Bosch FKT-1 Installation Manual
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Bosch FKT-1 Installation Manual

Bosch FKT-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 FKT-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 FKT-1

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

  • Page 2: Table Of Contents

    ..........52 6 720 642 564 (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. 6 720 642 564 (2009/12)

  • Page 4: Specifications

    Net weight, portrait version (44 kg) 99 lbs Net weight, landscape version (45 kg) Permissible operating pressure 145 psi of the collector (10 bar) Tab. 1 Specifications 6 720 642 564 (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. 6 720 642 564 (2009/12)

  • Page 6: Guideline Of Notices

    Solar pipes and solar fluid can cause severe burns. Extreme caution must be taken when a system is in stagnation. CAUTION! 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 7 KS pump stations. This system is not suitable for drain back installations. Only closed loop pressurized systems are permitted. CAUTION! Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 8: Before Installation

    Wall mounted collectors NOTICE It is recommended to consult a professional roofer if roof repairs are necessary. Have the work completed before installing the solar equipment. 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 9: 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. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 10 Connection set between the collectors, for each collector (in two carrying angles, Fig. 5) × Flexible collector connector × Clip 63043966.04-1.SD 63043966.04-1.SD Fig. 5 Two of the collector's protective corners 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 11: Other Equipment Needed For The Installation

    Fig. 6 Rubber caps on collector connections Protect the collectors using a tarp during transport in wet weather in an open truck. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 12: 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. 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 13 30° and 45°) 60° 63043970.27-1.SD 63043970.27-1.SD Fig. 10 Permitted inclination of the collector on a wall Inclination to the horizontal plane Inclination to the wall Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 14 For an inclination of 25°, shorten the top of the lower rail by 5-1/2 in (140 mm) and use the lower hole (Fig. 12, [2]). Fig. 12 Adjust inclination for portrait collectors 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 15: 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 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 16 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 version 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 17 (1.48 m) (18.88 m) 38' 4-3/4" 68' 10" (11.70 m) (20.98 m) Tab. 4 Space requirement for portrait collectors Tab. 5 Space requirements for landscape collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 18: 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 Landscape flat roof racks for 2 collectors 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 19: Distances Between Collector Triangles

    Fig. 20 Basic version for 3 – 10 portrait landscape collectors Fig. 21 Basic version for 2 landscape collectors Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 20 (Fig. 21), provided that a third profile rail is installed, (page 28). Fig. 22 Auxiliary supports for 3 portrait collectors 63043970.14-1.SD 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 21: Clearances Between The Collector Triangles When Using Ballast Trays (Accessory)

    22 1/2 in (571 mm) (571 mm) 22 1/2 in 22 1/2 in 15 in (571 mm) (571 mm) (381 mm) Tab. 6 Distances between auxiliary triangles Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 22 – max. wind speed of 94 mph (151 km/h) NOTICE 63043970.14-1.SD For distances between the landscape collector triangles, refer to Fig. 24. Fig. 25 Version for maximum loads, 3 portrait collectors 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 23: Stablizing The Flat Roof Rack

    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 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 24 2 guy wires (Fig. 28, [1]). 63043970.20-1.SD 63043970.20-1.SD Fig. 28 Flat roof support with guy wires 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 25: 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. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 26 B Use 3 screws to fasten each collector brace to the wall (see Tab. 8, Fig. 30, [1]). Fig. 30 Attaching the collector rack to the wall (for 2 collectors) 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 27: Installing The Profile Rails

    (Fig. 33, [3]) 63043970.45-1.SD 63043970.45-1.SD Fig. 33 Aligning the profile rails for loading trays Tab. 9 Aligning the lower and upper profile rails when using ballast trays Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 28 (Fig. 36, [1]) of the profile rails until it clicks into place (Fig. 36, [2]). 63043970.24-1.SD 63043970.24-1.SD Fig. 36 Attaching collector hanger Slots for collector hangers Snap the collector hangers in place Collector hangers 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 29: 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. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 30: Preparing To Install The Collectors Fkt-1

    (reverse-return principle, Fig. 41). Diagonal connection also applies if there are fewer than 6 collectors (Fig. 41). 63043966.08-1.SD 63043966.08-1.SD Fig. 41 Diagonal water connections 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 31: Installing The Plug

    The plastic parts of the collector clamps do not have any support function. They are simply intended to make installation easier. 63043970.26-1.SD 63043970.26-1.SD Fig. 43 Fasteners for the collector Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 32 The top (Fig. 46, [2]) of the collector clamp now grips Fig. 46 Single-sided collector clamp screwed in place the lower edge of the collector. 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 33 B Once the connectors are pushed all the way to the stop, place second clip (Fig. 49, [3]) over the flexible connector and collector connection. Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 34 63043970.34-1.SD 63043970.34-1.SD NOTICE Fig. 52 Single-sided collector clamp (left) When the screw is tightened, the plastic guide breaks away at the pre-determined cut-off points. 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 35: Collector Sensor Connection Fkt-1

    First remove the nut in the sensor well using the strain relief (Fig. 54, [2]). Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 36: Hydraulic Connection Fkt-1

    B Install supply pipe in the hose clamp. 63043970.35-1.SD 63043970.35-1.SD Fig. 56 Fastening holder to the collector frame Hose clamp (not supplied) M8 thread Bracket 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 37: Hydraulic Collector Connection Without An Air Vent

    Perform the same procedure with the return connection. 63043969.04-1.SD 63043969.04-1.SD Fig. 57 Installing supply pipe (with no vent on roof) Clip Elbow Compression ring 1/2" Compression ring Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 38: Hydraulic Collector Connection With An Air Vent (Accessory)

    Union nut (not needed here) × Gasket (not needed here) × 10 Large diameter washer (not needed here) × 11 Compression washer (not needed here) 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 39: Connecting Two Arrays

    "Hydraulic collector connection without an air vent". B Make on-site connection between collector arrays. 63043969.06-1.SD 63043969.06-1.SD Fig. 61 Two collector arrays, one behind the other Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 40: Final Activities

    In larger systems and where corrugated pipes are being used, it may be necessary to bleed additional air after 1-2 weeks of operation. 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.

  • Page 41: 10 Quick Reference Guide For Mounting And Pressure Filling

    40 Insulate supply and return pipes with UV and high temperature resistant material. 63043969.07-1.SD 63043969.07-1.SD Fig. 64 Installing the collector sensor and connection parts Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 42: Spare Parts

    42 | Collector Spare parts 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 43 Part Number Description Weight in lb 7747021975 FKT-1-S Solar Flat Plate Collector Portrait (vertical) 104 1/2 7747021976 FKT-1-W Solar Flat Plate Collector Landscape (horizontal) 106 1/2 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 44 44 | Flat Roof and Wall Mounted Installation 67910059-00 Flat roof system portrait/landscape and wall installation 67910059-00-Flachdachmontage senkrecht-waagerecht, Fassade waagerecht 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 45 Profile Rail - Cross Support - Horizontal 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 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 46 46 | Connection set FKT-1 67910063-00 Connection sets SKS/FKT 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 47 Set 5 Each 63045258 Connection Flex-Pipe Set SKS/FKT 0.05 Available Parts: 63045264 O-Ring 15x3 SHORE70 EPDM291 0.09 Set 5 Each 63045255 Clip SKS/FKT 0.05 Set 5 Each Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 48 48 | Row connection FKT-1 SKS/FKT Extension SKS/FKT Extension 67910167-00 Series connection set SKS/FKT 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 49 Set 5 Each 63045250 Compression Ring 1/2" 0.05 Set 5 Each 63045255 Clip SKS/FKT 0.04 Set 5 Each 63045259 Connection Flex-pipe VL/RL SKS/FKT kpl 2.46 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 50 50 | Air vent set FKT On-roof Connection SKS/FKT Air vent below roof Connection SKS/FKT 67910064-00 Air vent kit SKS/FKT 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 51 O-Ring 25x3,0 Shore70 0.02 Set 5 Each 63045264 O-Ring 15x3 SHORE70 EPDM291 0.01 Set 5 Each 63020599 Locking Washer, Stainless DN16x1,5 0.033 Set 10 Each Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

  • Page 52: 52 | Certification

    52 | Certification 12 Certifikation 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 53 Notes | 53 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)
  • Page 54 54 | Notes 6 720 642 564 (2009/12) Bosch Solar Collectors - Specifications subject to change without notice.
  • Page 55 Notes | 55 Bosch Solar Collectors - Specifications subject to change without notice. 6 720 642 564 (2009/12)

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