SOLAR SOLC220 - Integrated Roof Kit Installation Manual Page 1 of 28 RK0089-4 – 08/09
SOLC220 – Integrated roof kit SOLAR 0 Overall view 17.1 17.3 16.3 17.2 16.2 10 16.1 16.5 6.0 8.0 15.0 18.0 10.0 5.0 4.0 9.0 12.0 11.0 1.0 7.0 13.0 14.0 3.0 2.0 Figure 1 – Overall view of installation method 1.0 Bottom Left Hand Side Sheet 2.0 Bottom Right Hand Side Sheet 3.0 Bottom Middle Sheet 4.0 Top Left Hand Side Sheet 5.0 Top Right Hand Side Sheet 6.0 Top Middle Sheet 7.0 Bottom Bracket 8.0 Top Bracket 9.0 Rubber Seal 10.0 Foam Wedge (Tile Kit Only) 11.0 Securing Side Bracket 12.
SOLC220 – Integrated roof kit Contents SOLAR 0 OVERALL VIEW 2 CONTENTS 3 2 BEFORE YOU START 4 GENERAL COMPETENCE HEALTH AND SAFETY RISK ASSESSMENT TOOLS REQUIRED READING THIS MANUAL EARTHING AND LIGHTENING PROTECTION 4 4 4 4 5 5 6 3 SCOPE OF DELIVERY 6 4 PRODUCT FEATURES AND DESCRIPTIONS 8 5 COLLECTOR CONNECTIONS 5.1 SINGLE COLLECTOR VERTICAL CONNECTION 5.
SOLC220 – Integrated roof kit 2 Before you start SOLAR General Thank you for choosing a Dimplex product. We ensure you that every effort has been made at the design, manufacture and delivery stages to produce a product with superior quality. We will provide you with the best possible support throughout the product’s lifespan. As part of ongoing product development and improvement Dimplex reserves the right to undertake changes to the product without prior notice.
SOLC220 – Integrated roof kit SOLAR - scalding: where appropriate or required by law a thermostatic mixing valve is to be fitted to the hot water outlet of the cylinder - explosion: the unit is fully equipped with all relevant safety equipment to comply with current regulations. The correct design and function has been verified by independent third party testing. The correct application thereof is the responsibility of the competent installer. - water borne organisms (i.e.
SOLC220 – Integrated roof kit Earthing and Lightening Protection SOLAR If a lightening arrester is available, the collector frame should be connected to it. This may be preformed using the collector frame, because the slot for mounting on the reverse side of the collector is ideally suited for fixing a thick cable. If no arrester is available, the potential equalization is carried out using a connection of a cable at the tube(s) which are led in the building.
SOLC220 – Integrated roof kit 3 Scope of delivery SOLAR Please check the contents and the condition of your delivery before signing the delivery documentation against the content shown in Table 1 below and mark as appropriate. Contact your supplier immediately for any missing or damaged parts. Claims for missing of damaged parts after signing for the delivery documentation will not be accepted.
SOLC220 – Integrated roof kit SOLAR 4 Product features and descriptions The Dimplex Integrated Roof kit offers a unique solution for mounting solar thermal collectors to the roof of a building. The concept of the product is to make installation of the collectors a quick and simple process. The Integrated Roof Kit can cater for 2m² up to 20m² of collector area and comes in four variations, 2m² kit, 4m² kit, 6m² kit and 2m² extension kit. There are two further variations in these kits, i.e.
SOLC220 – Integrated roof kit 5 Collector connections SOLAR Because of its 4 connections, the collector offers a wide choice of connection options. Ensure that no part of the collector array or collector in the array is short circuited by following these instructions. When planning the collector array, the position of the various connection parts must be in accordance with the diagrams, also pay attention to the position of the highlighted sensor pockets.
SOLC220 – Integrated roof kit 5.2 Multiple collector vertical connection SOLAR When installing multiple collectors, (2 up to 10), component 10.1 is used to connect one collector to the next. The flow and return connections must be at diagonals to one another as illustrated in Figure 3 and Figure 4. These diagrams highlight the two connection options available when connecting multiple collectors vertically in an array.
SOLC220 – Integrated roof kit SOLAR 6 Installation NB: Ensure all the laths under the area of the installation are in good condition. Replace any damaged, week or broken laths and double nail or screw to the rafters. 1.0 B Tile Rook Kit = 2.4m B Slate Roof Kit = 2.31m NB: Sufficient overlap for slates/tiles must be allowed for when positioning the integrated roof kit. Step: 2.1 Tile Step: 2.2 Slate 120mm Fold and lath are aligned - Remove the BTM LHS sheet from the packaging.
SOLC220 – Integrated roof kit SOLAR Step: 3.1 Tile Step: 3.2 Slate To secure the sides of the sheets in place, bend securing bracket as illustrated. The head of the tacking nail is used to secure the side of the sheet in place. Use tacking nails to fix to the lath. One tacking nail can be used to secure each sheet at the outsides of the installation. With pliers secure the securing bracket to the roof kit edges. Step: 4.1 Tile Step: 4.
SOLC220 – Integrated roof kit SOLAR Step: 6.0 When installing the second bracket it is important that the two brackets are aligned to the fold as previously highlighted, and the brackets are aligned to each other. - Use a straight edge or a wooden lath to ensure both brackets are square. - Again use the 10mm hex head drill bit to fix the bracket with Fixing kit 1.2, 1.4 or 1.6. - For a 2m² kit, please skip to step 11.0. Step: 7.1 Tile Step: 7.
SOLC220 – Integrated roof kit SOLAR Step: 8.0 To complete the installation of the second sheet: - Fit the brackets and ensure they are aligned using a straight edge where necessary. - Pre-drill the brackets and secure using the self tapping screws provided. If there are further extension kits to be installed they should be done so as outlined in steps 6.0 to 8.0 above. Step: 9.0 To complete the bottom of the installation the bottom right hand sheet must be installed.
SOLC220 – Integrated roof kit SOLAR Step: 11.0 It is critical that the bottom and top sheets are square with each other. After the folds are butted against one another as described in 10.0, check and ensure the overlaps are as follows. x x The overlap between top and bottom varies for tile and slate kits: X = 200mm for Tile kit X = 180mm for Slate kit Step: 12.1 Tile Step: 12.
SOLC220 – Integrated roof kit SOLAR Step: 13.0 - Remove the backing from the tape and install the top brackets. (These brackets can be indentified by the hank bushes assembled on to the inside face and also the label on the bracket highlights its position on the assembly). Align back face to outer edge of tape Remove backing tape Align leg of bracket to edge of the tape - Align the back face of the bracket with the tape and the leg of the bracket along the side of the tape. - Use fixing kit 1.2, 1.
SOLC220 – Integrated roof kit SOLAR Step: 15.0 The rubber seal(s) must now be fitted to the installation. They are used to seal the vertical joins between the sheets. Bend the seal back on itself as illustrated in the image across. Start from the bottom of the installation and work up – keeping the rubber seal bent back on itself. The seal will fit into position as it is worked up the installation. It is important that the seal engages with the folds in the sheets all along its length.
SOLC220 – Integrated roof kit SOLAR Step: 16.0 The collector(s) can now be installed. See chapter 2 for information on the collector connections, it is critical the collectors are orientated correctly. - Rest the collectors on the bottom brackets as highlighted in the image across. The collectors can now only move left to right. There are markings on the aluminium sheets that highlight the approximate position of the collector.
SOLC220 – Integrated roof kit SOLAR Step: 18.0 - Remove 150mm of insulation from the flexible pipe to allow sufficient clearance when feeding through the dektite. 150mm - The insulation must be removed at the same end as the o-rings are placed. - The pipe can then be bent as illustrated so it can be connected to the collector after being fed through the dektite. A maximum bend of 60mm is sufficient. 60mm Step: 19.
SOLC220 – Integrated roof kit SOLAR Align inner insert ring and end of flange Step: 20.0 Insert the flexible pipe into the collector connection. It is important that: - The o-rings do not become deformed and retain their shape when being inserted into the collector. - Ensure the corrugated pipe is so that the first insert ring with the collector connection other is outside the collector tion.
SOLC220 – Integrated roof kit SOLAR Step: 22.0 To install the blanking connection: - Grease the o-rings using the grease supplied. - Insert the connection into the collector, the component must push in until it butts against the collector fitting. - It is important that the o-rings do not become deformed when the fitting is being inserted into the collector.
SOLC220 – Integrated roof kit SOLAR Step: 24.0 Both interconnection fittings can now be assembled. This is done in a similar way to the inlet/outlet connections. - Fit the insert rings to the interconnection component. Ensure that they are fitted in the same fashion as in step 19.0, i.e. there is a free corrugation between the o-rings and the first insert ring. - The insert rings must be firmly secured to the connection.
SOLC220 – Integrated roof kit SOLAR Step: 26.0 If additional collectors are being installed follow steps 16.0 to 25.0 inclusive, the same steps to make the connections should also be followed. - Ensure the collectors are connected using the interconnections. - The gap between the collector frames remains 90mm. - The connections are fitted and secured in the correct way. - The correct fixing kits are used to secure the collector in place.
SOLC220 – Integrated roof kit SOLAR Step: 28.1 Tile If using the flashing kits the foam wedge should be installed upon completion of these. - To fit the foam wedge simply remove the backing from the adhesive and apply around the perimeter of the installation as illustrated. - The straight edge of the foam wedge must butt against the fold in the sheets as illustrated. - There must be no gaps in the foam wedge when it is installed around the edges of the kit.
SOLC220 – Integrated roof kit SOLAR Step: 29.1 Tile Step: 29.2 Slate 1 - When fitting the tiles under the lead flashing at the front of the kit it is important to chamfer the top edge of the tiles so they don’t push up on the lead. All the tiles under the lead should be cut in this fashion. 2 When laying slates around the integrated roof kit: 1. A full slate must be fitted under the kit at both edges, the slate must extend above the fold in the sheet. 2.
SOLC220 – Integrated roof kit SOLAR Step: 30.1 Tile It is important when laying the tiles around the integrated roof kit to ensure: A - Sufficient overlap between the tiles and the edges of the kit exist. - Place a small cut A, in the foam wedge at the top of each tile to allow the foam wedge to fill the gap between that tile and the next tile being laid. Step: 31.0 Tile When laying the tiles around the top of the integrated roof kit installation it is required to use a tile support bracket.
SOLC220 – Integrated roof kit SOLAR Step: 33.0 The felt or membrane under the integrated roof kit where the inlet/outlet pipe work enter the building must be repaired. A To do this a suitable tape must be used. - Layer the tape in sections around the pipe as illustrated. - The sections must be applied such that they overlap starting from the back of the pipe, A, (furthest up the roof). - This must ensure the felt is completely sealed and watertight.
SOLC220 – Integrated roof kit 7 Operation & Maintenance SOLAR Connections should be double checked prior to commissioning of the system. Please refer to the On Site Guide for guidance on how to commission and operate the solar system. Risk of scalding! Before carrying out any maintenance work on the system ensure that it is safe to do so. The solar system must be decommissioned before work can be carried out. Refer to the On Site Guide for a maintenance schedule of the complete system.
