Worcester FKS Series Installation Instructions Manual Download

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FKC SERIES FLAT PANEL
SOLAR COLLECTORS

ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS

Installation instructions

63043965.01-1.SD

Summary of Contents for FKS Series

Page 1: ...FKC SERIES FLAT PANEL SOLAR COLLECTORS ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS GB Installation instructions 63043965 01 1 SD ...

Page 2: ...or equipment These technical documents should be retained in a safe place These may also be inspected at the manufacturer s premises The activities described in the installation manual assume expertise based on completed vocational training in gas or water related installation Only carry out these installation steps if you possess these skills B Hand these installation instructions to the customer...

Page 3: ... 15 5 2 Pan tile roofs 17 5 3 Crown tile roofs 19 5 4 Corrugated sheet roofs 21 5 5 Slate shingle roofs 24 5 6 Sheet roofs 24 5 7 Fitting additional rails accessory 25 5 8 Installing profile rails 26 6 Collector installation 28 6 1 Preparing to install the collectors 29 6 2 Fastening the collectors 31 7 Collector sensor connection 34 8 Header connection 35 8 1 De airing through pressure filling 35...

Page 4: ...anagement of Health and Safety at Work Regulations 1999 The Construction Health Safety and Welfare Regulations 1996 The Construction Design and Management Regulations 1994 The Lifting Operations and Lifting Equipment Regulations 1998 EN 12976 Thermal solar heating system and their components pre fabricated systems ENV 12977 Thermal solar heating system and their components bespoke systems BS 6795 ...

Page 5: ... Height 90 mm Clearance between collectors 25 mm Fluid content portrait version Vf 0 86 l Fluid content landscape version Vf 1 25 l Gross absorber surface area AG 2 37 m Net absorber surface area 2 23 m Net weight portrait version m 41 kg Net weight landscape version m 42 kg Permissible operating pressure of the collector pmax 6 bar DIN 0036 ...

Page 6: ...lation set holds the thermal solar collectors which are installed on sloping roofs with a slope of 25 to 60 The collectors can be installed on corrugated and sheet steel roofs with slopes of between 5 and 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 ...

Page 7: ...sible dangers which might lead to serious injury or death if appropriate care is not taken CAUTION RISK OF INJURY SYSTEM DAMAGE Identifies potentially dangerous situations which might lead to mild or slight injuries or to material losses WARNING RISK TO LIFE from electric shock i USER NOTE Tip for the optimum utilisation and setting of the products plus other useful information ...

Page 8: ...s check the secure positioning of the installed set and that of the collectors CAUTION RISK OF INJURY Injury and operating faults can result from making changes to the system construction B Never change the system construction CAUTION RISK OF INJURY Some parts may cause burns if the collector and installation materials are exposed to solar radiation for longer periods of time B Always wear your pe...

Page 9: ... who are experienced in working on roofs and will be fully aware of the risks of working at height are consid ered Fig 1 General overview of collector pair roof mounting 63043965 02 1 SD 63043965 02 1 SD CAUTION RISK OF INJURY If the collector and its installation material is left exposed to the sunlight for a long period the parts will become hot and may cause burns B Wear protective clothing B C...

Page 10: ...nd 2 roof connection installation sets 63043965 03 1 SD 63043965 03 1 SD 1 2 3 4 7 3 6 5 8 Basic installation set for each collector array and for the first collector Fig 2 Extended installation set for each additional collector Fig 2 Item 1 Profile rail 2 Item 1 Profile rail 2 Item 3 Single sided collector clamp 4 Item 2 Double sided collector clamp 2 Item 7 Anti slip protection 2 Item 7 Anti sli...

Page 11: ...n nection set Fig 3 Connection kit and connection set illustration shows 2 portrait collectors 63043965 04 1 SD 63043965 04 1 SD 1 2 3 4 5 7 8 3 4 6 Item 1 Hose clip 1 x spare 5 Item 6 Clamped joint for collector sensor 1 Item 3 Solar hose length 1000 mm 2 Item 7 Size 5 Allen key 1 Item 4 Dummy plug 2 Item 8 Hose nozzle R with 22 mm compression fittings 2 Item 5 Solar hose length 55 mm 2 Fig 4 Two...

Page 12: ...ollector connections are protected against damage by plastic caps Storage The collectors must be stored in dry conditions i USER NOTE When fitting the roof installation set and pipework connection the only tool re quired is the size 5 Allen key from the con nection kit i USER NOTE Dispose of the transport packaging in an environmentally friendly recycling sys tem Fig 5 Plastic caps on collector co...

Page 13: ...e accompanied by a separate document Fig 6 Solar heating system components and technical documentation 6720613577 00 1 SD 6720613577 00 1 SD 2 1 3 4 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 Item 4 DHW Cylinder inst...

Page 14: ...ension G Minimum 50 cm left and right of the collector array for the connection cables under the roof Dimension H Dimension H is 1 900 mm 1 000 mm for landscape collectors and is the minimum distance from the upper edge of the collector to the lower profile rail which is in stalled first Fig 7 Clearances to be observed G H 63043965 09 1 SD 63043965 09 1 SD Space requirements for portrait collector...

Page 15: ...z z x x 63043965 11 1 SD 63043965 11 1 SD i USER NOTE On pan tile roofs the tile troughs determine the true distance between the roof hooks Installation type Distance w Distance x Distance z portrait approx 1170 mm 610 1030 mm 170 540 mm landscape approx 2090 mm 1520 1950 mm 170 540 mm Tab 5 Distance between roof hooks i USER NOTE Distances x and z should always be approximately equal to distance ...

Page 16: ...043965 10 1 SD 63043965 10 1 SD WARNING RISK TO LIFE Whilst working on the roof take all necessary precautions against a possible fall WARNING RISK OF INJURY through a fall or falling parts B Take appropriate action to prevent accidents when working on roofs B Always wear personal protective clothing and safety equipment ...

Page 17: ...f the holes in the hexagon nut and turn Fig 11 Fitted roof hooks for two collectors 63043965 13 1 SD 63043965 13 1 SD i USER NOTE Do not modify the roof construction and avoid damaging the roof covering In the case of roof tiles laid in mortar lift the tiles starting with the 3rd row under the roof i USER NOTE Carefully cut away the base of the tile if necessary to ensure the tile lies correctly o...

Page 18: ...e 5 Allen key into the hole in the hexagon nut and turn B Using suitable screws fasten the lower part of the roof hook into the first Fig 15 Item 2 and second holes at least of the joist Fig 14 Fastening roof hooks to joists Item 1 Lower part of roof hook Item 2 Long hexagon nut Item 3 Upper hole for fastening the lower part Item 4 Pack if necessary Item 5 Cut off if necessary 63043965 16 1 SD 630...

Page 19: ...to upper hole Fig 17 Item 3 B Loosely fasten lower part of roof hook Fig 17 Item 1 Do not tighten the connection yet Fig 16 Fit boards planks if necessary 63043965 18 1 SD 63043965 18 1 SD 1 1 i USER NOTE Consult a roofer when installing on a roof with crown tiles i USER NOTE If the roof has been fitted with boards the same roof hook as with pan tile roofs can be used page 17 It may also be possib...

Page 20: ... Item 1 to size dashed line Fig 20 Item 2 Fig 18 Fitted roof hook Fig 19 Fitted roof hook cross section showing shortened lower part of roof hook Item 1 Long hexagon nut Item 2 Serated washer Item 3 Screw for fastening roof hook 63043965 20 1 SD 63043965 20 1 SD 1 63043965 21 1 SD 63043965 21 1 SD 1 3 2 CAUTION BUILDING DAMAGE caused by leaks B Fit each roof hook centrally on a crown tile i USER N...

Page 21: ...steel sheets Additional tools required Cordless screwdriver Tape measure Wood drill Ø 6 mm drill bit length see Chapter Fitting the carriage bolts page 22 Metal drill Ø 13 mm Spanner size 15 and 19 63043965 22 1 SD 63043965 22 1 SD 1 5 4 3 2 6 Item 1 M8 screw 4 Item 2 Holding bracket 4 Item 3 M12 nut 4 Item 4 Washer 4 Item 5 Sealing disc 4 Item 6 Carriage bolts 4 CAUTION SYSTEM DAMAGE due to an in...

Page 22: ... Fig 23 Item 5 B Screw the pre assembled carriage bolt into the roof using a size 15 spanner until distance B is reached Fig 22 Creating a drilling template Fig 23 Fitting the carriage bolts sequence Item 1 Holding bracket Item 2 M12 nut Item 3 Washer Item 4 Sealing disc Item 5 M12 carriage bolt 63043965 23 1 SD 63043965 23 1 SD 63043965 24 1 SD 63043965 24 1 SD 5 3 2 4 1 i USER NOTE Using the woo...

Page 23: ...g bracket Item 2 Nut M12 Item 3 Sealing disc 63043965 25 1 SD 63043965 25 1 SD 1 2 3 i USER NOTE B The holding bracket must be screwed fully onto the carriage bolt Height of peak dimension A Dim B 35 mm 70 mm 40 mm 65 mm 45 mm 60 mm 50 mm 55 mm 55 mm 50 mm 60 mm 45 mm Fig 25 Fastening the profile rail to the holding bracket Item 1 Screw Item 2 Profile rail Item 3 Holding bracket 63043965 26 1 SD 6...

Page 24: ...y between carriage bolts as detailed in Tab 5 and Tab 6 page 15 To ensure the roof is water tight sleeves for the carriage bolts Fig 27 Item 5 must be soldered onto the sheet steel roof Fig 26 Mounting on slate shingle roof Item 1 Flashing on building Item 2 Flashing on building Item 3 Multiple roofs Item 4 Gasket on building Item 5 Special roof hooks Item 6 Screw 63043965 27 1 SD 63043965 27 1 SD...

Page 25: ...ls The profile rails must be joined before they are fastened Please see Chapter 5 8 1 Connecting profile rails B Place the profile rails Fig 30 Item 1 into the inden tations Fig 30 Item 2 on the snow load profiles and loosely fasten using bolt and sliding nut Fig 30 Item 3 so that the profile rails can still be aligned B Carry out the same procedure for the other profile rails To continue with the...

Page 26: ...file rails B Push sliding nut Fig 32 Item 1 onto the roof hook in the direction of the arrow B Place the lower profile rails Fig 32 Item 2 onto the roof hooks and loosely fasten M8 bolt Fig 32 Item 3 so that the profile rails can still be aligned B Carry out the same procedure for the upper profile rails Fig 31 Connecting profile rails Item 1 Rail connector Item 2 Profile rail Item 3 M10 threaded ...

Page 27: ...slotted holes Fig 34 Item 1 over the profile rails until it clicks into place Fig 34 Item 2 Fig 33 Aligning the profile rails 90 90 90 90 63043965 35 1 SD 63043965 35 1 SD 1 1 i USER NOTE Measure the diagonals or place a roof batten Fig 33 Item 1 for example at the ends of the profile rails The angle between roof batten and profile rail must be 90 Align the profile rails over the slotted holes i U...

Page 28: ...essary precautions against a possible fall B Always wear your personal protective clothing and safety equipment B After completing the installation always check the secure positioning of the installed set and that of the collectors B Ensure that the correct equipment is used for working on roofs CAUTION RISK OF INJURY through interruption of work B Secure the collectors against falling B Stabilise...

Page 29: ... line Item 1 Solar hose 95 mm Item 2 55 mm solar hose and dummy plug Item 3 Flow line Item 4 Return line Fig 38 Water connection left hand flow line 63043965 38 1 SD 63043965 38 1 SD 1 2 63043965 39 1 SD 63043965 39 1 SD 1 2 2 1 3 4 63043965 19 1 SD 63043965 19 1 SD 1 CAUTION SYSTEM DAMAGE through leaks in the solar hoses B The hose clip MUST be positioned correctly BEFORE the release ring Fig 36 ...

Page 30: ...ections are needed when connecting a collector array so those that are not used must be closed B Remove plastic caps transport protection from the relevant collector connections B Put 55 mm solar hoses Fig 40 Item 2 together with the pre assembled dummy plug onto the two free connections on the collector array B Once the hose clips are sitting correctly pull the quick release rings to secure the c...

Page 31: ...the top to receive the collector sensor Begin by laying the collectors on the right hand side of the profile rails B Place the first collector onto the profile rails and allow it to slide into the anti slip protectors Fig 43 The lower collector edge must lie in the opening of the anti slip protector Fig 43 Item 1 Fig 41 Fasteners for the collector 2 1 63043965 42 1 SD 63043965 42 1 SD 2 1 i USER N...

Page 32: ...ith the pre assembled solar hoses Fig 46 Item 1 onto the profile rails and let it slide into the anti slip protectors B Push the second hose clip Fig 46 Item 3 onto the solar hose B Push the collector towards the first collector Fig 46 Item 2 in such a way that the pre assembled solar hoses are pushed onto the left hand connections on the first collector Fig 44 One sided collector clamp screwed in...

Page 33: ... and lower profile rails B Push collector clamp up against the collector frame and screw in place using size 5 spanner Fig 49 Item 2 Fig 47 Solar hose with hose jubilee clips 63043965 49 1 SD 63043965 49 1 SD CAUTION SYSTEM DAMAGE through unsecured solar hoses and dum my plug B Secure every solar hose to the collec tor connection using a hose clip Fig 47 Fig 48 Double sided collector clamp between...

Page 34: ...or sensor approx 250 mm into the sen sor guide tube as far as it will go B Tighten clamped joint Fig 51 Item 2 counterhold if necessary Fig 50 Collector sensor installation location schematic Item 1 Return line Item 2 Flow line B A 63043965 54 1 SD 63043965 54 1 SD 2 1 2 1 i USER NOTE The collector sensor is part of the pump station or the control unit delivery Observe the installation location fo...

Page 35: ...ace with hose clip B Feed solar hose together with the sensor cable through the ventilation tile Fig 52 Item 1 and through the roof insulation B Connect header pipe to the R hose nozzle with compression fitting 22 mm Fig 53 Item 2 Repeat the same procedure with the return connection Fig 52 Routing connection pipes under the roof Item 1 Flow line Item 2 Return line Item 3 Sensor cable 63043965 56 1...

Page 36: ... posi tioned over the weather protection cap to prevent mois ture entering through the opened weather protection cap into the solar heating system Open the air vent valve by unscrewing the weather pro tection cap one full revolution Universal air vent set scope of supply Fig 55 Fig 54 View air pot with vent valve for flow connection Item 1 Collector sensor Item 2 Automatic air vent valve on roof 6...

Page 37: ...g 57 Item 1 and 5 as far as they will go and fix in place using hose clips Fig 57 Item 2 B Insert hose nozzle with compression fitting Fig 57 Item 6 into the solar hose as far as it will go and fix in place with hose clip B Feed solar hose together with the sensor cable through the ventilation tile Fig 57 Item 7 and through the roof insulation B Connect header pipe to the hose nozzle with com pres...

Page 38: ... B Place the clamping disc Fig 60 Item 2 behind the bead on the collector connection and press together B Press angled nozzle with O ring Fig 60 Item 3 onto connection align and bolt together with union nut B Measure distance between the angled nozzles dim X once the collectors are installed and cut the solar hose Fig 60 Item 5 to size accordingly B Attach solar hose to the angled nozzles and secu...

Page 39: ...he final insulating work only once the appropriate checks have been performed 1 Solar hoses secured with hose clips quick release ring pulled 2 Screws on the collector clamp single sided and double sided tightened 3 Profile rails connected to roof hook and sliding nut 4 Anti slip protection installed and clicked into place in profile rails 5 Sensor inserted as far as it will go and secured with cl...

Page 40: ... 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 uk 6 720 613 577a 2006 04 ...

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