 2 1 63043969.01-1.SD Fig. 55 Feeding header pipes to the collector array Item 1: Flow line Item 2: Return line 8.
Header connection 8.2 Venting through pressure filling If venting of the solar heating system is carried out using a pressure filling pump, no vent is required on the roof. B Remove rubber caps (transport protection) from the relevant collector connections. 1 B Push elbow (Fig. 57, Item 2) with olive and union nut onto collector connection. B Secure elbow with bracket (Fig. 57, Item 1). 2 Perform the same procedure with the return connection. 3 4 63043969.04-1.SD Fig.
Header connection 8.3 De-airing through air vent (accessory) at highest point in the system 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. 58, Item 2) and the return line rising to the collector array (Fig. 58). 2 1 Avoid frequent changes in direction. i User note: For each change of direction downwards and each new rise, install an additional air pot with air vent.
Header connection Fitting the air vent 1 B Firmly screw threaded fitting (Fig. 60, Item 6) and double threaded fitting (Fig. 60, Item 4) into air pot (O-ring gasket). B Push air pot (Fig. 60, Item 5) and fitting onto collector connection and secure with clip. B Connect header pipe to the compression fitting (22 mm) (Fig. 60, Item 2). 6 Fig. 60 4 5 3 2 63043969.05-1.
Final activities 9 Final activities 9.1 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 9.2 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 header pipes 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 base anchoring and pressure filling 10 Quick reference guide for base anchoring 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 obey all safety and user instructions. 16 Fitting braces and profile rails 1. 2. 3. 4. 5. 6. 8,10 Insert telescopic rails into each other according to the selected angle of inclination, and fasten.
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.
