Installation Instructions

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1 Installation Instructions SOLC 220 SOLC 220 PAG SOLC 220 PAE SOLC 220 BAG SOLC 220 BAE Flat plate collector Basic kit Frankfurt tile Extension kit Frankfurt tile Basic kit plain tile Extension kit plain tile SOLC 220 WAG Basic kit corrugated sheet SOLC 220 WAE Extension kit corrugated sheet Flat plate collector SOLC 220 Roof mounting installation (Frankfurt tile, plain tile, corrugated sheet)

2 Explosion drawing Flat plate collector SOLC 220 on-roof installation instructions Page 2 of 19

3 Parts list No. Designation 1 Collector 2 Rail, 1,155 mm 3 Rail, 1,242 mm 4 Collector fixing kit 4.1 4x M8 x 14 hexagonal bolt 4.2 4x mounting profile (Z-hooks) 4.3 4x ø8.4 mm washer 4.4 1x installation aid 4.5 2x M8 x 10 hexagon socket head cap screw Quantity basic kit Quantity extension kit Rafter anchor for pantiles (variation A) Rafter anchor kit 6.1 4x ø10 wood screw 6.2 2x M10 hexagonal bolt 6.3 6x ø10.5 mm washer 6.4 2x M10 hexagonal nut 6.5 2x slot nut 6.6 4x wooden equalisation board (2 x 5 mm, 2 x 10 mm thick) 7 Rail connection kit 7.1 2x rail connector 7.2 4x M8 x 50 hexagonal bolt 7.3 8x ø8.4 mm washer 7.4 4x M8 hexagonal nut 7.5 2x 90 mm self-adhesive spacer Rail end set 8.1 4x rail connector 8.2 4x end piece 8.3 4x M8 x 50 hexagonal bolt 8.4 8x ø8.4 mm washer 8.5 4x M8 hexagonal nut 9 Connection kit 9.1 2x corrugated pipe 800 mm with two O-rings and ¾ union nut; insulated sleeve 9.2 2x end piece with two O-rings 9.3 4x clips 9.4 3x gaskets 9.5 1x silicone paste 9.6 5x insert rings 10 Connection kit x corrugated pipe compensator DN x insert rings x clips Rafter anchor for plain tiles (variation B) 4* 2* 12 Corrugated slab fastening (variation C) x hanger bolt x M10 hexagonal nut x seal x rail holder 4* 2* Flat plate collector SOLC 220 on-roof installation instructions Page 3 of 19

4 General The on-roof installation kit is for installing the SOLC 220 type collectors vertically or horizontally on a roof. It can be used on roofs with slopes of 20 and above. The rafter anchors are available in variations for the following roof coverings: pan tiles and similar roof tiles, and plain tiles. Fastening elements are also available for corrugated slabs (e.g. corrugated sheeting, corrugated fibre cement). Alternatively, standing seam clamps for standing seam roofs or fastenings for other types of roofs can be combined with the system. These must be procured by the contractor from the local roofing supplier. Extra materials such as ventilation tiles for the roof opening for the collector array connections (available from specialist suppliers) and tin/lead sheets for sealing the rafter anchors on a plain tile covering may be required. In some cases it is necessary to plan a means of transporting the collectors onto the roof. We recommend considering roof access near to the collectors so that checking and maintenance work can be carried out more easily. When connected hydraulically, up to 10 SOLC 220 collectors can be connected in series. If more than 10 collectors are connected, this must be done using a combination of series and parallel connection. We recommend declaring the solar energy system to your insurer as added value to the building, and taking out insurance against lightning and possibly glass breakage. Safety instructions The installation and safety instructions must be observed and adhered to. The accident prevention regulations of the trade associations must be adhered to, particularly when working on the roof. Where there is a danger of falling, precautions must absolutely be taken. The entire solar energy system must be installed and operated in accordance with the recognised technical regulations. Due to snow and wind loads, extreme forces can be at work on the collector fixings. Attention should therefore be paid to carrying out the installation carefully. The roof construction (rafters) must be capable of withstanding the additional load. Furthermore, care must be taken that the snow and wind loads are discharged into the roof construction at certain points. It may be necessary to consult a structural engineer. In case of snow loads of zone 3 and above, and installation locations more than 600 m above sea level, we ask that you enquire with us about the static test. When installing the collectors towards the edges of the roof, a minimum gap of 1.5 m from the eave and of 1.2 m from the ridge must be observed. If this minimum gap cannot be observed, a structural engineer must be consulted. Flat plate collector SOLC 220 on-roof installation instructions Page 4 of 19

5 Technical instructions Anti-freeze protection The solar energy system may only be filled with antifreeze mixture. As it is not possible to empty the collectors completely, it is imperative that the system be filled with the antifreeze mixture, even for function tests. We recommend using premixed antifreeze mixtures; alternatively, the water and antifreeze must be mixed outside the solar energy system. Caution! As the collector can reach temperatures of over 200 C, an antifreeze which is suitable for use in such conditions must be chosen (e.g. with a propylene glycol base). Bleeding The solar circuit must generally be bled below the roof. If automatic bleed valves are used, it is imperative that additional ball valves be installed for manual closure of the system. These ball valves must be closed after filling the plant again. Otherwise, the antifreeze mixture might leak during high temperatures and steam build-up in the collector. Recycling We guarantee that we will take back and recycle our products once they have come to the end of their life cycle. We have already ensured that our products are suitable for recycling during the development stage. This is therefore guaranteed. Electrical connections A dedicated electrical circuit/circuit breaker should be provided for the solar system. Earthing and lightning protection If the building already has lightning protection, the solar system's metal pipes must be connected to the lightning protection by means of a green/yellow conductor of at least 6 mm² Cu (H07 V-U or R). Otherwise it is possible to earth the system to an earth rod. Pictograms Here you will find important instructions which must be observed under all circumstances. Here you will find notices regarding dangers concerning health, damage to equipment and financial losses. Required tools Cordless screw driver with 6 mm wood drill bit, 13 mm socket wrench and 14 mm masonry drill bit Angle grinder with stone cutoff wheel Spanners 13/ 17/ 19/ 20/ 22/ 30/ 32 Measuring tape 6 mm Allen key Flat plate collector SOLC 220 on-roof installation instructions Page 5 of 19

6 Rafter anchor and hanger bolt installation Vertical 1. The collector array can be installed vertically or horizontally. For vertical installation, the rails (2/3) are installed horizontally. The distances B and C from the rails to the outer edge of the collector must be between 150 and 350 mm. A = 1,2 1,5 m Up to 10 collectors can be connected in series (1 basic kit and 9 extension kits). Horizontal 2. For horizontal installation, the rails (2/3) are installed vertically. The distances B and C from the rails to the outer edge of the collector must be between 150 and 500 mm. A = 0,9 1,5 m Up to 10 collectors can be connected in series (1 basic kit and 9 extension kits). A. Pan tiles and similar roof tiles 1. Remove one (or more) roof tiles above the planned installation position of each rafter anchor (5). The horizontal spacing is derived from the rafter spacing and the vertical spacing is derived from the roof tiles. The number of rafter anchors is derived from the size of the collector array (basic kit: 4 rafter anchors, extension kit: 2 rafter anchors). 2. Determine the position of the rafter anchor (5) so that it is located in the trough of the roof tile. Mark two fixing points on the rafter for each rafter anchor and pre-drill them with a 6 mm wood drill bit. Flat plate collector SOLC 220 on-roof installation instructions Page 6 of 19

7 Rafter anchor and hanger bolt installation 3. If necessary, cut a recess in the lower tile with an angle grinder at the point where the rafter anchor (5) comes through. Pay particular attention to the leak-tightness of the roof at the position where the rafter anchor comes through. The roof hook must not exert any pressure on the roof tile. 4. Fix each rafter anchor (5) to the roof rafters with 2 wood screws (6.1) and washers (6.3). The screws (6.1) must enter into the wood to a depth of at least 40 mm.. The rafter anchors (5) must not rest on the roof tiles! A spacing of 5 mm must be kept between the rafter and the roof tile. If necessary, underlay the rafter anchors with equalisation boards (6.6).. 5. Cut a recess in the upper tile with an angle grinder at the point where the rafter anchor (5) comes through. 6. Replace the upper roof tile. Pay particular attention to the leak-tightness of the roof at the position where the rafter anchor comes through. The roof tile must not be pushed up by the rafter anchor (5). Flat plate collector SOLC 220 on-roof installation instructions Page 7 of 19

8 Rafter anchor and hanger bolt installation B. Plain tiles 1. Remove several roof tiles above the planned installation position of each rafter anchor (11). The spacing to the side is derived from the rafter spacing and the number of rafter anchors. The spacing between the rails must be observed as described on Page Determine the position of the rafter anchor (11) so that it is located on a roof rafter directly above a roof batten. Mark two fixing points on the roof rafter for each rafter anchor and pre-drill them with a 6 mm wood drill bit. 3. Fix the rafter anchors (11) to the roof rafters using wood screws (6.1) and the washers which go with these (6.3). The wood screws must enter into the wood to a depth of at least 40 mm. 4. Using an angle grinder, at the point where the rafter anchor (11) comes through, cut a recess in the upper tile which overlaps the crown of the rafter anchor. Flat plate collector SOLC 220 on-roof installation instructions Page 8 of 19

9 Rafter anchor and hanger bolt installation 5. Replace the roof tiles. Pay particular attention to the leak-tightness of the roof at the position where the rafter anchor comes through. 6. Cover each rafter anchor (11) with a metal sheet. 7. As you do so, hang the plate with the standing seam edge on the upper edge of the roof tiles and fix it here. Replace the roof tiles. Once all the roof tiles have been replaced, check the leak-tightness of the roof! C. Corrugated slabs 1. In accordance with the planning, pre-drill the corrugated slabs at the crest with a ø14 mm drill bit. Remove existing hanger bolts as an alternative. The spacing to the side is derived from the rafter spacing and the number of rafter anchors. The spacing between the rails must be observed as described on Page 6. Do not drill the rafters! Flat plate collector SOLC 220 on-roof installation instructions Page 9 of 19

10 Rafter anchor and hanger bolt installation 2. Pre-drill the rafters through the hole in the corrugated slab with an ø6 mm wood drill bit. 3. Insert the hanger bolt (14.1) though the hole in the corrugated sheet and screw it into the pre-drilled rafter. The hanger bolt must not exert any pressure on the corrugated slab! 4. Seal the hole on the crest of the roof covering with seal (12.3). To do so, slide the seal with the flat side facing upwards onto the hanger bolt (12.1) up to the level of the fibre cement corrugated slab. Next, carefully secure the seal with an M10 hexagonal nut (12.2). 5. Attach the rail holder (12.4) to the hanger bolt (12.1) using two M10 hexagonal nuts (12.2). Flat plate collector SOLC 220 on-roof installation instructions Page 10 of 19

11 Assembling the rails 1. According to the number of rafter anchors (5/11/12), feed an M10 hexagonal bolt (6.2) with a slot nut (6.5) into the rail (2/3). The rails can be pre-assembled on the ground. 2. Extend the rail (2/3) with a rail connector (7.1). To do so, slide the rail connector into the ends of two rails (2/3) and screw it in place with two M8 hexagonal bolts (7.2) and M8 hexagonal nuts (7.4) with washers (7.3). 3. Fix two rail end pieces (8) to one side of the collector array. Attach one rail end piece consisting of a rail connector (8.1) and the end piece (8.2) per rail string as a stop for the first collector (1). To do so, slide the assembled end piece into the rail (2) and screw it in place with an M8 x 50 hexagonal bolt (8.3), a washer (8.4) and an M8 hexagonal nut (8.3). Flat plate collector SOLC 220 on-roof installation instructions Page 11 of 19

12 Installing the rails on the roof Vertical 4. Lock the lower rail (2/3) with the studs into the mounting profiles (4.2); mount the rail facing upwards. To do so, position the M10 hexagonal bolt (6.2) with slot nut (6.5) in the rail according to the positions of the rafter anchors and fix it to the rafter anchor (5/11/12) by hand with a washer (6.3) and an M10 hexagonal bolt (6.4). Vertical 5. Attach the upper rail (2/3) as described in steps 1 to 3 and position it sideways. To do so, position the rails with respect to each other so that the diagonals D and E are of equal length. Mark the correct position before installing them. Next, fasten both rails in place by tightening the M10 hexagonal bolts (6.4). The rail end pieces (8) must be on the side where the first collector is to be installed. Horizontal 4.1 Mount the first rail (2/3). Lock the stud into the mounting profiles (4.2), align towards the planned position of the collector connections. To do so, position the M10 hexagonal bolt (6.2) with slot nut (6.5) in the rail according to the positions of the rafter anchors and fix it to the rafter anchor (5/11/12) by hand with a washer (6.3) and an M10 hexagonal bolt (6.4). Horizontal 5.1 Attach the second rail (2/3) as described in steps 1 to 3 and position it vertically. To do so, position the rails with respect to each other so that the diagonals D and E are of equal length. Mark the correct position before installing them. Next, fasten both rails in place by tightening the M10 hexagonal bolts (6.4). The rail end pieces (8) must be at the bottom end of the rails. Flat plate collector SOLC 220 on-roof installation instructions Page 12 of 19

13 Installing the collectors 1. Position the square nuts in the slot on the back of the collector with a screwdriver and secure them with the installation aid (4.4). Using the installation aid, the square nut can easily be positioned for further installation of the fixing profile (4.2) when the collector (1) has been erected. 2. Preassemble the mounting profile (4.2) with an M8 hexagonal bolt (4.1) and washer (4.3) on the square nuts on the rear side of the collector. When installing the mounting profiles, pay attention to the planned orientation of the collector on the roof (and thus the position of the immersion sleeves). Observe the chapter on hydraulic connection! 3. Determine the definitive lower spacing C of the mounting profiles (4.2) on the collector. To do so, keep a distance of mm between the lower edge of the collector and the lower mounting profile for vertical installation and mm for horizontal installation. Attach the upper mounting profiles in accordance with the spacing A of the rails (2/3) to the lower mounting rails. The distance B to the top edge of the collector must also be within the range given above. The mounting profiles must be facing downwards. Preassemble the securing screws (4.5) 100 mm beneath the lower mounting profiles. Flat plate collector SOLC 220 on-roof installation instructions Page 13 of 19

14 Installing the collectors 4. Punch the two drainage holes at each bottom corner of the collector, according to how it is positioned on the roof, with the aid of a slotted screwdriver. To do so, punch at the bottom edge. To ensure that water can drain properly from the collector, it is absolutely essential that all drainage holes are punched at the bottom of the collector (depending how it is oriented on the roof). 5. Hoist the collectors (1) onto the roof. For hoisting onto the roof, fix two sufficiently sturdy ropes to the collector as shown in the diagram. When doing so, make sure that the ropes are not fed over the plastic edges of the collector. We recommend using a crane for doing the lifting. If necessary, carefully hoist the collector up onto the roof via a ladder. Work as a pair: one installer secures the collector, the second guides it. Observe the labour safety regulations! Do not walk under suspended loads. Secure the collectors (1) to prevent them falling! Vertical 6. Carefully lift the basic kit collector (1) onto the rails (2), remove the hoisting guys and position the collector. To do so, position the collector against the rail end pieces (8) and slowly let it slide downwards until the mounting profiles (4.2) lock into the rails (2). Next, position the securing screws (4.5) against the rail from underneath and tighten it. Horizontal 6.1 Carefully lift the basic kit collector (1) onto the rails (2), remove the hoisting guys and position the collector. To do so, let the collector slowly slide downwards against the rail end pieces (8) and move it sideways until the mounting profiles (4.2) lock into the rails (2). Next, position the securing screws (4.5) against the rail from the side and tighten it. Flat plate collector SOLC 220 on-roof installation instructions Page 14 of 19

15 Installing the collectors 7. Installing more collectors For both horizontal and vertical installation, first stick the spacer (7.5) onto the rails with the stopper against the first collector. The next collector must be positioned next to the spacers. 8. Coat the O-rings of the corrugated pipe compensators (10.1) with silicone paste (9.5) and fit one of them in each of the connection of the preassembled collector. The compensators must be slid into the connections of the collector till the compensator bellows fit tight to the connectors. Ensure that the O-rings sit tight in their fittings Use excluding the paste contained in the scope of supply. Vertical 9. Position the next collector (1) on the rails and slowly let it slide downwards along the spacers until the mounting profiles (4.2) lock into the rails (3). Next, position the securing screw (4.5) against the rail from underneath and tighten it. Flat plate collector SOLC 220 on-roof installation instructions Page 15 of 19

16 Installing the collectors Horizontal 9.1 Position the next collector (1) on the rails and move it sidewards until the mounting profiles (4.2) lock into the rails. Let collector slowly slide downwards until it locks into the spacers. Next, position the securing screw (4.5) against the rail from the side and tighten it. 10. Put in two insert rings (10.2) in the 4th and 5th trough of the corrugated pipe (10.1), counted from the end, on the side faced to the next collector. Next insert corrugated pipe (10.1) until blocked by the 1 st insert ring. The same procudure needs to done on the other side. If all rings are fitted they are laying on the compensator connections and straighten it. So that the compensator is correctly placed must the restrictor inserts in the marked (4. and 5.) wave valleys lie. 11. Pull clips (10.3) over the collector connections and the outer insert rings, then press with a snip and screw it. Make sure that the outer insert ring is covered by the clip. After installing the last collector, attach two rail end pieces (8) to the open ends of the rails (2/3). Flat plate collector SOLC 220 on-roof installation instructions Page 16 of 19

17 Hydraulic connection 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. When planning the collector array, the position of the various connection parts must be in accordance with the diagrams. The numbering in the diagrams corresponds with the numbering in the parts list. To ensure the full flowthrough of the collector array, the positions of the immersion sleeves must be observed! There are enough connectors supplied to arrange the collectors as shown in the diagrams. If other arrangements are chosen, extra connectors may be required. 1. Diagram 1 shows the connections for connecting a collector. The immersion sleeves must be on the side of the end pieces (9.2). 2. Diagram 2 shows the connections to connect 2 or more collectors with the positions of the pieces of the connection kit (9/10) (the position of the sensor pockets have to be observed as well). Attention should be paid that a collector array of two or more collectors are always diagonal connected. Only then it is ensured that all collectors are flown through equally. Flat plate collector SOLC 220 on-roof installation instructions Page 17 of 19

18 Hydraulic connection 3. Replace one roof tile with a ventilation tile above each connecting pipes feed-through. Feed the connecting pipes (9.1) through the ventilation tile into the interior of the building. Next, if necessary, seal the sarking membrane with suitable adhesive tape. 4. Coat in O-rings of the connection pipe (9.1) with silicon paste (9.5) and two insert rings (9.2) in the 4th and 5th trough of the corrugated pipe (10.1), counted from the end. Next insert connection pipe (10.1) into collector connection until it blocks. Use excluding the paste contained in the scope of supply. 5. Pull clamps (9.3) over collector connections and outer insert rings, then press with a snip and screw it.. Make sure that outer insert ring is covered by clip! 6. Put in O-rings of the end piece (9.2), coat with silicon paste (9.5) and insert it into collector connection until it blocked. Next pull clips (9.3) over collector connections and outer insert rings, then press with a snip and screw it. Use excluding the paste contained in the scope of supply. Flat plate collector SOLC 220 on-roof installation instructions Page 18 of 19

19 Installing the sensor 1. Carefully remove the plugs from the collector frame. 2. Slide the plugs over the temperature sensor (included with the solar controller). 3. Coat the temperature sensor with heat-conducting paste (included with the solar controller). 4. Insert the temperature sensor fully into the immersion sleeve. Seal the collector frame with plugs. To do so, make sure that the plugs are positioned correctly. Glen Dimplex Flat plate Deutschland collector SOLC GmbH 220 on-roof Telefon: installation +49 (0) instructions Technical specifications Page subject 19 of to 19 change Am Goldenen Feld 18 Telefax: +49 (0) Internet: D Kulmbach Stand 10/2009

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