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Bosch FKC-1 Installation Manual
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Bosch FKC-1 Installation Manual

Bosch FKC-1 Installation Manual

Solar thermal flat plate collectors rack system for flat roof and wall installation
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Solar Thermal Flat Plate Collectors FKC-1
Rack System for Flat Roof and Wall Installation
Installation Manual
for Contractors
63043970.01-1.SD
63043970.01-1.SD

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Summary of Contents for Bosch FKC-1

  • Page 1 63043970.01-1.SD 63043970.01-1.SD Solar Thermal Flat Plate Collectors FKC-1 Rack System for Flat Roof and Wall Installation Installation Manual for Contractors...

  • Page 2: Table Of Contents

    ........53 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 3: General

    (installation height) exceeds 66 ft (20 m), it is recommended to have lightning arrestors installed on the tallest equipment including the solar collectors. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 4: Specifications

    Net weight, Portrait version (41 kg) 93 lbs Net weight, Landscape version (42 kg) Permissible operating pressure 87 psi of the collector (6 bar) Tab. 1 Specifications 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 5: Safety

    66 ft (20 m) and a maximum snow load of 42 lbs/sqft (2.0 kN/m²). Ensure that falling rain water, snow, and ice do not cause a nuisance or hazard below. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 6: Guideline Of Notices

    CAUTION! CAUTION! result from altered construction. B Never modify structural elements. B Never drill additional holes. B Never attach non-system related components (e.g. antennas). 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 7: Before Installation

    It is recommended to consult a Fig. 2 Wall mounted collectors professional roofer if roof repairs are necessary. Have the work completed before installing the solar equipment. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 8: Component Description

    M8 nut × × Collector hanger Bottom rail × Collector hanger NOTICE For higher snow and wind loads, auxiliary braces and additional horizontal rails are needed. 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 9 (in two of the collector's protective corners, Fig. 5) × Hose clamp × Collector connection hose 63043965.05-1.SD 63043965.05-1.SD Fig. 5 Two protective corners carry the collector connection sets Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 10: Other Equipment Needed For The Installation

    Fig. 6 Rubber caps on collector connections weather proof. Protect the collectors using a tarp during transport in wet weather in an open truck. 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 11: Technical Documentation

    Area of application, inclination range NOTICE Above tab. 2 is valid for areas at 40-60° Latitude. For areas further north steeper angles, and further south shallower angles are recommended. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 12 (Fig. 10, [2]) must be between 30° and 45°. 63043970.27-1.SD 63043970.27-1.SD Fig. 10 Permitted inclination of the collector on a wall Inclination to the horizontal plane Angle to the wall 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 13 5-1/2 inches (140 mm) and use the lower hole (Fig. 12, [2]). Fig. 12 Adjustment angle for Portrait collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 14: Determining Space Requirements

    264 in (6.74 m) 146-7/16 in (3.73 m) 60° 271 in (6.90 m) 150-7/10 in (3.82 m) Tab. 3 Required clearance between two collector arrays to avoid shading 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 15 In addition, allow at least 1-1/2 ft (0.5 m) on either side of the collector array for pipework. 63043970.10-1.SD 63043970.10-1.SD Fig. 16 Space requirements – collector array – Portrait collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 16 (18.88 m) (0.85 m) 38' 4-3/4" 68' 10" (11.70 m) (20.98 m) Tab. 5 Space requirements for Landscape collectors Tab. 4 Space requirement for Portrait collectors 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 17: Installing Racks On Flat Roofs And Walls

    The Landscape version is installed in the same way. Notes identify any variations. 63043970.23-1.SD 63043970.23-1.SD Fig. 18 Flat roof rack for 2 Landscape collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 18: Distances Between Collector Triangles

    Fig. 20 Basic version for 3 – 10 Portrait collectors (1820 mm) (1820 mm) (275 mm) Fig. 21 Basic version for 2 Landscape collectors 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 19: Clearances Between The Collector Triangles When Using Ballast Trays (Accessory)

    4th, 7th and 10th collector in order for the ballast trays to fit (Fig. 23, [1]). See Tab. 7 for minimum ballast tray weights. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 20 22 1/2 in 15 in (571 mm) (571 mm) (381 mm) Tab. 6 Distances between triangles Fig. 23 Basic version for up to 10 Portrait collectors 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 21: Stablizing The Flat Roof Rack

    – Tie down the racks using guy lines as necessary. For all methods, please consider the structural integrity of the roof. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 22 742 lbs-ft (3.3 kN) (20 to 100 m (151 km/h) Tab. 7 Minimum measures to stabilize one collector With additional profile rail only Per collector triangle Or equivalent 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 23 2 guy wires (Fig. 28, [1]). 63043970.20-1.SD 63043970.20-1.SD Fig. 28 Flat roof rack with guy wires Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 24: Wall Mounting Racks - Installation

    B Never place or mount objects in the space underneath the collector racks, or mount non-related equipment to the racks. B Do not close off the sides and bottom of the racks. 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 25: Installing The Profile Rails

    B To lock, tighten both installed M10 threaded studs (Fig. 31, [3]) in the connector using a size 5 Allen wrench: 63043965.33-1.SD 63043965.33-1.SD Fig. 31 Connecting profile rails Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 26 (Fig. 33, [3]) right (Fig. 33, [3]) Tab. 9 Aligning the lower and upper profile rails when using ballast trays 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 27 (Fig. 36, [2]). 63043970.24-1.SD 63043970.24-1.SD Fig. 36 Attaching collector hanger Slots for hanger Snap the hanger in place Collector hanger Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 28: Collector Installation

    3-point suction handles or special carrying handles (available as accessories) for easier lifting. NOTICE Unsecured collectors may fall during handling and installation. 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 29: Preparing To Install The Collectors

    (accessory) will be installed at the highest point of the system, pitch the supply and return pipes toward the top. 63043970.51-1.SD 63043970.51-1.SD Fig. 41 Water connection – supply line (left) Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 30 63043965.41-1.SD 63043965.41-1.SD Fig. 43 Fitting the dummy plug and hose clamp Hose clamp 2" (55 mm) solar hose Dummy plug 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 31: Attaching The Collectors

    63043970.31-1.SD 63043970.31-1.SD Fig. 45 Fitting the single-sided collector clamp Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 32 Do not tighten the screw until the second collector has been pushed up against the double-sided collector clamp. 63043970.33-1.SD 63043970.33-1.SD Fig. 48 Fitting a double-sided collector clamp 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 33 Repeat the procedure for all other profile rails installed, and all other collectors. 63043965.48-1.SD 63043965.48-1.SD Fig. 51 Double-sided collector clamp between two collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 34 NOTICE 63043970.34-1.SD 63043970.34-1.SD When the screw is tightened, the Fig. 52 Single-sided collector clamp (left) plastic guide breaks away at the pre- determined cut-off points. 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 35: Collector Sensor Connection

    Collector sensor B Use cable ties or similar to route the sensor cable Strain relief securely until it meets up with the twin tube. Sensor well Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 36 First remove the nut in the sensor well using the strain relief (Fig. 54, [2]). 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 37: Hydraulic Connection

    63043970.35-1.SD 63043970.35-1.SD B Install supply pipe in the hose clamp. Fig. 56 Fastening holder to the collector frame Hose clamp (not supplied) M8 thread Bracket Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 38: Hydraulic Collector Connection Without An Air Vent

    63043965.58-1.SD 63043965.58-1.SD Fig. 58 Air vent with pipes sloped upward Collector sensor Automatic air-vent above the collector supply pipe 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 39 Hose connector R¾ with O-ring Ensure the air vent is positioned vertically otherwise the float will not Air vent body work properly. Double nipple with O-ring 1/2" Compression fitting Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)

  • Page 40: Connecting Two Arrays

    "Hydraulic collector connection without an air vent". B Make on-site connection between collector array. 63043970.37-1.SD 63043970.37-1.SD Fig. 61 Two collector arrays, one behind the other 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 41: Final Activities

    – For the insulation of internal pipework, use only high temperature resistant materials. – Ensure the insulation is weather, rhodent and bird proof. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2009/12)

  • Page 42: 10 Quick Reference Guide For Mounting And Pressure Filling

    41 Insulate supply and return pipes with UV and high temperature resistant material. 63043970.49-1.SD 63043970.49-1.SD Fig. 64 Fitting the collector sensor and connection parts 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 43: Spare Parts

    Collector | 43 Spare parts SKN 3.0 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 44 Item Part Number Description Weight in lb 7747021978 FKC-1s Solar Flate Plate Collector Portrait 93 1/2 7747021980 FKC-1w Solar Flate Plate Collector Landscape 95 1/2 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 45 Flat Roof and Wall Mounted Installation | 45 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 46 Profile Rail - Cross Support - Landscape 63045244 Double-sided Collector Clamp 63045246 Single-sided Collector Clamp 63045241 Profile connector with threaded studs 0.24 63045243 Collector hanger 63046150 Bracket for supply pipe 0.24 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 47 Connection set FKC | 47 67910062-00-Connection Sets FKC, SKN Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 48 Elbow G1xD21 Ms kpl 0.27 Available Parts: 63045310 O-Ring 21x3,0 Shore70 0.01 Set 5 Each 63045306 Union Assembly FKC/SKN Available Parts: Union Nut G1 D25x17Ms Washer G1xD21 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 49 Row connection set FKC /SKN| 49 67910167-00-raw connection sets FKC, SKN Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 50 Nut G1 D25x17Ms 63045247 Hose clamp 0.19 Set 5 Each 85336132 Solar Hose 3/4"x40" (1000 mm) 1.54 Solar Hose 3/4x4" (95mm) 63045248 Dummy Plug D21 0.14 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 51 Air vent set | 51 FKC/SKN air vent FKC/SKN air vent above the roof below the roof 67910064-00-Air vent valve set FKC, SKN /SKN Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 52 63045249 Hose connector 18 ClampG3/4xD21 kpl Available Parts: 63045301 O-Ring 25x3,0 Shore70 0.02 Set 5 Each 63045250 Compression Ring 5/8" (18mm) 0.05 Set 5 Each 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 53: Certification

    | 53 12 Certifikation Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 54 54 | Notes 6 720 614 820 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 55 Notes | 55 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 820 (2009/12)
  • Page 56 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-584-1681 www.boschsolar.com Products manufactured by Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.