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KPG1H-ALC

KPG1H-ALC

EN

Installation and Operation Manual

Solar Thermal System with KPG1H-ALC Collectors

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Summary of Contents for KPG1H-ALC

Page 1: ...www regulus eu KPG1H ALC KPG1H ALC EN Installation and Operation Manual Solar Thermal System with KPG1H ALC Collectors ...

Page 2: ...r interconnecting 16 6 Temperature Probe Positioning 18 7 Pump Station 19 8 Expansion Vessel Sizing and Working Pressure Calculation 20 8 1 Expansion vessel sizing 20 8 2 Calculation of a system working pressure 20 8 3 Calculation of an expansion vessel preset pressure 20 8 4 Examples of calculating working pressure and expansion vessel pressure 20 8 4 1 Example of calculating system working press...

Page 3: ... con sult the fastening method with a structural statics expert During installation the collectors and accessories shall be handled carefully Defects caused by improper hand ling or DIY installation are not cover by warranty Generally valid rules and standards for occupational safety shall be respected during installation This con cerns mainly technicians walking on a roof and the secu ring the ar...

Page 4: ...r for slate roofs 11574 Anchor for pantiles hot dip galvanized steel 7929 Aluminum anchor for pantiles rafter mounted 6932 Stainless steel anchor for pantiles 6857 Stainless steel anchor for pantiles rafter mounted incl self tapping screws 10159 Bolt for fitting rails onto a roof 7320 1 DELIVERY OF MOUNTING SYSTEM Supports and support strut for landscape installation on flat roof Code Triangle sup...

Page 5: ...3 9 10 11 Pos Item Code 1 Flat plate collector 11427 2 Roof anchor with M8 bolt special head for rails 6857 or other depending on roofing type Triangle struts for inclination adjustment suitable for anchors for sloping roofs 15 25 and 45 angle 11070 11071 11072 Interconnecting pipes ...

Page 6: ...ectors 2 pcs 10673 11 H rail end plug 4 pcs 4 pcs 11773 Insulation tape 0 8 m 0 8 m 7227 8 22 mm nipple 1 pcs 7629 Nipple 3 4 M M thick wall 1 pcs 6970 Elbow 3 4 M brass 1 pcs 13496 Pipe cross 3 4 F Cu 22mm pipes brass 1 pcs 7632 Single sheath 7x8 x 200 mm 1 sensor 1 2 1 pcs 7217 Capillary spring small 1 2 stainless steel 1 pcs 10845 Extension mount and interconnection kits for 1 KPG1H solar colle...

Page 7: ...the auxiliary board see Fig 3 Installation Remove roofing so that auxiliary boards can be inserted approx distance between boards 800 900 mm For roof tiles just shifting them upwards in the length of the auxiliary board is sufficient see Fig 4 Fit the auxiliary boards to battens so that the distribu tion of anchors resembles the positions in Fig 2 At the same time screw the boards so high that the...

Page 8: ... manufacturer Simply lay the anchor onto the roof tiles and fasten it with stainless steel bolts If the roofing is made of e g copper or zinc pla ted iron then the anchor contact surface shall be isolated using suitable underlay rubber Other wise there is a risk of contact corrosion 2 1 4 Installation using bolts for fitting rails onto a roof This method of installation is preferably used for roof...

Page 9: ...0 40 45 150 7 5 e Roofing bolt for rail fastening RIGHT 10 30 mm Fig 8 Right anchor position with roof tiles c Roof anchor of stainless steel or zinc plated steel for pantiles a Stainless steel anchor on rafter for pantiles incl screws b Aluminum anchor on rafter for pantiles d Stainless steel roof anchor for metal or slate roofing RIGHT 70 230 35 2 Ø6 72 6 ...

Page 10: ...ottom rail 2 brackets per collector Insert the retaining brackets into the bottom rail about 100 mm from the collector edge Lay the first collector carefully on the rails and align it in the brackets Collectors shall be placed on the rails with the connection piping upwards The distance between the bottom edge of the collector and of the base rail depends on the design and size of the retaining br...

Page 11: ...ten the nuts More on this in chapter 5 Hydraulic Connection Continue mounting further collectors in the same way see page 14 48 6 7 5 For passing the connection pipes through a roof e g ventilation tiles can be used where the hole is modified according to the diameter of the pipe with insulation Anyway standards of the roofing manufacturer shall be respected for pipe passage through a roof 3 CONNE...

Page 12: ...te collector 11427 2 Triangle support for horizontal installation on flat roof Number of collectors No of supports needed 10907 10921 12786 1 2 2 3 3 Support strut incl bolts for triangle supports for horizontal installation on flat roof 10908 Horizontal collector installation 3 2 1 8 9 6 7 5 4 10 11 12 ...

Page 13: ... Retaining bracket between 2 collectors 2 pcs 10673 12 H rail end plug 4 pcs 4 pcs 11773 Insulation tape 0 8 m 0 6 m 7227 9 Threaded fittings 22 mm 1 pcs 7629 Nipple 3 4 M M thick wall 1 pcs 6970 3 4 M M Brass Elbow 1 pcs 13694 Pipe cross 3 4 F Cu 22mm pipes brass 1 pcs 7632 Single sheath 7x8 x 200 mm 1 sensor 1 2 1 pcs 7217 Capillary spring small 1 2 stainless steel 1 pcs 10845 Extension mount an...

Page 14: ...grooves cca 350 mm D2 2 4 4 885 mm T strut base rails L strut D1 Fig 15 Aligning the rails and mounting the first triangular support Assemble the triangular supports that come partially screwed together Fig 16 Join the loose support ends with a bolt Fig 16 and tighten all connections Locate the positions to fit triangular supports The distance of the first triangular support from the end of the ra...

Page 15: ...ar supports is similar to that of roof anchors in Fig 2 and the last support shall be located about 350 mm from the ends of both rails After fitting the strut and other supports kip the entire structure into the position intended for collector installation The strut is upright T rail of each triangular support lies on the ground spanner No 13 3 strut 2 c Fig 19 Installation of further supports Fig...

Page 16: ...ructions in chapter 5 2 Fasten the first collector and lay the following one next to the first one maintaining a sufficient gap Then put the threaded fittings on both the upper and lower out lets and push the collector to the already mounted until stop Hold the fitting with a spanner Fig 23 to prevent turning and tighten the nuts Continue in the same way with further collectors Put the insulation ...

Page 17: ...r connection piping we recommend using KOMBIFLEX stainless steel flexible pipes or copper pipes connected by soldering In no event plastic tubes can be used for inlet outlet pi ping as they do not meet the operation requirements for solar thermal systems Pipes for collectors can be lead through disused chim neys ventilation shafts or grooves in a wall In order to prevent high thermal losses throug...

Page 18: ...e temperature sensor into the pocket of the X piece at the outlet from the last collector see pic 25 A twisted wire 2x1 mm2 non shielded should be used separated from power cables Its maximum length is 100 m Minimize the number of electrical boxes a terminal blocks connection length up to 25 m cross section 0 25 mm2 connection length up to 50 m cross section 0 5 mm2 connection length up to 100 m c...

Page 19: ... No shut off valve shall be installed between a safety valve and collectors Fig 26 Solar Pump Station 1 2 3 4 5 6 7 8 9 10 1 Ball valve on flow line red frame thermometer 0 120 C dial with check valve 2 Ball valve on return line blue frame thermometer 0 120 C dial with check valve 3 Safety unit protects the installation from overpressure It involves a 6 bar safety valve manometer and G connection ...

Page 20: ... p pressure in a solar thermal system bar h height from a pressure gauge to the middle of a col lector field m Adjust the pressure by discharging solar liquid after the pressure test is done 8 3 Calculation of expansion vessel preset pressure Before filling the system adjust the initial overpressure in the expansion vessel to a value by 0 5 bar below the calculated system pressure p exp p 0 5 bar ...

Page 21: ...les from the fluid see pic 29 A ball valve shall be always installed under the automatic air vent valve so that the automatic air vent can be clo sed after the system commissioning Solar liquid leaks can be avoided in case of system stagnation For an efficient removal of bubbles from the system it is advisable to fit the pump station with an air separator see Fig 28 9 INSTALLATION OF AIR RELEASE V...

Page 22: ...connect the filling pump hoses set the circulation pump s to the highest speed and repeat switching on and off to air bleed the system an air free pump works almost noiselessly watch the system pressure and when it starts falling increase it by turning on the filling pump and opening the feed valve to 5 bar repeat air bleeding so long until the float in the flowmeter s regulation valve takes a ste...

Page 23: ...m pressure and pump operation shall be checked Once a year preferably during a sunny day it is nece ssary to check the working order and tight fastening of the collectors verify the system tightness and pressure incl pressure in the expansion vessel and the pump operation At least once in every 2 years the solar fluid shall be checked for its antifrost properties The system shall be always repleni...

Page 24: ...ut at 1000 W m solar irradiance Qmax 1866 W Collector efficiency at zero heat loss η0b 0 744 per gross area 0 812 per aperture Linear collector heat loss coefficient a1a 3 716 W m2 K per gross area 4 054 W m2 K per aperture Quadratic collector heat loss coefficient a2a 0 013 W m2 K2 per gross area 0 014 W m2 K2 per aperture Insulation thickness 40 mm Empty weight 38 kg Width x Height x Depth 2150 ...

Page 25: ...elation to gross area Col at G 1000 W m2 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 20 40 60 80 100 Efficiency tm ta K p mH2O Collector Pressure Drop Graph 0 00 0 02 0 04 0 06 0 08 0 10 0 100 200 300 400 500 600 700 p mH2O Q l h ...

Page 26: ...26 85 2150 1170 70 ø22 2193 21 5 15 CONNECTION DIMENSIONS ...

Page 27: ...heck pipe insulation Check the proper flow rate Check temperature probes Check the quality of antifreeze liquid with a refractometer Check the heat carrier pressure replenish if necessary Check the controller settings Check for possible error messages in the controller and their reason Check wiring Check backup heating function el heating rod gas fired boiler Check the magnesium anode rod in the t...

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Page 29: ...t the service action This Service Action has been carried out by an authorized servicing company Date of Service Action Name of the servicing company Address of the servicing company Name of the servicing person Contact phone Description of the intervention Signature of the person who has carried out the service action This Service Action has been carried out by an authorized servicing company Dat...

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Page 32: ... 2021 We reserve the right to errors changes and improvements without prior notice REGULUS spol s r o E mail sales regulus eu Web www regulus eu v1 3 11 2021 ...

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