Wolf CFK-1 Installation, Operating And Maintenance Instructions
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Wolf CFK-1 Installation, Operating And Maintenance Instructions

Wolf CFK-1 Installation, Operating And Maintenance Instructions

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Installation, operating and
maintenance instructions
High performance solar collector
CFK-1
Roof top installation with
AluPlus installation system
Single-row roof integration
P 9
Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +498751/74-0, Fax +498751/741600, Internet: www.wolf-heiztechnik.de
3062815_201508
Subject to technical modifications
GB

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Summary of Contents for Wolf CFK-1

  • Page 1 Installation, operating and maintenance instructions High performance solar collector CFK-1 Roof top installation with AluPlus installation system Single-row roof integration Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +498751/74-0, Fax +498751/741600, Internet: www.wolf-heiztechnik.de 3062815_201508 Subject to technical modifications...

  • Page 2: Table Of Contents

    Contents Contents Standards and regulations ........4 Safety instructions / Protection against lightning .
  • Page 3 Specification Collector CFK-1 Casing Deep-drawn aluminium tray, natural, sea-water resistant. Dimensions (L x W x H) / (external edge) 2099 x 1099 x 110 mm 2.3 m² Gross surface area Effective absorber area 2.0 m² Weight (dry) 36 kg Content 1.1 litres...

  • Page 4: Standards And Regulations

    Standards and regulations Standards and Observe the locally applicable regulations, rules and guidelines during regulations assembly, installation and operation. The following standards and regulations must also be observed: Installation on roofs Observe all current Health & Safety regulations - EN 1991 (+NA) Effects on load-bearing structures In particular Parts 1-3: Snow loads...

  • Page 5: Safety Instructions

    Safety instructions / Protection against lightning The following symbols are used in conjunction with these important instructions Safety instructions concerning personal safety, as well as operational reliability. "Safety instructions" are instructions that must be observed exactly, to prevent injury and material losses, e.g.

  • Page 6: Snow And Wind Loads

    A precise calculation of the assumed loads must be carried out for each specific installation, in line with EN 1990 (+NA) and EN 1991 (+NA) and under consideration of regional regulations. CFK-1 collectors may be used for pressure and suction loads of up to 2.4 kN/m². By using the snow load extension set, the maximum permissible pressure load may be increased to 4 kN/m².

  • Page 7: Information On System Hydraulics

    Information on system hydraulics With alternating pipework a maximum of 10 CFK-1 collectors may be connected in parallel. - Do not use zinc-plated/galvanized pipes, fittings, etc. Thermal insulation must be temperature-resistant to >175 °C, in external areas it must also be UV and weather-resistant. Only use the gaskets supplied.

  • Page 8: Information Regarding The System Hydraulics

    SEM-1-1000 All details are recommendations and may vary from system to system. The expansion vessel sizes stated are valid for a static head of up to 10 metres only. Pressure drop, CFK-1 with ANRO 30 °C 3 coll. 1 coll.

  • Page 9: General Preparations

    General preparations Transport and storage For handling and storage of the collector pile only use the packing strips and pallets. Never move more than 16 collectors in a single pile and never store more than 24 collectors in a single pile. Never move collectors with the glass facing down.
  • Page 10 Compensator Return connector (compulsory for Plug roof integration) Grub screws M8 x 30 Layout example: 3 CFK-1 collectors, on end, alternating pipework (max. 10 collectors) Flow connector Compensators Are all gaskets in place? Sensor well Plug opposite the connectors Plug opposite the connectors...

  • Page 11: Rooftop Installation - General

    Length of mounting rail Alu + for 3 collectors mounted on end 3290 mm Length of mounting rail joiner: 100 mm Collector width: 1100 mm Distance between installed collectors: 31 mm Number of CFK-1 collectors Collector array width [m] 2.23 3.36 4.49 5.62 6.75 7.89...
  • Page 12 Rooftop installation - General >15° Preparatory installation of roof hooks Top roof hooks Bottom roof hooks Fitting roof hooks to battens Short bracket (installed before) on top M8 washer nut M8 x 20 coach bolt M8 washer nut M8 x 20 M8 x 20 coach bolt coach bolt...

  • Page 13: Rooftop Installation

    Rooftop installation - Interlocking tiles, plain tiles >15° Special features for interlocking or plain tile roofs Roof hook installation on battens (example for 2 collectors) Fitted top roof hook Mounting rail If required, trim or bend Mounting rail the roof hook over Min.
  • Page 14 Rooftop installation - Interlocking tiles, plain tiles >15° Fitting the roof hooks to the rafters (Example for 2 collectors) Fitted top roof hook If required, trim or bend the roof hook over Mounting rail Mounting rail Min. 3 rows Option Snow load extension set M8 x 20 coach bolt Fit hooks bottom / top...

  • Page 15: Rooftop Installation - Slate Tiles

    Rooftop installation - Slate tiles >15° Special features for rooftop installation on slate roofs with slate hooks Option Snow load extension set with hooks Lead flashing Collector array width M8 x 20 coach bolt Crosshead screw 6 x 70 mm M8 x 20 coach bolt Mounting rail M8 x 20 coach bolt...

  • Page 16: Rooftop Installation - Corrugated Roof

    Rooftop installation - Corrugated roof >15° Special features for corrugated/sheet steel roofs with double-ended screws Option Snow load extension set Max. 0.4 m Max. 0.4 m Double-ended screw rail protrusion rail protrusion with mounting plate Rail width Fitting the Aluminium mounting plate 6 mm Use thread-locking double-ended screw compound to prevent...
  • Page 17 Rooftop installation of collectors >15° Collector mounting M8 x 20 combination screw grub screw washer nut - Are all gaskets in place? - Maintain the necessary distance - Align all threaded fittings - Counter hold with a second open-ended spanner max. torque 20 Nm 1.

  • Page 18: Roof Integration - Interlocking Tile

    Roof integration - Interlocking tile 30-60° For safety reasons, the [German] roofing contractor’s association specifies a CAUTION covered substrate with bitumen sheeting or other suitable material below the collector area to prevent the ingress of moisture in case of leaks. This must terminate in the roof gutter. Standard delivery Edge Installation parts protector...
  • Page 19 Roof integration - Interlocking tile 30-60° Roof integration overview Wooden spacers in the thickness of the battens Triangular sealing strip Recommendation: Top panel Stuff the space below the top panel at the tile Collector contact point to prevent the tile from pushing through.
  • Page 20 Roof integration - Interlocking tile 30-60° Installation of the lower mounting rail 8 x 80 Wooden spacer (batten thickness less 9 mm) Mounting rail Overlap > 5 cm Flashing tape 1. After fitting the extension, centre the mounting rail so that a gap of less than 12 cm is created on both sides between the collector array and the finished tiling. If this is not possible, use half tiles or cut tiles to size. Ensure that the gap dimension remains <12 cm to ensure the roof cover is fully rainproof.
  • Page 21 Roof integration - Interlocking tile 30-60° Collector installation Top mounting rail 8 x 80 Top mounting rail M8 x 20 combination screw Wooden spacer (batten height) Bottom mounting rail Flashing tape washer nut Wooden spacer (batten height less 9 mm) CAUTION - Are all gaskets in place? - Maintain the necessary distance...
  • Page 22 Roof integration - Interlocking tile 30-60° Installation of the intermediate panels Tabs Intermediate panels Flashing tape Fold Intermediate panel 1. Push in the intermediate panels as per diagram. If this should foul during Create a fold the installation, correct the collector position. Then bend the tabs at the top of the intermediate panels to prevent them from sliding through.
  • Page 23 Roof integration - Interlocking tile 30-60° Installation of the skirts Clamp Wood screw Triangular sealing strip (2 pce. per top panel) at the top 4 x 60 Top panel Edge protector Wooden spacer height = batten Triangular sealing strip at the top and side Rafter 4 x 30...

  • Page 24: Roof Integration - Slate Roof

    Roof integration - Slate roof 15-60° For safety reasons, the [German] roofing contractor’s association specifies a CAUTION covered substrate with bitumen sheeting or other suitable material below the collector area to prevent the ingress of moisture in case of leaks. This must terminate in the roof gutter. Standard delivery Edge protector Top skirts Installation parts...
  • Page 25 Roof integration - Slate roof 15-60° Construction Top panel Collector Mounting rail Flashing tape Waterproof substrate Installation and extension Flashing tape Connecting rail Flashing tape base, left of the lower mounting rail base, right 4 x M8 x 16 coach bolts 2 x M8 x 16 Mounting rail for Mounting rail for...
  • Page 26 Roof integration - Slate roof 15-60° Collector installation 8 x 80 Top mounting rail Top mounting rail M8 x 20 Bottom mounting rail Flashing tape washer nut CAUTION - Are all gaskets in place? - Maintain the necessary distance - Align all threaded fittings - Counter hold with a second open-ended spanner max.
  • Page 27 Roof integration - Slate roof 15-60° Installation of the intermediate panels Tabs Intermediate panels Fold Intermediate panel Flashing tape Create a fold 1. Push in the intermediate panels as per diagram. If this should foul during the installation, correct the collector position. Then bend the tabs at the top of the intermediate panels to prevent them from sliding through.
  • Page 28 Roof integration - Slate roof 15-60° Mounting the flashing pieces / lift plates 1. Fit bottom lift plate to the fold in the flashing tape and trim with scissors if necessary. Ensure sufficient overlap (8-10 cm). 2. Align lift plates parallel to glass retaining strip of collector, at a distance of 65 mm. 3. Fix the lift plates at the top with 2 nails each. 4. Refit roof tiles on both sides, roughly to upper edge of collector.
  • Page 29 Roof integration - Slate roof 15-60° Fitting the top edging panel Loosely place tiles and upper edging panel in final position 1. Loosely place tiles and upper edging panel in their final position. 2. Fit top lift plate and cut to size. Ensure sufficient overlap (8-10 cm). 3. Firmly secure lift plate and tiles. 4. Depending on the size and overlap of the tiles a dimension X results, by which the collector must be raised in order to fit the upper edging panel.
  • Page 30 Roof integration - Slate roof 15-60° Mounting the edging panels Edge protector Metal retainers 1. Fit the top edging panels with 2 metal retainers each. 2. Cover the joints in the top edging panel with the edge protector. 3. Hook the side panels into the glass retaining strip of the collector using a rotating motion and slide them upwards until they are flush with the collector at the bottom.

  • Page 31: Roof Integration - Mönch-Nonne

    Roof integration - Mönch-Nonne 15-60° For safety reasons, the [German] roofing contractor’s association specifies a CAUTION covered substrate with bitumen sheeting or other suitable material below the collector area to prevent the ingress of moisture in case of leaks. This must terminate in the roof gutter. Standard delivery Edge Top skirts Assembly components protector...
  • Page 32 Roof integration - Mönch-Nonne 15-60° Construction Wooden spacers in the thickness of the battens Triangular sealing strip Recommendation: Top panel Stuff the space below the top panel at the tile Top mounting rail contact point to prevent the tile from pushing Collector through.
  • Page 33 Roof integration - Mönch-Nonne 15-60° 1. Pre-drill with Ø 5 mm bit and secure the mounting rail and timber spacers (batten thickness less 9 mm) to the rafters with the hexagonal screws 8 x 80. 2. Affix the flashing tape, taking care to remove the protective foil only in the area to be affixed to the mounting rail. The flashing tape must protrude on the left and right approx. 40 cm over the flashing tape bases. If several strips of flashing tape are used these must be joined with an overlap of at least 5 cm. (Do not yet affix the flashing tape to the roof tiles as the collectors have yet to be secured to the mounting rail.) Collector installation Top mounting rail...
  • Page 34 Roof integration - Mönch-Nonne 15-60° Installation of the Tabs intermediate panels Intermediate panels Flashing tape Intermediate panel 1. Push in the intermediate panels as per diagram. If this should foul during the installation, correct the collector position. Then bend the tabs at the top of the intermediate panels to prevent them from sliding through.
  • Page 35 Roof integration - Mönch-Nonne 15-60° Remove protective foil. Apply uniform pressure (e.g. with a hammer) Affix the tape end to the support Create a fold and the highest point. Mark the width of 2 tiles along the entire length of the flashing tape and trim. Affix the entire tape to the support, starting at the highest point.
  • Page 36 Roof integration - Mönch-Nonne 15-60° Installation of the skirts Wood screw Triangular sealing strip at Clamp (2 pce. per top panel) 4 x 60 the top Top panel Edge protector Wooden spacer height = batten Triangular sealing strip at the top and side Rafter Hook in side panel...

  • Page 37: Fitting The Sensors

    In stagnation the collectors can reach temperatures of up to 200 °C. Therefore only to use the solar-specific flat gaskets supplied and ensure that the mounting and connecting components used are sufficiently temperature-resistant, particularly near the collectors. Note also the information provided in chapter "Pipework". Example: CFK-1, Air vent trap alternating pipework, up to 10 collectors 1 collector...

  • Page 38: Filling The System / Safety Datasheet / Initial Start-Up

    Not dangerous cargo in the sense of the transport regulations. Water risk category: WGK1; little risk to water. The full safety data sheet is available from the "Download Centre" of the Wolf homepage. Initial start-up During commissioning the solar circuit is flushed, filled and pressurised. At this stage the collector must not transfer any heat - it should be covered, unless solar radiation levels are very low.

  • Page 39: Pressure Testing / Venting The System

    Pressure testing / Venting the system Once the entire solar circuit including the collectors is filled with heat transfer medium, the system must be thoroughly flushed (flow velocity > 0.4 m/s) to ensure that all foreign bodies (scale, swarf, etc.) and air pockets are removed. Experience suggests that the flushing should be maintained for at least 20 minutes in order to flush out all foreign bodies and air pockets.

  • Page 40: System Operating Pressure

    System operating pressure System operating pressure An indication of the correct system operating pressure is an overpressure of 1.5 - 2.0 bar at the highest point of the system when cold. The system operating pressure at the solar module is therefore 1.5 - 2.0 bar plus 0.1 bar per metre of static head between the pressure gauge in the solar module and the highest point of the system.

  • Page 41: Commissioning Check List

    Commissioning check list Installation Collectors installed safe in case of storms Solar line connected to the earthing system Blow-off line permanently secured to the safety valve of the solar circuit Drip container positioned below the blow-off line (solar circuit) Blow-off line fitted to the safety valve and connected to the drain Thermostatic mixing valve installed at the DHW outlet or cylinder temperature limited to 60 °C by the control unit Commissioning...

  • Page 42: Operation / Inspection And Service

    Operation / Inspection and service Operation - A vapour film can appear particularly in the early hours of the morning due to the temperature differential between the outside air and the collector. It will disappear as the collector heats up. Where possible avoid switching off the power during solar irradiation. If vapour forms during very high solar yield, the system starts again automatically after it has cooled down.
  • Page 43 (e.g. collector cleaning, replacement of solar fluid or anode, etc.). Return At the end of their useful life the collectors may be returned to Wolf GmbH. These collectors must be clearly identified (e.g. as "scrap") and be delivered expenses paid during business hours. All collector materials are either correctly recycled or disposed of by Wolf GmbH.

  • Page 44: Inspection And Service Checklist

    Inspection and service checklist Date: Date: Collector inspection Visual collector inspection - Visual inspection of the collector fixings Visual inspection for potential leaks in the roof Visual inspection of the thermal insulation on pipework Solar heating circuit Visual inspection for potential leaks in the solar circuit (joints) Colour check of the ANRO heat transfer medium pH value test of ANRO heat transfer medium only in case the medium has turned brown;...
  • Page 45 Inspection and service checklist Date: Date: Collector inspection Visual collector inspection - Visual inspection of the collector fixings Visual inspection for potential leaks in the roof Visual inspection of the thermal insulation on pipework Solar heating circuit Visual inspection for potential leaks in the solar circuit (joints) Colour check of the ANRO heat transfer medium pH value test of ANRO heat transfer medium only in case the medium has turned brown;...
  • Page 46 Inspection and service checklist Date: Date: Collector inspection Visual collector inspection - Visual inspection of the collector fixings Visual inspection for potential leaks in the roof Visual inspection of the thermal insulation on pipework Solar heating circuit Visual inspection for potential leaks in the solar circuit (joints) Colour check of the ANRO heat transfer medium pH value test of ANRO heat transfer medium only in case the medium has turned brown;...

  • Page 47: Faults - Causes - Remedies

    Faults - Causes - Remedies Notes to system user: Please also refer to the instructions provided for the individual components connected. If it is not possible to rectify a fault, please inform your specialist contractor. Fault Possible cause Remedy Desired flow • Flow rate set too high or • Note the relationship between the flow rate and the temperature not...

  • Page 48: Product Fiche According To Regulation (Eu) No. 811-812/2013

    Pump power consumption solpump Standby power consumption solstandby Annual auxiliary electricity consumption 93.8 93.8 93.8 93.8 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3021001 03/2015 3062815_201508...
  • Page 49 Annual non-solar heat contribution ge tank and load nonsol profile Pump power consumption solpump Standby power consumption solstandby Annual auxiliary electricity consumption 93.8 Wolf GmbH, Postfach 1380, D-84048 Mainburg, Tel. +49-8751/74-0, Fax +49-8751/741600, Internet: www.wolf-heiztechnik.de Material number: 3021001 03/2015 3062815_201508...

  • Page 50: Notes

    Notes 3062815_201508...
  • Page 51 Notes 3062815_201508...

  • Page 52: Declaration Of Conformity

    Applied standards and EN 12975-1 specifications: EN 12975-2 We, Wolf GmbH, Industriestraße 1, D-84048 Mainburg, Germany hereby declare that the above solar collectors comply with the appropriate regulations laid down in the Directive 97/23/EC. This declaration loses its validity, if the product has been modified without our express permission. Observe the safety instructions in the documentation and the operating instructions.

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