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Summary of Contents for Bosch Worcester FKT Series
- Page 1 FKT SERIES FLAT PANEL SOLAR COLLECTORS IN ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS 63043975.00-1.SD 63043975.00-1.SD Installation instructions...
- Page 2 About this manual This installation manual contains important information for the safe and appropriate installation of the roof mounted solar collectors. Notes are included with important information for situations in which there is no danger for persons or equipment. These technical documents should be retained in a safe place.
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Page 3: Table Of Contents
General information ......... .4 Specifications . -
Page 4: General Information
General information General information This chapter details which technical rules and regulations apply to this installation. USER NOTE Observe all standards and guidelines applicable to the installation and operation of this system in your country. Connection of thermal solar Installation and equipment of DHW Installation work on roofs heating systems cylinders... -
Page 5: Specifications
Specifications Specifications FKT Series solar collectors Certificates 0036 Length 2070 mm Width 1145 mm Height 90 mm Clearance between collectors 25 mm Fluid content, portrait version 1.43 l Fluid content, landscape version 1.76 l Gross absorber surface area 2.37 m² Net absorber surface area 2.23 m²... -
Page 6: Safety
Safety Safety This chapter explains the meaning of the notes you will find in this manual and provides general safety instruc- tions for safe and trouble-free operation. The installation-specific safety and user notes next to the appropriate installation steps are found here. Carefully read the safety instructions before commenc- ing the installation. -
Page 7: Correct Use
Safety Correct use This installation set holds the thermal solar collectors (portrait and landscape), which are installed on pitched roofs with a pitch angle of 25° to 65°. Operating conditions Only erect the installation set on roofs whose construc- tion can support the weight. If necessary, consult a structural engineer or a roofer. -
Page 8: Notes Structure
Safety Notes structure Two levels are identified by signal terms: RISK TO LIFE Identifies possible dangers which might lead to serious injury or death if WARNING! appropriate care is not taken. RISK OF INJURY/SYSTEM DAMAGE Identifies potentially dangerous situations, which might lead to mild or slight injuries CAUTION! or to material losses. -
Page 9: Please Observe These Safety Instructions
Safety Please observe these safety instructions RISK TO LIFE through a fall or falling parts. B Ensure you have the correct safety WARNING! equipment for working on roofs. B Take appropriate action to prevent accidents when working on roofs. B Whilst working on the roof, take all necessary precautions against a possible fall. -
Page 10: Before Installation
Before installation Before installation General notes USER NOTE It is recommended that the services of a roofing company, who are experienced in working on roofs and will be fully aware of the risks of working at height are considered. Make yourself familiar with the on-site conditions and lo- cal regulations before commencing the installation. -
Page 11: Component Description
Before installation Component description 4.2.1 Installation set for the collectors The installation sets are for fixing the collectors in place and sealing them. The lower facing panels (Fig. 2, Item 6, 9 and 10) are designed for slate/shingle roofs with no flashing. If installing more than one row of collectors, basic and extended installation sets are delivered separately. - Page 12 Before installation 4.2.2 Pipework connections For the pipework connection a connection kit and a con- nection set between the collectors will be required. 63043966.03-1.SD 63043966.03-1.SD Fig. 3 Connection kit and connection set (illustration shows 2 portrait collectors) Connection kit, per collector array (Fig. 3) ×...
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Page 13: Other Equipment
Before installation Other equipment – Spirit level – Plumb line – Filling pump – Vest harness with safety rope – Pipe insulation – Scaffolding – Roofing ladder – Crane or mobile hoist – Cordless screwdriver and drill (Ø 4 mm) –... -
Page 14: Technical Documentation
Before installation Technical documentation The solar heating system consists of various compo- nents (Fig. 6). Installation, operation and maintenance documentation is provided for each component. Acces- sories may be accompanied by a separate document. Collector: instructions for in-roof installation Item 1: are enclosed with the connection kit Pump station: instructions enclosed with the Item 2:... -
Page 15: Determining Space Required On Roof
Before installation Determining space required on roof Please note the following minimum space requirements. Dimension A and B Area required for the collector array, incl. facing panels. Dimension C At least two tiles to the roof or chimney. Otherwise there is a risk of damaging the tiles, particularly if the tiles are laid in mortar. -
Page 16: Roof Preparations
Roof preparations Roof preparations RISK TO LIFE Whilst working on the roof, take all neces- sary precautions against a possible fall. WARNING! RISK OF INJURY through a fall or falling parts. B Take appropriate action to prevent ac- WARNING! cidents when working on roofs. B Always wear personal protective cloth- ing and safety equipment. -
Page 17: Determining The Initial Installation Positions
Roof preparations Determining the initial installation positions Before installation, carefully determine the initial posi- Number Dimension A Dimension X Collectors tions. portrait landscape portrait landscape 1.50 m 2.42 m 1.32 m 2.24 m Initial horizontal position 2.67 m 4.52 m 2.49 m 4.34 m B Determine dim. -
Page 18: Fitting Additional Roof Battens
Roof preparations Fitting additional roof battens When laying the facing panels and collectors in place, there will have to be additional roof battens of equal height to those already on the building. USER NOTE As an alternative to additional roof bat- tens, those already present around the collector array area can be adjusted to the same dimensions as the additional roof... - Page 19 Roof preparations 5.2.1 Fitting anti-slip protection devices to first additional roof batten Due to limited space it may be possible for the anti-slip protection devices to be fitted directly on to the roof. If so they should be pre-assembled on the ground and fitted to the first additional roof batten.
- Page 20 Roof preparations USER NOTE If an additional roof batten (Fig. 13, Item 1) has to be fitted near a pre-existing one, the pre-existing one must be moved near to the collector array (Fig. 13, Item 3) and adequately fastened (Fig. 13, Item 2).
- Page 21 Roof preparations Installing more than one row When installing more than one row, the roof battens in the first row must be laid just as if you were installing one row (Fig. 14). The 5th and 6th batten for the lower row are not needed.
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Page 22: Collector Installation
Collector installation Collector installation Observe the following safety and user instructions when commencing the collector installation. RISK TO LIFE through a fall or falling parts. B Take appropriate action to prevent WARNING! accidents when working on roofs. B Whilst working on the roof, take all necessary precautions against a possible fall. -
Page 23: Preparing To Install The Collectors
Collector installation Preparing to install the collectors Before beginning actual installation on the roof, fit the end caps to the collectors on the ground to make work on the roof easier. To secure the end caps (and later the corrugated pipe connectors and connecting pipes as well), attach brackets to the connections. - Page 24 Collector installation 6.1.2 Fitting the end cap Not all the connections are needed when connecting a collector array. Those that are not used must be closed. B Remove rubber caps (transport protection) from the relevant collector connections. B Push end cap with the O-rings (Fig. 20, Item 1) onto the collector connection.
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Page 25: Fastening The Collectors
Collector installation Fastening the collectors Begin laying the collectors on the right-hand side. 6.2.1 Laying first collector B Allow first collector (Fig. 22, Item 1) to slide into 80 mm place in the anti-slip protection device and position 80 mm from the outer (cut if necessary) pan tile (Fig. - Page 26 Collector installation Fitting corrugated pipe connectors to the first collector B Remove the rubber caps from the connections. B Push corrugated pipe connectors (Fig. 45, Item 1) onto the left-hand connections on the first collector. B Push bracket (Fig. 45, Item 2) over the corrugated pipe connector and collector connection to secure the connection.
- Page 27 Collector installation B Tighten the screw on the double-sided clamp (Fig. 27, Item 1). Use a size 10 socket wrench with a minimum length of 80 mm for this purpose. The clamp now grips into the lower edges of the collec- tor.
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Page 28: Collector Sensor Connection
Collector sensor connection Collector sensor connection USER NOTE The collector sensor is supplied with the solar controller. Observe the installation location for single or dual row collector systems (Fig. 30). Insertion point The collector sensor must be fitted in the collector near- est to the flow connection (Fig. -
Page 29: Header Connection
Header connection Header connection Information on laying the header pipes can be found in the complete station installation instructions. The water connection to the header pipes is made using the long flexible connection pipes. It is not permitted to connect a fixed header pipe directly to the collector. USER NOTE Feed the sensor cable together with the flow line under the roof. -
Page 30: Venting Through Air Vent (Accessory) On Roof
Header connection Venting through air vent (accessory) on roof If you intend to vent the solar heating system with an au- tomatic air-vent valve (accessory) at the highest point of the system, run the flow line rising to the air-vent valve (Fig. - Page 31 Header connection 8.2.1 Fitting the air vent valve under the roof B Push connection pipe (Fig. 36, Item 3) onto the flow connection on the collector array and fix in place using bracket (Fig. 36, Item 5). B Feed connection pipe together with the sensor cable through the de-airing tile (Fig.
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Page 32: Fitting The Connection Set For Two Rows (Accessory)
Fitting the connection set for two rows (accessory) Fitting the connection set for two rows (accessory) The connection set (Fig. 37, Item 9) is available as an accessory, and connects two rows of collectors. USER NOTE Fit as many connection parts as possible to the collectors on the ground. -
Page 33: Installing The Facing Panels
Installing the facing panels 10 Installing the facing panels Before you block access to the collector array with the facing panels, you must carry out the following checks: Solar hoses secured with clips? Every collector secured on the left and right with clamps? Sensor inserted as far as it will go and se- cured with clamped joint? -
Page 34: Lower Facing Panels
Installing the facing panels 10.1 Lower facing panels B Bend flashing for all facing panels towards the front (Fig. 41, Item 2). B Likewise, lay the ends of the upper outer facing pan- els (Fig. 41, Item 1) towards the front. 63043975.46-1.SD 63043975.46-1.SD Fig. - Page 35 Installing the facing panels USER NOTE For two landscape collectors, facing pan- els are necessary underneath in the mid- dle (Fig. 44, Item 1). They must overlap by 80 – 100 mm. 80 - 100 mm 80 - 100 mm 63043975.42-1.SD 63043975.42-1.SD Fig.
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Page 36: Side Facing Panels
Installing the facing panels 10.2 Side facing panels BUILDING DAMAGE from leaks in the roof. CAUTION! B Place the mounting plates (Fig. 47, Item 2) into the lower edge of the col- lector. B Place the edge of the right and left side facing panels (Fig. -
Page 37: Middle Facing Panel (When More Than One Row Is Being Installed)
Installing the facing panels 10.4 Middle facing panel (when more than one row is being installed) The space between two collector arrays is sealed with the middle facing panels. B Insert the upward fold on the facing panel (Fig. 50, Item 2) into the recessed grip on the collector frame. -
Page 38: Side Facing Panels On The Upper Row (If Installing More Than One Row)
Installing the facing panels 10.5 Side facing panels on the upper row (if installing more than one row) B Fit the upper side facing panels (Fig. 53, Item 1) in the same way as the lower ones (Chapter 10.2 "Side facing panels"). - Page 39 Installing the facing panels B Shorten the rubber lip (Fig. 56, Item 2), so that it touches the rubber lip on the right-hand facing panel. B Place rubber lip on the left-hand facing panel onto the fold on the right-hand facing panel (Fig. 56, Item 1). 63043975.47-1.SD 63043975.47-1.SD Fig.
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Page 40: Covering The Roof
Installing the facing panels 10.7 Covering the roof USER NOTE Fasten cut pan tiles with suitable brackets if necessary (available from a roofing spe- cialist). BUILDING DAMAGE from roof leaks if pan tiles are not placed far enough over the facing panels. CAUTION! 10.7.1 Upper pan tiles B Place one whole pan tile on top of the upper facing... -
Page 41: Final Activities
Final activities 11 Final activities USER NOTE If you are venting the solar heating sys- tem with an automatic air-vent valve (ac- cessory), you must close the ball valve after the venting procedure (see pump station installation instructions). 11.1 Checking the installation In addition to the checks on page 33, you must check the following: –... -
Page 42: Quick Reference Guide For Two Collectors
Quick reference guide for two collectors 12 Quick reference guide for two collectors These instructions are only intended as an overview of the work to be carried out. You MUST follow the detailed descriptions for the work on the pages mentioned, and obey all safety and user instructions. - Page 43 6 720 613 057 (2006/04)
- Page 44 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 6 720 613 057 (2006/04)