WIKORA Wikosun 2020-Mi Manuel utilisateur

Errors excepted.

WIKORA GmbH

89568 Hermaringen

Phone: (07322) 9605-0

Fax: (07322) 9605-30

E-mail: contact@wikora.de

Installation manual

In roof mounting

Flat plate collectors

Wikosun 2020-Mi / 2340-Ti

roof angles from 25°to 87°

Installation and commissioning should be

undertaken by a specialist.

General terms and conditions of warranty state that

all installations must be performed by a suitably

trained and qualified plumber by taking into account

local norms and regulations.

Factory warranty will only be covered if the

installation instructions are followed.

Warranty does not cover any damages, caused by

non-observance of this manual.

The correct functioning is only guaranteed if the

installation instructions are followed.

The system is to be checked annually by a

specialized company. Independently, occurring

defects must be repaired immediately.

This document should be handed over to the

client on completion of works.

Index

1 Mounting accessories ...................................................................................................................................................................................3

2 Installation ......................................................................................................................................................................................................4

3 Planning and layout data for collectors ....................................................................................................................................................10

4 Technical data..............................................................................................................................................................................................11

5 General operation and maintenance instruction.....................................................................................................................................11

6 Safety instructions .......................................................................................................................................................................................13

8 Warranties .................................................................................................................................................................................................... 15

9 Installation and maintenance record ........................................................................................................................................................16

Errors excepted.

Pos. No. Description

Collector 2020-Mi / 2340-Ti

Clamp and positioning clip U-shape

Parallel compression fitting 22mm

Compression -T-fitting 22x22x1/2“, collector flow (hot)

Sensor pocket ½“x 100mm, with cable bushing

Compression plug 22mm

Compression-elbow 22mm

Collector support bracket

Chart 1: Part list

Errors excepted.

1 Mounting accessories

1.1 Mounting kits

Collector mounting kits are available as follows:

Mounting kit Content Amount

Kit for two collectors

ST-IDM-2Z, tile (2020-Mi)

ST-IDM-2.1Z, tile (2340-Ti)

ST-IDM-2.1S, slate (2340-Ti)

Lower flashing incl. flexible gasket strip, left 1

Lower flashing incl. flexible gasket strip, right 1

Side flashing, left 1

Side flashing, right 1

Upper flashing, left 1

Upper flashing, right 1

Center flashing, middle, long 1

Center flashing, middle, short 1

Sheet metal screw 2

Sheet metal screw 1

Hanger support bracket, VA 4

Fixing hook with nails 8

Clamp and spacer bracket 8

Hex head wood screw 5 x 35 12

Hex head wood screw 6 x 30 8

Extension kit

ST-IDM-1Z, tile (2020-Mi)

ST-IDM-1.1Z, tile (2340-Ti)

ST-IDM-1.1S, slate (2340-Ti)

Lower flashing incl. flexible gasket strip, middle 1

Upper flashing, middle 1

Center flashing, middle, long 1

Center flashing, middle, short 1

Sheet metal screw 1

Hanger support bracket, VA 2

Clamp and spacer bracket 4

Hex head wood screw 5 x 35 6

Hex head wood screw 6 x 30 4

Universal connection kit

ST-ADM-V

Aluminum elbow 2

Hex head screw M8 x 20mm + nut M8 VA 8

Lock washer M8 8

Standard connection kit

ST-AVS-2S

Parallel compression fitting 22 x 22 mm 2

Compression elbow 22 x 22 mm 1

Compression sealing plug 22mm 2

Compression -T-fitting 22x22x1/2“, collector flow (hot) 1

Sensor pocket ½“x 160mm, with cable bushing 1

ST-AVS-1S Compression fittings 22 x 22 mm 2

Flexible tube kit

ST-ADF-1

Flexible stainless steel tube with Cu-joints 22mm 2

Chart 2: Mounting accessories

Prior to installation:

•Check the content of the delivery with the delivery note!

•Read the installation instructions carefully and pay attention to the different steps!

•Respect the safety instructions!

Necessary tools Application

Socket key or ratch with extension SW 13

Combination spanner SW 13

Open-ended spanner SW 21

Open-ended spanner SW 32

Pipe tongs

Drill d=2,0 mm

Angle grinder (hammer and chisel)

Screwdriver, cross

Hammer

Installation of rafter brackets and kiln furniture

Sensor pocket

Parallel compression fitting

Pre-drilling of rafter brackets

Removal of drainage area

Tightening of wood screws

Driving nails

Chart 3: Tool list

1.2 Transport and storage of collectors

Collectors should be transported in their packaging horizontally (glass facing upward) or vertically. It must be ensured that

collectors can at any time be safely put down (e.g. tilting danger by wind, endangering of other people). Collectors should never

be put down over the edge! Please take special precaution while transporting the collectors on the roof. If collectors can not be

put down at any time and/or if a risk of slipping exists, auxiliary material like safety ropes should be used.

Store collectors in closed and sun-protected areas either horizontally with the glass facing upward or in an upright position. Do

not stack collectors on their connectors.

Errors excepted.

2 Installation

2.1 Positioning of collectors

In order to protect the roof against entering humidity (snow,

rain) a foil leading into the gutter should be placed below the

collector surface.

Wind loads on roofs can create suction forces on the solar

collectors. In order to minimize suction forces, the distance

between the outer edge of the roof and the collector should

be minimum 70 cm (about 3 tiles). The distance from the

roof ridge should be approx. 2 tile rows.

2.2 Measure and open the roof area

Measure the area of the collector field on the roof and define the position of the collectors.

The supporting area of the collectors must be sufficiently stable. If the distance between the battens or the rafters is too big,

additional battens should be inserted.

Number of collectors 2 3 4

Width of collector field (mm) 2950 4075 5200

Number of tiles to be widened per tile row, covering width 30 cm 11 15 19

Number of tiles to be widened per tile row, covering width 20 cm 16 21 27

2.3 Preparationofthecollectors

To facilitate the work on the roof, following activities should be undertaken on the ground.

Seal the sensor pocket and screw it together with the compression T-fitting. Afterwards, put the compression T-fitting, the

fitting, the sealing plug and the bracket onto the absorber pipes and tighten carefully. Please take care of the immersion depth

and hold it with a second wrench.

The collectors should be lifted onto the roof by taking into consideration the local conditions and safety regulations.

Errors excepted.

2.4 Installation of the collectors and the flashings

Mark the left and the right edge of the collector field on the battens.

Depending on the distance of the battens an auxiliary batten must be

installed to support the lower flashings.

Lower flashings incl. flexible gasket strip are installed from the left to the

right and should protrude the collector field on both sides by about 32-35

cm. The lower flashings should be put with the folded edge on the upper

edge of the main batten.

Position the hanger support brackets (distance between the hanger support

brackets of ca. 80 cm) und pre-drill the lower flashing.

Screw the hanger support brackets and the lower flashings to the batten (3

wooden screws 5x35 mm).

Install further lower flashings overlapping and as previously mentioned.

Adjust the flexible gasket strip by hand or with the hammer shaft to the

tiles. Depending on the type of tiles, adjust the tile carefully by using an

angle grinder or a hammer.

Lower the collectors on the hanger brackets (Pos. 8), center them and

tighten the parallel compression fitting between the collectors.

Errors excepted.

Mount the flexible tube and tighten the parallel compression fitting. Put the

sensor into the sensor pocket as far as it will go. Screw carefully the cable

sheet on the sensor pocket.

Attention: The collector temperature sensor is not part of the in roof

mounting kit but part of the controller.

Position 2

clamp and spacer brackets between the collectors and the upper

and lower side of each collector and screw it on the batten with wooden

screws 6x60 mm (Pos. 2).

Before installing further flashings, the collectors should be pressure

tested with 6 bar independently from the rest of the solar system!

Position the left side flashing from the side on the collector and nail it with 3 fixing hooks onto the batten. Repeat the same

procedure with the right collector and the right side flashing.

Bend the long center flashing up and slide it down between the collectors. Bend the lower flashing lip and push it under the

collector.

Errors excepted.

Bend the upper flashing lip and push it under the collector.

Depending on the distance of the battens, an auxiliary batten must be

installed for the mounting of the upper flashing in order to support the center

flashing.

Position the upper flashings over the side flashings.

Secure upper left and right hand flashings to side flashings with the supplied

screws. Fix it with one hook from the side on the batten.

Errors excepted.

Fix the two self adhesive sealing strips and position sealing cover. Press down sealing cover and strip into position. Then

secure strip with screw and fiber washer supplied and fold sealing strip over flashings.

Cover the flashings with the missing tiles and adjust them if necessary.

Errors excepted.

2.5 Installation of collector temperature sensor

The collector temperature sensor is part of the controller. It is to be installed at the flow of the system (hot water side). Put the

sensor into the sensor pocket (11) as far as it will go. Apply a heat-conductive paste onto the sensor to improve the heat

transfer. Screw carefully the cable sheet on the sensor pocket.

The 1 m cable is laid with the pipe work through the roofing. The cable can be extended in the interior

(2 x 0,75²). For the connection of the temperature sensor cable with the controller the use of an over voltage protection

(protection against over voltage damages) is recommended.

2.6 Installation of pipe work

Install the pipe work

•on shortest way to minimize losses.

•with a complete high temperature insulation (100% according to EnEv).

•rising to the collector to prevent air cushions.

2.7 Hydraulic pressure test

•After a successful installation, rinse the entire collector circulation with water!

•Before commissioning, the collector circulation must be checked with a water pressure of 6 bar !

•If the solar heating system is not commissioned immediately after installation, the collector area must be covered!

•Before filling the system with heat transfer fluid, the system must be completely purged!

Open the lower plug at the collector field to purge the system.

Subsequently, the system is to be filled with a water-antifreeze-mixture. Please refer to chapter 7 „Antifreeze“ for it’s

preparation. The liquid capacity amounts to 1,4 Liter for Wikosun 2020-Mi and 1,6 Liter for Wikosun 2340-Ti.

Once the mixing is completed (recirculation lasting several hours), the antifreeze concentrate should be checked with an

antifreeze testing tool.

Important:

Please note that only a solar concentrate released by Wikora may be refilled. Solar concentrate must be prepared according to

manufacturer’s specifications with clean, ph-neutral and lime-free water. Please use an antifreeze controller to ensure the

antifreeze capacity. If another solar concentrate is applied, the warranty expires automatically. Moreover, damages that are

due to an insufficient antifreeze protection are not part of the warranty.

The installation instructions of solar stations, solar controllers and connecting kits must be considered separately!

2.8 Regulation of flow rate (Taco-Setter)

The set-up of the flow rate according to our

instructions is important for an efficient

functioning of the system (see chart page 7).

When setting-up the flow rate, please pay

attention to the scale of the taco-setter used (see

sample fig. 11).

Scale WIKORA Solar stations:

WIK-PG 20/12 - floater bottom edge

WIK-PG 25/14 - floater upper edge

WIK-PG 25/30 - floater upper edge

WIK-PS 25/14 - floater upper edge

WIK PS 25/30 - floater upper edge

Fig. 11 : Scale

Errors excepted.

3 Planning and layout data for collectors

Recommendation:

System pressure

Primary pressure of expansion vessel

Flow rate

Switch-on temperature difference of controller

Switch-off temperature difference of controller

3,0 bar

2,5 bar

120 l/(h x collector)

7 to 15 K *

3 to 8 K * (*internal to the plant)

Please note that for the layout of the collector circuit, the solar tube circuit and the heat exchanger circuit, the corresponding

pressure losses and the total pressure loss in combination with the desired flow rate must be considered.

Furthermore, please note that the calculation of the piping cross-sections must be carried out under the aspect of the

necessary flow velocity for solar installations from min. 0.4 m/s up to max. 1,5 m/s with the required flow rate liter/h.

Moreover, it must be considered that the hydraulic faulty wiring results in a system specific and demand specific flow rate which

involves a loss of pressure. This again has an influence on the layout of piping cross-sections, solar medium capacities, pump

pressures, flow-meter set-ups and flow-meter configurations as well as on their number.

The values indicated in chart 4 apply only for pipe works up to an overall length of 40 m and heat exchangers with a capacity of

16 l.

Number of collectors 2 3 4 5 6 7 8 9 10

External diameter

of the connection pipe in mm

Flow rate in l/min

Flow rate in l/h

Expansion vessel in l

240

360

480

600

720

840

960

1080

1200

Chart 4: Reference values for pipe work size, flow rates and diaphragm type expansion vessels.

Each solar system needs an adequate and competent planning and execution. Please note that only a specialized

company is responsible for the layout of piping cross-sections, the layout of diaphragm type expansion vessel, the

determination of the solar pump group as well as the necessary flow-meter. Our data do not relieve of a special planning.

3.1 Hydraulic faulty wiring possibilities

Up to 10 collectors can be connected in parallel. The connections between the collectors must be realized with copper tubes of

22 mm. The collector fittings must be prepared with the corresponding compression fittings. This is to guarantee the

exchangeability of the collectors (enlargement of the system or change of system).

Crimp connections in the pipe work system are allowed. Seals must be approved for use in combination with solar systems and

temperatures up to 200°C. In case of a multiple-line installation, the return (cold water connection) should be located at the

collector line on the bottom.

Fig. 6: Installation in one line (6l/min)

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