FKT SERIES FLAT PANEL SOLAR COLLECTORS IN ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS 63043975.00-1.
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 roofs 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 Series 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 2070 mm 1145 mm 90 mm 25 mm 1.43 l 1.76 l 2.37 m² 2.
Safety 3 Safety This chapter explains the meaning of the notes you will find in this manual and provides general safety instructions for safe and trouble-free operation. The installation-specific safety and user notes next to the appropriate installation steps are found here. Carefully read the safety instructions before commencing the installation. Severe injury and even death, as well as material losses and environmental damage, may follow if you ignore safety instructions.
Safety 3.1 Correct use This installation set holds the thermal solar collectors (portrait and landscape), which are installed on pitched roofs with a pitch angle of 25° to 65°. Operating conditions Only erect the installation set on roofs whose construction can support the weight. If necessary, consult a structural engineer or a roofer. The installation set is suitable for a max. standard snow load of 3,8 kN/m² and an installation height of max. 20 m.
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 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 The installation sets are for fixing the collectors in place and sealing them. The lower facing panels (Fig. 2, Item 6, 9 and 10) are designed for slate/shingle roofs with no flashing. If installing more than one row of collectors, basic and extended installation sets are delivered separately. 2 1 19 12 4 3 11 13 14 15 16 17 18 4 5 10 Fig.
Before installation 4.2.2 Pipework connections For the pipework connection a connection kit and a connection set between the collectors will be required. 1 2 3 7 6 Fig. 3 4 5 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 – Cordless screwdriver and drill (Ø 4 mm) – Size 10 and 8 spanners (incl. 80 mm extension) 4.4 Transport and storage Please ensure that the corner protectors are retained. They contain pipework connection pieces which are required for installation. All components are protected by transport packaging.
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 in-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, incl. facing panels. 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 Roof overhang including gable wall thickness. Dimension E Minimum 30 cm for fitting the connection cables in the attic. 63043975.28-1.SD Fig.
Roof preparations 5 Roof preparations 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.
Roof preparations 5.1 Determining the initial installation positions Before installation, carefully determine the initial positions. Initial horizontal position B Determine dim. X (distance between the tiles that lie on the side facing panels, Fig. 8, Item 1) on the roof and mark it on the roof. i USER NOTE If possible, plan in such a way that the tiles are only cut on the right side of the collector array, but always in a tile trough. After cutting, at least half of the tile should still remain.
Roof preparations 5.2 Fitting additional roof battens When laying the facing panels and collectors in place, there will have to be additional roof battens of equal height to those already on the building. i USER NOTE As an alternative to additional roof battens, those already present around the collector array area can be adjusted to the same dimensions as the additional roof battens. These instructions describe installation using additional roof battens.
Roof preparations 5.2.1 Fitting anti-slip protection devices to first additional roof batten Due to limited space it may be possible for the anti-slip protection devices to be fitted directly on to the roof. If so they should be pre-assembled on the ground and fitted to the first additional roof batten. i 1 2 USER NOTE For landscape installation, 3 anti-slip protection devices (Fig. 10, Item 1) must be fastened to one strip of wood (2 on the outside, 1 in the middle).
Roof preparations i USER NOTE 2 1 If an additional roof batten (Fig. 13, Item 1) has to be fitted near a pre-existing one, the pre-existing one must be moved near to the collector array (Fig. 13, Item 3) and adequately fastened (Fig. 13, Item 2). 3 4 The pan tiles on the side facing panels MUST be covered. Installing one row B Attach first roof batten with the anti-slip protection devices (Fig. 14, Item 1). 63043975.39-1.SD B Attach second roof batten for the lower side clamp (Fig. 14, Item 2).
Roof preparations Installing more than one row When installing more than one row, the roof battens in the first row must be laid just as if you were installing one row (Fig. 14). The 5th and 6th batten for the lower row are not needed. i USER NOTE The fourth additional roof batten (one-row installation) is also the first roof batten of the row above (Fig. 15, Item 1) and is required for anti-slip protection on the upper collector array. B Attach second roof batten for the side clamp (Fig. 15, Item 2).
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, fit the end caps to the collectors 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. 20, Item 1) onto the collector connection. 2 B Push bracket (Fig. 20, Item 2) over the end cap and collector connection to secure the connection. SYSTEM DAMAGE from unsecured locking caps.
Collector installation 6.2 Fastening the collectors Begin laying the collectors on the right-hand side. 6.2.1 Laying first collector 1 B Allow first collector (Fig. 22, Item 1) to slide into place in the anti-slip protection device and position 80 mm from the outer (cut if necessary) pan tile (Fig. 22, Item 2). 80 mm 2 63043975.43-1.SD Fig.
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. 63043966.11-1.
Collector installation B Tighten the screw on the double-sided clamp (Fig. 27, Item 1). Use a size 10 socket wrench with a minimum length of 80 mm for this purpose. 80 mm The clamp now grips into the lower edges of the collector. Repeat the procedure for all other collectors. 1 63043975.08-1.SD Fig. 27 Screwing in double-sided clamp 6.2.
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. 30). Insertion point The collector sensor must be fitted in the collector nearest to the flow connection (Fig. 30, Item 2). 1 2 – Insertion point (Fig. 30, Item A) for single row collector systems. – Insertion point (Fig. 30, Item B) for dual row collector systems. 1 2 63043966.25-1.
Header connection 8 Header connection Information on laying the header pipes can be found in the complete station installation instructions. The water 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 1 USER NOTE Feed the sensor cable together with the flow line under the roof. 2 63043973.04-1.SD Fig. 32 Routing connection pipes under the roof Item 1: Flow line Item 2: Return line 8.
Header connection 8.2 Venting 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. 34, Item 2) and the return line rising to the collector array (Fig. 34). 2 1 Avoid frequent changes in direction. i User note: For each change of direction downwards and each new rise, install an additional air vent. 63043966.20-1.SD Fig.
Header connection 8.2.1 Fitting the air vent valve under the roof B Push connection pipe (Fig. 36, Item 3) onto the flow connection on the collector array and fix in place using bracket (Fig. 36, Item 5). B Feed connection pipe together with the sensor cable through the de-airing tile (Fig. 36, 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.
Fitting the connection set for two rows (accessory) 9 Fitting the connection set for two rows (accessory) The connection set (Fig. 37, 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.
Installing the facing panels 10 Installing the facing panels Before you block access to the collector array with the facing panels, you must carry out the following checks: Solar hoses secured with clips? 1. 2. Every collector secured on the left and right with clamps? 3. Sensor inserted as far as it will go and secured with clamped joint? 4.
Installing the facing panels 10.1 Lower facing panels B Bend flashing for all facing panels towards the front (Fig. 41, Item 2). 1 B Likewise, lay the ends of the upper outer facing panels (Fig. 41, Item 1) towards the front. 2 63043975.46-1.SD Fig. 41 Laying flashing CAUTION! 10 > from roof leaks, if the distance between upper edge of the collector to the upper edge of the first additional roof batten is not 90 – 92 mm.
Installing the facing panels i USER NOTE For two landscape collectors, facing panels are necessary underneath in the middle (Fig. 44, Item 1). They must overlap by 80 – 100 mm. 80 - 100 mm 80 - 100 mm 1 63043975.42-1.SD Fig. 44 Positioning the middle facing panels for landscape collectors B Lay the left-hand facing panel (Fig. 45, Item 2) on the previous one, and fit in the same way as the righthand one (Fig. 42).
Installing the facing panels 10.2 Side facing panels BUILDING DAMAGE from leaks in the roof. CAUTION! B Place the mounting plates (Fig. 47, Item 2) into the lower edge of the collector. 3. 2 B Place the edge of the right and left side facing panels (Fig. 47, Item 1) up into the recessed grip on the collector and push in over the lower facing panel. B Press the fold overlap on both panels together to fix in place (Fig. 47, Item 3). 1 3 Fig. 47 63043975.13-1.
Installing the facing panels 10.4 Middle facing panel (when more than one row is being installed) 3. 1 The space between two collector arrays is sealed with the middle facing panels. B Insert the upward fold on the facing panel (Fig. 50, Item 2) into the recessed grip on the collector frame. 4 B Feed facing panel (Fig. 50, Item 1) towards the collector and into the side facing panel on the right. B Place the rubber lip (Fig. 50, Item 4) on top of the collector.
Installing the facing panels 10.5 Side facing panels on the upper row (if installing more than one row) 1 B Fit the upper side facing panels (Fig. 53, Item 1) in the same way as the lower ones (Chapter 10.2 "Side facing panels"). BUILDING DAMAGE from leaks in the roof. CAUTION! 2 B Push the side facing panels over the collector fold in the middle panels (Fig. 53, Item 2). 63043975.48-1.SD Fig. 53 Upper right facing panel 10.6 Upper facing panels Begin on the right when fitting the upper facing panel.
Installing the facing panels B Shorten the rubber lip (Fig. 56, Item 2), so that it touches the rubber lip on the right-hand facing panel. B Place rubber lip on the left-hand facing panel onto the fold on the right-hand facing panel (Fig. 56, Item 1). 2 1 63043975.47-1.SD Fig. 56 Upper left facing panel B Fasten each panel overlap with two 25 mm long plumbing screws (Fig. 57, Item 1) (provided). 1 63043975.41-1.SD Fig. 57 Each upper facing panel must be fastened to the roof battens with two clips.
Installing the facing panels 10.7 Covering the roof i USER NOTE Fasten cut pan tiles with suitable brackets if necessary (available from a roofing specialist). BUILDING DAMAGE CAUTION! from roof leaks if pan tiles are not placed far enough over the facing panels. 10.7.1 Upper pan tiles B Place one whole pan tile on top of the upper facing panel. B Cut the pan tile so that: – it covers the facing panel (Fig.
Final activities 11 Final activities i USER NOTE If you are venting the solar heating system with an automatic air-vent valve (accessory), you must close the ball valve after the venting procedure (see pump station installation instructions). 11.1 Checking the installation In addition to the checks on page 33, you must check the following: – Are all collector and roof cover joints snow and rain proof? 11.
Quick reference guide for two collectors 12 Quick reference guide for two collectors 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. 3 3 3 3 Roof preparations 1. 2. 3. Mark dim. X on the roof. p. 17 Installation of anti-slip protection devices p. 19 Attach additional roof battens to the roof. p. 19 Preparing to install the collectors 4. 5.
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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.