Related Manuals for Worcester FKS Series
Summary of Contents for Worcester FKS Series
- Page 1 FKC SERIES FLAT PANEL SOLAR COLLECTORS ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS 63043965.01-1.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.
-
Page 3: Table Of Contents
General information ......... .4 Specifications . -
Page 4: General Information
General information General information This chapter details which technical rules and regulations 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 Installation and equipment of DHW Installation work on roofs heating systems cylinders... -
Page 5: Specifications
Specifications Specifications FKC SERIES SOLAR PANELS Certificates 0036 Length 2070 mm Width 1145 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 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 instuctions, necessary for safe and truoble-free operation, are arranged in this manual. Safety and user notes, which specifically refer to the installation, in the installation manual immerdiately 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 which might lead to serious injury or death if WARNING! appropriate care is not taken. RISK OF INJURY/SYSTEM DAMAGE Identifies potentially dangerous situations, which might lead to mild or slight injuries CAUTION! or to material losses. -
Page 8: Please Observe These Safety Instructions
Safety Please observe these safety instructions RISK TO LIFE through a fall or falling parts. B Ensure you have the correct safety WARNING! 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 solar hoses (con- nection set). 63043965.04-1.SD 63043965.04-1.SD Fig. 3 Connection kit and connection set (illustration shows 2 portrait collectors) Connection kit, per collector array (Fig.
-
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 pipework connection, the only tool re- quired is the size 5 Allen key from the con- nection 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 determine the true distance between the roof hooks. - Page 16 Fitting the roof connection and profile rails RISK TO LIFE Whilst working on the roof, take all necessary precautions against a possible WARNING! fall. RISK OF INJURY through a fall or falling parts. B Take appropriate action to prevent WARNING! accidents when working on roofs.
-
Page 17: 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 18 Fitting the roof connection and profile rails 5.2.2 Fastening roof hooks to joists Alternatively, the roof hook can also be used for fastening 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.
-
Page 19: 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 distances (w, x and y) between the roof hooks as detailed in (Tab. 5 and Tab. 6, page 15). According to the roof hook positions shown in (Tab. - 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 between the second and third holes.
-
Page 21: Corrugated Sheet Roofs
Fitting the roof connection and profile rails Corrugated sheet 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, dimension A Dim.
-
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 connectors. 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.
-
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 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 connection set The pipework connection between two collectors is made using the 95 mm solar hoses and hose clips from the connection set in 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.
-
Page 31: Fastening The Collectors
Collector installation Fastening the collectors The collectors are fastened to the profile rails using the single-sided collector clamps (Fig. 41, Item 2) at the be- ginning and end of a collector array, and double-sided clamps (Fig. 41, Item 1) between each collector. In addition, the anti-slip protectors prevent the collector from slipping. - Page 32 Collector installation B Carefully push collector (Fig. 44, Item 1) up against the single-sided collector clamp and align horizontal- B Screw in single-sided collector clamp using size 5 Allen key (Fig. 44, Item 2). USER NOTE When the screw is tightened, the plastic guide at the pre-determined cut-off points breaks 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.
-
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. 50). SYSTEM DAMAGE through faulty sensor cable. B Protect the cable from possible CAUTION! damage. -
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 solar hoses. It is not permitted to connect a fixed header pipe directly to the collector. USER NOTE Use standard ventilation tiles or pipe con- duits when laying the connection pipes... -
Page 36: De-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 37 Header connection 8.2.1 Fitting the air vent valve under the roof B Push long solar hose (1000 mm, Fig. 56, Item 2) onto the flow connection on the collector array and fix in place using hose clip. B Feed solar hose together with the sensor cable through the ventilation tile (Fig.
-
Page 38: 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. 58, Item 8) is available as an accessory, and connects two rows of collectors. USER NOTE Fit all connection parts to the collectors on the ground. -
Page 39: 10 Final Activities
Final activities 10 Final activities 10.1 Checking the installation USER NOTE Carry out the final insulating work only once the appropriate checks have been performed. Checks Solar hoses secured with hose clips (quick release ring pulled)? Screws on the collector clamp (single-sided and double-sided) tightened? Profile rails connected to roof hook and sliding nut? - Page 40 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 577a (2006/04)