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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. mounting system for sloped roofs
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6720614825.02-1.SD
Solar Thermal Flat Plate Collectors FKC-1
Mounting System for Sloped Roofs
Installation Manual
for Contractors

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Summary of Contents for Bosch FKC-1

  • Page 1 6720614825.02-1.SD Solar Thermal Flat Plate Collectors FKC-1 Mounting System for Sloped Roofs Installation Manual for Contractors...
  • Page 2 ..........54 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 3 (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. 6 720 614 821 (2010/06)
  • Page 4 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 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 5 B Hand these installation instructions to the building owner. B Explain to the customer the function and operation of the related devices. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 6 328 ft (100 m). See Chapter 5.7 "Installing high load rails (accessory)". Do not attach any other devices, e.g. antennas, to collector racks. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 7 B Never attach non-system related B Cover the collector (collector covers components (e.g. antennas). are available as an accessory) during installation to prevent high temperatures resulting from solar radiation. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 8 KS pump stations. This system is not suitable for drain back installations. Only closed loop pressurized systems are permitted. CAUTION! 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 9 NOTICE It is recommended to consult a 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. 6 720 614 821 (2010/06)
  • Page 10 Roof hook for tile roofs, adjustable × Sliding nut NOTICE For higher snow and wind loads, additional horizontal rails and roof hooks may be needed. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 11 Hose clamp × Solar hose, length (95 mm) 63043965.05-1.SD 63043965.05-1.SD Fig. 4 Two of the four protective corners of each collector carry parts for interconnecting collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 12 The collectors must be stored in dry conditions. NOTICE Do not store collectors outside without protection from the rain. 63043965.06-1.SD 63043965.06-1.SD Fig. 5 Rubber caps on collector connections 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 13 Pump station: instructions enclosed with the pump station DHW storage tank: instructions enclosed with the DHW storage tank 63043965.07-1.SD 63043965.07-1.SD Fig. 6 Solar thermal system components and technical documentation Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 14 81 1/2 in (2.07 m) 824 in (20.93 m) 45 5/16 in (1.15 m) Tab. 2 Space requirement for Portrait collectors Tab. 3 Space requirement for Landscape collectors 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 15 Take measures to protect the roof membrane when working on the roof. It is recommended to consult a professional roofer to ensure the membrane is not damaged. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 16 23 5/8 in (600 mm) 32 5/16 in (820 mm) Tab. 5 Distance (center to center) between bottom and top rail 63043965.12-1.SD 63043965.12-1.SD Fig. 10 Distance between profile rails 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 17 B If the roof hook requires adjustment after this time the adhesive may be compromised. It must then be secured on-site (e.g. lock washer). Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 18 L-shaped part of the roof hook to the building Toothed washer substructure. The sheathing alone will not offer sufficient support. Sheathing, or board/shim if needed 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 19 Fig. 15 Repositioning lower part of roof hook CAUTION! not positioned in the upper hole, resulting in uneven load distribution. L-shaped attachment piece Long hex-nut Upper hole Cut off if necessary Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 20 B If necessary cut adjacent shingles/tiles (Fig. 18, [1]) to size (dashed line, Fig. 18, [2]). Fig. 18 Tiles/shingles may have to be trimmed to size 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 21 B Do not install hanger bolts in less than 2x6 framing. B Follow the local building code and best practice when installing hanger bolts. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 22 B Tighten the attachment block and turn horizontally. B Use a level to ensure all attachment blocks are at the same height. Use a cord across all blocks to confirm. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 23 63043965.26-1.SD 63043965.26-1.SD Fig. 22 Attaching the horizontal rail to the attachment blocks on the hanger bolts. Screw Horizontal rail Attachment block Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 24 B Do not install hanger bolts in less than 2x6 framing. B Follow the local building code and best practice when installing roof hooks. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 25 B Do not install hanger bolts in less than 2x6 framing. B Follow the local building code and best practice when installing hanger bolts. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 26 B Repeat the same procedure for the other rails. 63043965.32-1.SD 63043965.32-1.SD To continue with the installation, see Chapter 5.8.3 Fig. 27 Installing horizontal rails "Aligning the horizontal rails". 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 27 63043965.34-1.SD 63043965.34-1.SD stress onto the collectors causing Fig. 29 Fastening profile rails to the roof hook premature failure. Threaded clip Horizontal rail Screw Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 28 (Fig. 31, [2]). Fig. 31 Attaching collector hanger Slots reserved for the hanger Both teeth must engage with the rail Collector hanger 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 29 Two of the protective corners of each collector's packaging hold connectors and clips needed for installation. Do not throw those out before removing those parts! Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 30 63043965.19-1.SD 63043965.19-1.SD Fig. 35 Water connection – left-hand supply line 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 31 63043965.41-1.SD 63043965.41-1.SD Fig. 37 Installing the dummy plug and hose clamps Hose clamps Solar hose 2-3/16 in (55 mm) Dummy plug Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 32 The lower collector edge must engage evenly with the hooks of both collector hangers (Fig. 40, [1]). 63043965.44-1.SD 63043965.44-1.SD Fig. 40 Laying the first collector on the profile rails 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 33 (Fig. 43, [2]) in such a way that the preassembled solar hoses are pushed onto the left-hand connections on the first collector. 63043965.47-1.SD 63043965.47-1.SD Fig. 43 Pushing second collector toward the first Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 34 When the screw is tightened, the plastic spacer holding the clamp apart 63043965.50-1.SD 63043965.50-1.SD will break away. Discard this piece. Fig. 46 Single-sided collector clamp (left) 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 35 For that the nut installed at Sensor well the outside of the well must be removed. Route the sensor cable along the pipework using zip ties. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 36 In either case in order to work properly the air vent must be positioned perfectly vertically. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 37 Vent body × Item 6: Double nipple × Item 7: Hose adapter × Item 8: Hose clamp × Item 9: Solar hose 2 in (55 mm) Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 38 For the return connection, install the hose adapter with compression fitting Hose adapter with compression fitting (from the connection kit) into the long Roof penetration solar hose. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 39 B Attach solar hose to the elbows and secure using hose clamps (Fig. 56, [4]). 63043965.53-1.SD 63043965.53-1.SD Fig. 56 Connection set between two collector rows Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 40 – Use only material that is bird and rodent proof. – Verify all penetrations are weather proof and discourage critters from entering the building. 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without...
  • Page 41 Perform installation checks. Fig. 59 Installing the collector sensor and header pipes p. 40 Insulate header pipes with UV and high temperature resistant material. Tab. 6 Bosch Solar Collectors - Specifications subject to change without 6 720 614 821 (2010/06)
  • Page 42 42 | Collector 67910057-00-Type of collectors and rating labels 12 Spare parts 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 43 Collector | 43 Item Part Number Description Weight 7747021978 FKC-1s Solar Flat Plate Collector 93 1/2 7747021980 FKC-1w Solar Flat Plate Collector 95 1/2 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 44 44 | On roof installation material 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 45 Connector rail connector 0.25 63045244 Double sided collector clamp 0.26 63045233 Roof hooks adjustable kpl 0.66 Available individual part: 63045237 Threaded clip M8 0.06 Screw M8x25 m. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 46 46 | On roof installation material 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 47 Roof hooks for slate roofs 1 piece Screw M8x25 1 piece Washer DIN125 8,4 V2A 1 piece Hex nut DIN985 M8 A4 1 piece Wood screw 6x70 1 piece Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 48 48 | Connection Set FKC 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 49 O-Ring 25x3,0 Shore70 0.02 Set 5 Pieces 87182237740 Compression ring 1/2" (16 mm) 0.05 Set 5 pieces 63045250 Compression ring 3/4" (18 mm) Set 5 pieces Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 50 50 | Row connection set SKS/SKN/FKC Row connection set SKN/SKS 6 720 614 825 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 51 Set 5 pieces 85336132 Solar hose 3/4"x40" (1000 mm) 1.65 Solarhose 3/4x2" (55 mm) Use Pos. 50 and cut to length 63045248 Dummy plugs D21 0.14 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 825 (2010/06)
  • Page 52 52 | Air vent set SKN-SKS Air vent below the roof Air vent below the roof Air vent above the roof SKN/FKC 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 53 Hose to pipe adapter G3/4xD21 kpl Available individual parts: 87182237740 Compression ring 1/2" (16 mm) 0.05 Set 5 pieces 63045250 Compression ring 3/4" (18 mm) Set 5 pieces Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 54 54 | Certification 13 Certification 6 720 614 821 (2010/06) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 55 Notes | 55 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 614 821 (2010/06)
  • Page 56 Bosch Thermotechnology Corporation 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-584-1681 www.boschsolar.com Products manufactured by Bosch Thermotechnik GmbH D-73249 Wernau www.bosch-thermotechnology.com.de Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.