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Summary of Contents for Worcester FKC Series
- Page 1 FKC SERIES FLAT PANEL SOLAR COLLECTORS FLAT ROOF AND WALL MOUNTED INSTALLATION FOR WORCESTER SOLAR HEATING SYSTEMS 63043970.01-1.SD 63043970.01-1.SD Installation instructions For latest prices and delivery to your door visit MyTub Ltd - www.mytub.co.uk - info@mytub.co.uk 0844 556 1818...
- Page 2 About this manual This installation manual contains important informa- tion for the safe and appropriate installation of the flat roof set. The illustrations in this manual show the collectors in- stalled vertically. These technical documents should be stored in a safe place.
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Page 3: Table Of Contents
General information ......... .4 Specification . -
Page 4: General Information
(installation height) of 20 m, and there is no lightning conductor installed, ask your The installation of the Worcester Solar local electrical contractor to connect the components on System must be carried out in accordance... -
Page 5: Specification
Specification Specification FKC Series Solar Panels Certificates 0036 Length 2,070 mm Width 1,145 mm Height 90 mm Clearance between collectors 25 mm Fluid content, portrait version 0.86 l Fluid content, landscape version 1.25 l Gross absorber surface area 2.37 m²... -
Page 6: Safety
Safety Safety Correct use Install components only on roofs with sufficient strength. This chapter explains the meaning of the notes you will Please take the additional roof load per flat roof support, find in this manual and provides general safety instruc- including solar collector, into consideration. -
Page 7: Notes Structure
Safety Notes structure Two levels are identified by signal terms: Please observe these safety instructions RISK TO LIFE Identifies possible dangers emanating RISK TO LIFE from a product, which might lead to seri- WARNING! through a fall or falling parts. ous injury or death if appropriate care is not taken. -
Page 8: Before Installation
Before installation Before installation General notes USER NOTE It is recommended that the services of a roofing company, who are fully experi- enced in working on roofs and will be aware of the risk of working at height, are considered. Make yourself familiar with the on-site conditions and lo- cal regulations before commencing the installation. -
Page 9: Component Description
Before installation Component description 4.2.1 Installation set for the collectors The installation sets are for mounting and fixing the col- lectors in place. 63043970.03-1.SD 63043970.03-1.SD Fig. 3 Installation set for 2 collectors - 1 basic installation set, 1 extended installation set Basic installation set for each collector array and Extended installation set for each additional for the first collector (Fig. - Page 10 Before installation 4.2.2 Water connection USER NOTE You will require one connection kit for each collector array. The collectors are connected together by solar hoses (con- nection set). 63043970.04-1.SD Fig. 4 Connection kit and connection set (illustration shows 2 portrait collectors) Connection kit, per collector array (Fig.
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Page 11: 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 Transport and storage Please ensure that the corner protectors are retained. They contain pipework connection pieces which are re- quired for installation. -
Page 12: Technical Documentation
Before installation Technical documentation The solar heating system consists of various compo- nents (Fig. 7). Installation, operation and maintenance documentation is provided for each component. Acces- sories may be accompanied by a separate document. Collector: instructions for flat roof mounting Item 1: are enclosed with the connection kit Pump station: instructions enclosed with the... - Page 13 Before installation 4.6.2 Sloping roofs On roofs that slope slightly in a southerly direction, the pitch angles are deducted from the angle of incidence. On roofs that slope slightly in a northerly direction, the pitch angles are added to the angle of incidence (Fig. 9). RISK TO LIFE 45°...
- Page 14 Before installation 4.6.4 Fitting telescopic rails Different angles of incidence can be set using the tele- scopic rails. B Select holes on the upper and lower telescopic rails as shown in Fig. 12 and Fig. 14. B Insert telescopic rails into each other and fasten with M8 ×...
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Page 15: Determining Space Requirements
Before installation USER NOTE 35° For landscape installation of a collector 40° with an angle of inclination of 35° to 60°, 45° use the uppermost hole on the lower tele- 50° scopic rail (Fig. 13, Item 3). 55° For an angle of inclination of 25° and 30°, 60°... - Page 16 Before installation 4.7.2 Estimating your space requirements SYSTEM DAMAGE through wind, eddies and pressure peaks around the roof edges. CAUTION! B Before commencing the installation, ensure that at least one metre is al- >1 m lowed between the flat roof supports and the edge of the roof (Fig.
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Page 17: Installing Flat Roof Supports
Installing flat roof supports Installing flat roof supports 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. -
Page 18: Distances Between Collector Braces For On-Site Base Anchoring
Installing flat roof supports Distances between collector braces for on-site base anchoring The distances between the collector braces (mid- dle/middle, in mm) depend on: – the collector version (portrait, landscape) – and the maximum snow and wind loads. USER NOTE You must strictly observe the clearances between the collector braces so that the profile rails can still be installed at a later... - Page 19 Installing flat roof supports 5.1.2 Version with auxiliary brace (accessory) For greater loads, an auxiliary brace (and additional pro- file rails, page 26) is required for vertical installation for the second and all further collectors (Fig. 22). This ver- sion can be used for the following loads: –...
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Page 20: Clearances Between The Collector Braces When Using Loading Trays (Accessory)
Installing flat roof supports Clearances between the collector braces when using loading trays (accessory) The distances between the collector braces (mid- dle/middle, in mm) depend on: – the collector version (portrait, landscape) – and the maximum snow and wind loads. For portrait installation, an auxiliary brace must be erect- ed for the 4th, 7th and 10th collectors (Fig. - Page 21 Installing flat roof supports USER NOTE Landscape installation can be carried out using only the auxiliary brace (accesso- ry). For landscape installation, 3 collector braces must be fit- ted for each collector (Fig. 24). 63043970.16-1.SD 63043970.16-1.SD Fig. 24 Basic version for 2 landscape collectors 5.2.2 Version for maximum loads (accessory, Fig.
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Page 22: Stabilising The Flat Roof Supports
Installing flat roof supports Stabilising the flat roof supports The following details refer to a single collector. Individual flat roof supports may be secured in the fol- lowing three ways to prevent slippage or tipping of the structure due to the effect of wind: –... - Page 23 Installing flat roof supports 5.3.1 Securing flat roof supports on site with base anchoring You can fasten the flat roof supports with anchor bolts. As an example, we describe fastening onto girders (Fig. 26, Item 3). Design the substructure so that the collectors can with- stand the snow loads and wind forces placed upon them.
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Page 24: Wall Mounting Supports - Installation
Installing flat roof supports Wall mounting supports – installation The landscape collector braces can also be used for wall-mounted installation. RISK TO LIFE from falling collectors, due to incorrect use. WARNING! B Only landscape collector braces are allowed for wall-mounted installation. B Collectors may only be installed on walls of buildings with a height up to 20 m (wind velocity = 129 km/h) and a... - Page 25 Installing flat roof supports 63043970.30-1.SD 63043970.30-1.SD Fig. 30 Fastening collector braces to the wall (for 2 collectors, dimensions in mm) 6 720 613 053 (2006/04) For latest prices and delivery to your door visit MyTub Ltd - www.mytub.co.uk - info@mytub.co.uk 0844 556 1818...
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Page 26: Installing The Profile Rails
Installing flat roof supports Installing the profile rails The profile rails must be joined together using plug con- nectors. Each collector is provided with an upper and lower profile rail. 5.5.1 Connecting profile rails B Push plug connector (Fig. 31, Item 1) as far as it will go into both profile rails (Fig. - Page 27 Installing flat roof supports B Lightly tighten the pre-assembled profile rails (Fig. 34, Item 2) with M8 x 20 bolts (Fig. 34, Item 1) so that the profile rails can still be aligned. B Align the sides of the upper and lower profile rails. B Tighten bolts.
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Page 28: 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 ac- WARNING! cidents when working on roofs. B Whilst working on the roof, take all necessary precautions against a pos- sible fall. -
Page 29: Preparing To Install The Collectors
Collector installation Preparing to install the collectors Before beginning actual installation on the roof, preas- semble the short solar hoses and dummy plugs on the ground to make work on the roof easier. To secure the solar hoses, the hose clips must be fitted with the release ring. - Page 30 Collector installation 6.1.2 Preassembling the connection set The water connection between two collectors is made using the connection set (solar hoses 95 mm and hose clips from the panel corner protectors). USER NOTE To make installation easier, we recom- mend that you place the solar hoses in hot water, especially when the ambient temperature is low.
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Page 31: Fastening The Collectors
Collector installation Fastening the collectors The collectors are fastened to the profile rails using the one-sided collector clamps (Fig. 44, Item 2) at the be- ginning and end of a collector array, and double-sided clamps (Fig. 44, Item 1) between each collector. In addition, the anti-slip protectors (Fig. - Page 32 Collector installation B Carefully push collector (Fig. 47, Item 1) up against the one-sided collector clamp and align horizontally. B Screw in one-sided collector clamp using size 5 spanner (Fig. 47, Item 2). USER NOTE When the screw is tightened, the plastic guide at the pre-determined cut-off points will break away and can be discarded.
- Page 33 Collector installation B Push the hose clip over the bead on the collector connection and pull the locking ring. SYSTEM DAMAGE through unsecured solar hoses and dum- my plug. CAUTION! B Secure every solar hose to the collec- tor connection using a hose clip (Fig.
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Page 34: Collector Sensor Connection
Collector sensor connection Collector sensor connection USER NOTE The collector sensor is part of the pump station or the control unit delivery. Observe the installation location for single or dual row collector systems (Fig. 53). SYSTEM DAMAGE through faulty sensor cable. B Protect the cable from possible dam- CAUTION! age. -
Page 35: Header Connection
Header connection Header connection Information on laying the header pipes can be found in the pump station installation instructions. SYSTEM DAMAGE from leaks in the collector connection, due to movements caused by heat. CAUTION! B Feed the on-site flow line (Fig. -
Page 36: Airing Through Pressure Filling
Header connection De-airing through pressure filling If venting of the solar heating system is carried out using a pressure filling pump, no vent is required on the roof. B Push the long solar hose (1000 mm, Fig. 57, Item 3) onto the flow connection on the collector array and fix in place using hose clip (Fig. -
Page 37: Airing Through Air Vent (Accessory) At Highest Point In The System
Header connection De-airing through air vent (accessory) at highest point in the system 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 38: Connecting Two Arrays
Header connection 8.3.1 Fitting the air vent valve on the roof B Push short solar hose (55 mm, Fig. 60, Item 1) onto the flow connection on the collector array and fix in place using hose clip. B Firmly screw R¾ hose nozzles with O-rings (Fig. 60, Item 3) into the air pot (Fig. -
Page 39: Final Activities
Final activities Final activities Checking the installation USER NOTE Do not carry out the final insulating work until the appropriate checks have been performed. Checks Solar hoses secured with hose clips (locking ring pulled)? Screws on the collector clamp (single-sided and double-sided) tightened? All collector braces connected to profile rails? -
Page 40: Contact Information
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 053a (2006/04) For latest prices and delivery to your door visit MyTub Ltd - www.mytub.co.uk - info@mytub.co.uk 0844 556 1818...
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