Worcester FKS Series Manuel utilisateur

FKC SERIES FLAT PANEL

SOLAR COLLECTORS

ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS

Installation instructions

63043965.01-1.SD

6 720 613 577 (2006/04)

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. These may also be inspected at the

manufacturer's premises.

The activities described in the installation manual

assume expertise based on completed vocational

training in gas or water-related installation. Only carry

out these installation steps, if you possess these

skills.

BHand these installation instructions to the

customer.

BExplain to the customer the function and operation

of the related devices.

6 720 613 577 (2006/04) 3

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.2 Notes structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.3 Please observe these safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

4 Before installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.2 Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.3 Other equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.5 Technical documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.6 Determining space required on roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Fitting the roof connection and profile rails . . . . . . . . . . . . . . . . . . . . . . . 15

5.1 Setting clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2 Pan tile roofs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.3 Crown tile roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.4 Corrugated sheet roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.5 Slate/shingle roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.6 Sheet roofs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.7 Fitting additional rails (accessory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.8 Installing profile rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6 Collector installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.1 Preparing to install the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.2 Fastening the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7 Collector sensor connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8 Header connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.1 De-airing through pressure filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.2 De-airing through air vent (accessory) at highest point in the system . . . . . . . . . . . 36

9 Fitting the connection set for two rows (accessory). . . . . . . . . . . . . . . . . 38

10 Final activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10.1 Checking the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10.2 Insulating the connection and header pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General information

6 720 613 577 (2006/04)

1 General information

This chapter details which technical rules and

regulations apply to this installation.

Lightning protection

If the building height (installation height) exceeds 20 m,

and there is no lightning conductor installed, ask your lo-

cal electrical contractor to connect the components on

the roof which conduct electricity with an electrical earth

cable of at least 16 mm2to the earth bonding.

Special measures regarding lightning protection are not

required for building heights (installation heights) of less

than 20 m.

Where there is a lightning conductor system installed,

ask your local electrical contractor to check the inclusion

of the solar heating system into the lightning protection

system.

iUSER NOTE

Observe all standards and guidelines

applicable to the installation and operation

of this system in your country.

Installation work on roofs Connection of thermal solar

heating systems

Installation and equipment of DHW

cylinders

The Health and Safety at Work etc

Act 1974

The Management of Health and Safety

at Work Regulations 1999

The Construction (Health Safety and

Welfare) Regulations 1996

The Construction (Design and

Management) Regulations 1994

The Lifting Operations and Lifting

Equipment Regulations 1998

EN 12976: Thermal solar heating

system and their components (pre-

fabricated systems).

ENV 12977: Thermal solar heating

system and their components

(bespoke systems).

BS 6795: Code of practice for solar

heating systems for swimming pools.

BS5546: 2000 Specification for

installation of hot water supplies for

domestic purposes, using gas-fired

appliances of rated input not

exceeding 70 kW.

BS6700:1997 Specification for

design, installation, testing and

maintenance, of servicing supplying

water for domestic use within

buildings and their curtilages.

Tab. 1 Technical rules for the installation of thermal solar heating systems (selection) in UK

iUSER NOTE

The installation of the Worcester Solar

System must be carried out in accordance

with the relevant requirements for safety,

current IEE wiring regulations, local

building regulations, building standards

(Scotland) (Consolidation) regulations and

by-laws of the local water company and

health and safety document No 635

(Electricity at Work Regulations 1989).

BS 6795: Latest version

Specifications

6 720 613 577 (2006/04) 5

2 Specifications

Tab. 2 Specifications

FKC SERIES SOLAR PANELS

Certificates

Length 2070 mm

Width 1145 mm

Height 90 mm

Clearance between collectors 25 mm

Fluid content, portrait version Vf0.86 l

Fluid content, landscape version Vf1.25 l

Gross absorber surface area AG2.37 m²

Net absorber surface area 2.23 m²

Net weight, portrait version m41 kg

Net weight, landscape version m42 kg

Permissible operating pressure

of the collector

pmax 6 bar

DIN

0036

Safety

6 720 613 577 (2006/04)

3 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.

Carefully read the safety instructions before

commencing the installation.

Severe injury and even death, as well as material losses

and environmental damage, may follow if you ignore

safety instuctions.

3.1 Correct use

This installation set holds the thermal solar collectors,

which are installed on sloping roofs with a slope of 25°

to 60°. The collectors can be installed on corrugated and

sheet steel roofs with slopes of between 5° and 65°.

Operating conditions

Only erect the installation set on roofs whose

construction can support the weight. If necessary,

consult a structural engineer or a roofer.

The installation set is suitable for a max. standard snow

load of 2.0 kN/m² and an installation height of max, 20m.

Using appropriate accessories, the installation set can

be used for a max. standard snow load of 3.1 kN/m² and

a max. installation height of 100 m. See Chapter 5.8

"Installing profile rails".

The roof installation set must not be used for fixing any

other objects to the roof. The kit is intended exclusively

for the safe fixing of solar collectors.

Safety

6 720 613 577 (2006/04) 7

3.2 Notes structure

Two levels are identified by signal terms:

Further symbols identifying dangers and user notes:

WARNING!

RISK TO LIFE

Identifies possible dangers which might

lead to serious injury or death if

appropriate care is not taken.

CAUTION!

RISK OF INJURY/SYSTEM DAMAGE

Identifies potentiallydangerous situations,

which might lead to mild or slight injuries

or to material losses.

WARNING!

RISK TO LIFE

from electric shock.

iUSER NOTE

Tip for the optimum utilisation and setting

of the products plus other useful

information.

Safety

6 720 613 577 (2006/04)

3.3 Please observe these safety

instructions

WARNING!

RISK TO LIFE

through a fall or falling parts.

BEnsure you have the correct safety

equipment for working on roofs.

BTake appropriate action to prevent

accidents when working on roofs.

BWhilst working on the roof, take all

necessary precautions against a

possible fall.

BAlways wear your personal protective

clothing and safety equipment.

BAfter completing the installation, always

check the secure positioning of the

installed set and that of the collectors.

CAUTION!

RISK OF INJURY

Injury and operating faults can result from

making changes to the system

construction.

BNever change the system construction.

CAUTION!

RISK OF INJURY

Some parts may cause burns, if the

collector and installation materials are

exposed to solar radiation for longer

periods of time.

BAlways wear your personal protective

clothing and safety equipment.

BCover the collector (e.g. with a covering

sheet – available as an accessory

7739 300 399) and the installation

material during the installation as

protection against high temperatures

resulting from solar irradiation.

Before installation

6 720 613 577 (2006/04) 9

4 Before installation

4.1 General notes

Make yourself familiar with the on-site conditions and lo-

cal regulations before commencing the installation.

Check

Bthe delivery for completeness and perfect condition.

Bthe optimum arrangement of the solar collectors.

Take account of the direction of the sunlight (angle of

inclination, southerly direction). Avoid the shade of

high trees or structures and match the collector array

to the shape of the building (e.g. aligned with win-

dows, doors, etc.).

iUSER 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.

Fig. 1 General overview of collector pair – roof mounting

63043965.02-1.SD

CAUTION!

RISK OF INJURY

If the collector and its installation material

is left exposed to the sunlight for a long

period, the parts will become hot and may

cause burns.

BWear protective clothing.

BCover the collector (e.g. with

a covering sheet – available as an ac-

cessory 7739 300 399) and the instal-

lation material during the installation

as protection against high tempera-

tures resulting from solar irradiation.

iUSER NOTE

Only use OEM components and replace

any damaged or faulty parts immediately.

iUSER NOTE

Remove broken tiles, shingles or plates in

the area of the collectors and replace

them.

Before installation

6 720 613 577 (2006/04)

4.2 Component description

4.2.1 Installation set for the collectors

Roof connection, pan tile roofs, per collector

(Fig. 2):

iUSER NOTE

The installation sets are for mounting and

fixing the collectors in place.

Fig. 2 Installation set for 2 collectors – 1 basic installation set, 1 extended installation set and 2 roof connection installation sets

63043965.03-1.SD

123

Basic installation set for each collector array and

for the first collector (Fig. 2):

Extended installation set for each additional collector

(Fig. 2):

Item 1: Profile rail 2 ×Item 1: Profile rail 2 ×

Item 3: Single-sided collector clamp 4 ×Item 2: Double-sided collector clamp 2 ×

Item 7: Anti-slip protection 2 ×Item 7: Anti-slip protection 2 ×

Item 8: M8 screw 4 ×Item 6: Rail connector with threaded studs 2 ×

Item 8: M8 screw 4 ×

Item 4: Roof hook, adjustable 4 ×

Item 5: Sliding nut 4 ×

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