Related Manuals for Worcester FKT Series
Summary of Contents for Worcester FKT Series
- Page 1 FKT SERIES FLAT PANEL SOLAR COLLECTORS ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS 63043966.01-1.SD 63043966.01-1.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 panels. 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 regula- tions 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 heating Installation and equipment of DHW Installation work on roofs systems... -
Page 5: Specifications
Specifications Specifications Specifications FKT Solar Panels Certificates 0036 Length 2,070 mm Width 1,145 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 details how the notes for the installation instructions, as well as the general safety instructions, necessary for safe and trouble-free operation, are arranged in this manual. Safety and user notes, which specifically refer to the installation, in the installation manual immediately following the individual installation steps, are found here. -
Page 7: Notes Structure
Safety Notes structure Two levels are identified by signal terms: RISK TO LIFE Identifies possible dangers emanating from a product, which might lead to WARNING! serious injury or death if appropriate care is not taken. RISK OF INJURY/ SYSTEM DAMAGE/ BUILDING DAMAGE CAUTION! Identifies potentially hazardous situations,... -
Page 8: Please Observe These Safety Instructions
Safety Please observe these safety instructions RISK TO LIFE through a fall or falling parts. WARNING! B Ensure you have the correct safety 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 9: 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 consid- ered. Make yourself familiar with the on-site conditions and lo- cal regulations before commencing the installation. -
Page 10: Component Description
Before installation Component description 4.2.1 Installation set for the collectors USER NOTE The installation sets are for mounting and fixing the collectors in place. 63043965.03-1.SD 63043965.03-1.SD Fig. 2 Installation set for 2 collectors – 1 basic installation set, 1 extended installation set and 2 roof connection installation sets Extended installation set for each additional collector Basic installation set for each collector array and (Fig. - Page 11 Before installation 4.2.2 Hydraulic connection USER NOTE One connection kit for each collector ar- ray will be required. The collectors are connected together by a connection set. 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.
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Page 12: 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 USER NOTE When fitting the roof installation set and water connection, the only tool reqiured is the size 5 allen key from the connection kit. -
Page 13: 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 roof installation Item 1: are enclosed with the connection kit Pump station: instructions enclosed with the Item 2:... -
Page 14: 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. 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 15: Fitting The Roof Connection And Profile Rails
Fitting the roof connection and profile rails Fitting the roof connection and profile rails Setting clearances The dimensions given are guide values that should be approximately maintained. USER NOTE On pan tile roofs the tile troughs deter- mine the true distance between the roof hooks. -
Page 16: Pan Tile Roofs
Fitting the roof connection and profile rails Pan tile roofs Fit all roof hooks according to the guide values shown in tables 5 and 6 on page 15. USER NOTE Do not modify the roof construction and avoid damaging the roof covering. In the case of roof tiles laid in mortar, lift the tiles starting with the 3rd row under the roof. - Page 17 Fitting the roof connection and profile rails 5.2.2 Fastening roof hooks to joists Alternatively, the roof hook can also be used for fasten- ing to the joist. According to the roof hook positions shown in (Tab. 5 and Tab. 6, page 15), sufficiently strong boards must be attached to the joists so that the roof hook can be fitted between the joists.
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Page 18: Crown Tile Roofs
Fitting the roof connection and profile rails Crown tile roofs USER NOTE Consult a roofer when installing on a roof with crown tiles. During installation, please maintain the required distanc- es (w, x and y) between the roof hooks as detailed in (Tab. - Page 19 Fitting the roof connection and profile rails 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 20 Fitting the roof connection and profile rails Fitting the roof hook BUILDING DAMAGE caused by leaks. B Fit each roof hook centrally on a crown CAUTION! tile. USER NOTE If the roof battens are too close together, remove the lower part of the roof hook be- tween the second and third holes.
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Page 21: Corrugated Sheet Steel Roofs
Fitting the roof connection and profile rails Corrugated sheet steel roofs Carriage bolts must be used instead of roof hooks for fastening the profile rails. Standard delivery (Fig. 21): × Item 1: M8 screw × Item 2: Holding bracket × Item 3: M12 nut ×... - Page 22 Fitting the roof connection and profile rails Fitting the carriage bolts USER NOTE Using the wood drill, drill precisely at a 90° angle through the roof subframe to obtain a flat, level surface between the holding bracket and profile rail. BUILDING DAMAGE caused by leaks.
- Page 23 Fitting the roof connection and profile rails B Tighten the nuts (Fig. 24, Item 2) until the sealing disc (Fig. 24, Item 3) is lying completely flush on the roof. USER NOTE B The holding bracket must be screwed fully onto the carriage bolt. Height of peak, dim.
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Page 24: Slate/Shingle Roofs
Fitting the roof connection and profile rails Slate/shingle roofs USER NOTE A roofer must carry out the installation on slates or shingles. Here is an example of the installation of the special roof hooks and the watertight seal with custom flashing (Fig. -
Page 25: Fitting Additional Rails (Accessory)
Fitting the roof connection and profile rails Fitting additional rails (accessory) Additional measures are needed for installation heights of 20 to 100 m and/or with standard snow loads of 2.0 to 3.1 kN/m USER NOTE The example here shows an installation on pan tile roofs. -
Page 26: Installing Profile Rails
Fitting the roof connection and profile rails Installing profile rails The profile rails must be joined together using rail con- nectors. Each collector has been provided with an upper and lower profile rail. 5.8.1 Connecting profile rails B Push rail connector (Fig. 31, Item 1) as far as it will go into both profile rails (Fig. - Page 27 Fitting the roof connection and profile rails 5.8.3 Aligning the profile rails B Align the upper and lower profile rails to the side flush with each other and level them (Fig. 33, use a spirit level).. USER NOTE 90° 90° Measure the diagonals or place a roof batten (Fig.
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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 WARNING! accidents when working on roofs. B Whilst working on the roof, take all necessary precautions against a possible 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 end caps 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 brack- ets to the connections. -
Page 30: Fastening The Collectors
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. 39, Item 1) onto the collector connection. - Page 31 Collector installation Putting the first collector in place Lay the collector on the profile rails in such a way that the sensor bush is at the top to receive the collector sen- sor. Begin by laying the collectors on the right-hand side of the profile rails.
- Page 32 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 33 Collector installation B Tighten the screw on the double-sided collector clamp using the size 5 Allen key. USER NOTE When the screw is tightened, the plastic lugs at the pre-determined cut-off points break away. The grip (Fig. 48, Item 1) on the collector clamp now grips the lower collector edges.
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Page 34: 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. 50). 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 complete station installation instructions. The pipework connection to the header pipes is made using the long flexible connection pipes. It is not permit- ted to connect a fixed header pipe directly to the collec- tor. -
Page 36: De-Airing Through Air Vent (Accessory) On Roof
Header connection De-airing 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 37 Header connection 8.2.1 Fitting the air vent valve under the roof B Push connection pipe (Fig. 56, Item 3) onto the flow connection on the collector array and fix in place us- ing bracket (Fig. 56, Item 5). B Feed connection pipe together with the sensor cable through the ventilation tile (Fig.
- Page 38 Header connection 8.2.2 Fitting the air vent valve on the roof To connect the connection pipe to the air vent (flow connection), the elbow must be removed from the connection pipe and the double threaded fitting fitted. B Cut elbow (Fig. 57, Item 1) from connection pipe us- ing pipe cutter.
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Page 39: 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. 59, 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 40: Final Activities
Final activities 10 Final activities 10.1 Checking the installation SYSTEM DAMAGE through corrosion if water remains in the solar heating system for an extended CAUTION! period after it has been flushed or after a pressure test. B Start up the solar heating system im- mediately after flushing/pressure test with solar fluid (for instructions on flushing/pressure test see pump... -
Page 41: Insulating The Connection And Header Pipes
Final activities 10.2 Insulating the connection and header pipes B Cut enclosed insulation (710 mm long) into 88 mm lengths and place around the corrugated pipe con- nectors between the collectors. Insulation of the manifolds in internal or external installations –... -
Page 42: Quick Reference Guide For Pan Tile Roof And Pressure Filling
Quick reference guide for pan tile roof and pressure filling 11 Quick reference guide for pan tile roof and pressure filling These instructions are only intended as an overview of 11, 14 the work to be carried out. You MUST follow the detailed descriptions for the work on the pages mentioned, and all safety and user instructions. - Page 43 6 720 613 055 (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 055a (2006/04)