Bosch Worcester FKT Series, Installation Instructions Manual

Page 1: ...FKT SERIES FLAT PANEL SOLAR COLLECTORS IN ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS GB Installation instructions 63043975 00 1 SD 63043975 00 1 SD ...

Page 2: ...s 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 B Hand these installation instructions to the custom...

Page 3: ...ollectors 23 6 2 Fastening the collectors 25 7 Collector sensor connection 28 8 Header connection 29 8 1 Venting through pressure filling 29 8 2 Venting through air vent accessory on roof 30 9 Fitting the connection set for two rows accessory 32 10 Installing the facing panels 33 10 1 Lower facing panels 34 10 2 Side facing panels 36 10 3 Middle cover strip between two collectors 36 10 4 Middle fa...

Page 4: ...anagement 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 ...

Page 5: ...mm Height 90 mm Clearance between collectors 25 mm Fluid content portrait version Vf 1 43 l Fluid content landscape version Vf 1 76 l Gross absorber surface area AG 2 37 m Net absorber surface area 2 23 m Net weight portrait version m 46 kg Net weight landscape version m 47 kg Permissible operating pressure of the collector pmax 10 bar DIN 0036 ...

Page 6: ...uc tions for safe and trouble free operation The installation specific safety and user notes next to the appropriate installation steps are found here Carefully read the safety instructions before commenc ing the installation Severe injury and even death as well as material losses and environmental damage may follow if you ignore safety instructions ...

Page 7: ...are installed on pitched roofs with a pitch angle of 25 to 65 Operating conditions Only erect the installation set on roofs whose construc tion 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 3 8 kN m and an installation height of max 20 m ...

Page 8: ...sible dangers which might lead to serious injury or death if appropriate care is not taken CAUTION RISK OF INJURY SYSTEM DAMAGE Identifies potentially dangerous situations which might lead to mild or slight injuries or to material losses WARNING RISK TO LIFE from electric shock i USER NOTE Tip for the optimum utilisation and setting of the products plus other useful information ...

Page 9: ...n 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 B Never 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 B Always wear ...

Page 10: ...company who are experienced in working on roofs and will be fully aware of the risks of working at height are considered Fig 1 General overview of collector pair in roof mounting 63043975 26 1 SD 63043975 26 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 B Wear protective clo...

Page 11: ...for each additional collector Fig 2 Item 1 Upper left hand facing panel 1 Item 2 Upper middle facing panel 1 Item 3 Upper right hand facing panel 1 Item 4 Clips 4 spares 6 Item 4 Clips 12 Item 7 Anti slip protection bar 1 Item 5 Side facing panel right 1 Item 8 Anti slip protection Item 6 Lower facing panel right 1 x 3 for horizontal collectors 2 Item 7 Anti slip protection bar 2 Item 9 Lower faci...

Page 12: ...Fig 3 Connection kit and connection set illustration shows 2 portrait collectors 63043966 03 1 SD 63043966 03 1 SD 2 1 3 4 7 6 5 Item 2 Pipe clip 2 Item 6 Size 5 spanner 1 Item 3 Connecting pipe insulation not shown 2 Item 7 End cap 2 Item 4 Insulation for corrugated pipe Item 8 Sensor bush plug not shown 1 connector 710 mm 1 Item 5 Fitting for collector sensor 1 Fig 4 Two corner protectors with o...

Page 13: ...tallation All components are protected by transport packaging Transport protection for collector connections The collector connections are protected against damage by plastic caps Storage The collectors must be stored in dry conditions i USER NOTE Dispose of the transport packaging in an environmentally friendly recycling sys tem Fig 5 Plastic caps on collector connections 63043965 06 1 SD 6304396...

Page 14: ... accompanied by a separate document Fig 6 Solar heating system components and technical documentation 6720613577 00 1 SD 6720613577 00 1 SD 2 1 3 4 Item 1 Collector instructions for in roof installation are enclosed with the connection kit Item 2 Pump station instructions enclosed with the complete station Item 3 Solar Controller instructions are enclosed with the controller Item 4 DHW Cylinder in...

Page 15: ... note that the air vent must be the highest point of the system Fig 7 Clearances to be observed 63043975 28 1 SD 63043975 28 1 SD Space requirements for portrait collectors Space requirements for landscape collectors Number of collectors Dimension A Dim B Number of collectors Dimension A Dim B 2 2 67 m 2 80 m 2 4 52 m 1 87 m 3 3 84 m 2 80 m 3 6 61 m 1 87 m 4 5 01 m 2 80 m 4 8 71 m 1 87 m 5 6 18 m ...

Page 16: ...O 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 cidents when working on roofs B Always wear personal protective cloth ing and safety equipment ...

Page 17: ...m 10 80 m 6 00 m 10 62 m 6 7 41 m 12 90 m 7 23 m 12 72 m 7 8 52 m 14 99 m 8 34 m 14 81 m 8 9 69 m 17 09 m 9 51 m 16 91 m 9 10 86 m 18 96 m 10 68 m 18 78 m 10 12 03 m 21 28 m 11 85 m 21 10 m Tab 5 Width of collector array incl facing panels dim A and distance between the tiles dim X i USER NOTE If possible plan in such a way that the tiles are only cut on the right side of the collector array but a...

Page 18: ...ional roof bat tens those already present around the collector array area can be adjusted to the same dimensions as the additional roof battens These instructions describe installation using additional roof battens CAUTION BUILDING DAMAGE from leaks in the roof B Fasten batten butt joints to the joist or ensure that they are adequately se cure e g by fastening them to the al ready existing roof ba...

Page 19: ...ten using two screws 4 40 Fig 11 Item 1 ob serve measurements 5 2 2 Fitting additional roof battens Fig 10 Pre assembling anti slip protection devices with strip of wood 63043975 37 1 SD 63043975 37 1 SD 1 2 i USER NOTE For landscape installation 3 anti slip pro tection devices Fig 10 Item 1 must be fastened to one strip of wood 2 on the outside 1 in the middle Fig 11 Fasten anti slip protection d...

Page 20: ...battens around the collector array area Item 1 Moved roof batten Item 2 Fastening for roof batten ends counter batten Item 3 Collector array outside Item 4 Joist 63043975 39 1 SD 63043975 39 1 SD 1 2 3 4 i USER NOTE If an additional roof batten Fig 13 Item 1 has to be fitted near a pre existing one the pre existing one must be moved near to the collector array Fig 13 Item 3 and adequately fastened...

Page 21: ...tem 4 B Attach fifth roof batten for supporting the upper facing panels Fig 15 Item 5 B Attach sixth roof batten for supporting and fastening the upper facing panels Fig 15 Item 6 i USER NOTE The fourth additional roof batten one row installation is also the first roof batten of the row above Fig 15 Item 1 and is re quired for anti slip protection on the upper collector array Fig 15 Distances betw...

Page 22: ...recautions against a possible fall B Always wear your personal protective clothing and safety equipment B After completing the installation always check the secure positioning of the installed set and that of the collectors B Ensure that the correct equipment is used for working on roofs CAUTION RISK OF INJURY through interruption of work B Secure the collectors against falling B Stabilise the col...

Page 23: ...llector array the water connection must be two way Tichelmann principle Fig 19 The two way connection can also be made if there are fewer than 6 collectors Fig 19 If more than 9 collectors are required then a further AGS pump station is required Fig 17 Water connection right up to max 5 collectors Item 1 Corrugated pipe connector Item 2 Flow line Item 3 Return line Item 4 End cap Fig 18 Water conn...

Page 24: ...side and lower facing pan els and the collectors Fig 21 Item 1 must be sealed with the sealing tape B Clean the recessed channel on the collector B Remove protective film from the sealing tape B Insert sealing tape Fig 21 Item 2 adhesive side first into the recessed channel on the outer edges of the outer collectors and at the bottom of every collec tor Fig 21 Item 1 incl the corner connector Fig ...

Page 25: ...with a 6x40 screw Fig 23 Item 1 and washer use size 10 spanner The clamp now grips into the lower edge of the collector B Lift collector slightly and on the 2nd and 3rd addition al battens as well as halfway along the collector on a free batten push the pack plate Fig 24 Item 2 with the double sided clamp under the collector until the roof pushes against the lower edge of the collec tor B For the ...

Page 26: ...ctor connections are pushed into the preassembled corrugated pipe connectors Fig 25 Item 1 on the first collector B Place second bracket Fig 25 Item 3 over the corrugated pipe connector and collector connection 63043966 11 1 SD 63043966 11 1 SD Fig 25 Pushing second collector towards the first 2 63043966 15 1 SD 63043966 15 1 SD 1 2 3 CAUTION SYSTEM DAMAGE through damaged corrugated pipe connector...

Page 27: ...6 2 3 Installing more than one row If you intend to install more than one collector array one above the other anti slip protection devices must be fit ted for the upper collectors B Put two anti slip protection devices Fig 29 Item 1 per collector halfway along 700 mm apart over the lower collector onto the fourth additional batten on the lower row and fasten with two 4x40 screws B Allow the collec...

Page 28: ...n sor bush B Insert collector sensor approx 250 mm into the sen sor guide tube as far as it will go B Tighten compression fitting Fig 31 Item 2 coun terhold if necessary Fig 30 Collector sensor installation location schematic Item 1 Return line Item 2 Flow line B A 63043966 25 1 SD 63043966 25 1 SD 2 1 2 1 i USER NOTE The collector sensor is supplied with the solar controller Observe the installat...

Page 29: ...g pump no vent is required on the roof B Push connection pipe 1000 mm Fig 33 Item 2 onto the flow connection on the collector array and fix in place using bracket Fig 33 Item 1 B Feed connection pipe together with the sensor cable through the roof B Connect header pipe to the compression fitting Fig 33 Item 3 Perform the same procedure with the return connection Fig 32 Routing connection pipes und...

Page 30: ...ather pro tection cap one full revolution Universal air vent set Fig 35 Fig 34 View air pot with vent valve for flow connection Item 1 Collector sensor Item 2 Automatic air vent valve on roof 63043966 20 1 SD 63043966 20 1 SD 2 1 i User note For each change of direction downwards and each new rise install an additional air vent Fig 35 Universal air vent set 63043966 21 2 SD 63043966 21 2 SD 2 1 3 ...

Page 31: ...f insulation Perform the same procedure with the return connection B Remove nut and compression fitting from connection pipe B Firmly screw connection pipe Fig 36 Item 3 and double threaded fitting Fig 36 Item 1 into air pot O ring gasket B Connect header pipe to double threaded fitting with compression fitting Fig 36 Item 1 Fig 36 Fitting the air vent valve under the roof Item 1 Double threaded f...

Page 32: ... union nut so that a flat sealing surface is created on the connection pipe B Remove double threaded fitting and large diameter washer and check that a flat sealing surface has been created B Remove any burrs as required Installing the connection set B Insert gasket Fig 39 Item 2 B Insert pipe bend Fig 39 Item 3 into union nut align and screw tight B Push connection pipe Fig 39 Item 1 onto the col...

Page 33: ...carried out and all connections leak proof see pump station instructions CAUTION BUILDING DAMAGE from leaks in the roof B Fit the facing panels very carefully so that no leaks can occur through the collector array Fig 40 Facing panels fitted all round the edges 63043975 09 1 SD 63043975 09 1 SD 1 CAUTION RISK OF INJURY Like other components incorporated into the roof the space between the collecto...

Page 34: ...ashing 63043975 46 1 SD 63043975 46 1 SD 1 2 Fig 42 Lower right facing panel Fig 43 Positioning the middle facing panels for portrait collectors 63043975 10 1 SD 63043975 10 1 SD 1 0 m m 90 92 mm 1 2 3 63043975 38 1 SD 63043975 38 1 SD 1 CAUTION BUILDING DAMAGE from roof leaks if the distance between upper edge of the collector to the upper edge of the first additional roof batten is not 90 92 mm ...

Page 35: ...ck of the flashing B Carefully adjust flashing in the area in front of the roof tile contour Fig 46 Item 2 Fig 44 Positioning the middle facing panels for landscape collectors 63043975 42 1 SD 63043975 42 1 SD 80 100 mm 80 100 mm 1 i USER NOTE For two landscape collectors facing pan els are necessary underneath in the mid dle Fig 44 Item 1 They must overlap by 80 100 mm Fig 45 Fitting the left han...

Page 36: ...ed against the collector B Fasten clip with nail provided 10 3 Middle cover strip between two collectors The middle cover strip seals the gap between two collec tors B Press cover strip Fig 49 Item 1 with the folded edge facing downwards into the gap between the two collectors and make sure it is centrally positioned B Using size 8 spanner tighten screws Fig 49 Item 2 by hand beginning at the bott...

Page 37: ...he side facing panel on the left B By applying pressure to the top of the facing panel it clicks under the recessed channel on the collector frame Fig 50 Item 3 B Shorten the rubber lip Fig 52 Item 3 so that it touches the rubber lip on the right hand facing panel B Place rubber lip on the left hand facing panel onto the fold on the right hand facing panel Fig 52 Item 2 B Press the upper facing pa...

Page 38: ... the rubber lip Fig 54 Item 2 on top of the col lector B Feed panel fold on remaining upper facing panels Fig 55 Item 2 into the fitted facing panel and then push towards the collector B Feed the upper left facing panel Fig 55 Item 1 into the side facing panel on the left B By applying pressure to the top of the facing panel it clicks under the recessed channel on the collector frame Fig 54 Item 3...

Page 39: ... panel must be fastened to the roof battens with two clips In addition each outer facing pan el must be fixed in place with one clip B Insert clip Fig 58 Item 1 into the edge of the facing panel B Push clip with facing panel towards collector so that the facing panel is pressed against the collector B Fasten clip with nail provided Fig 56 Upper left facing panel 63043975 47 1 SD 63043975 47 1 SD 1...

Page 40: ...n adjust the angle using the pan tile overlay B Place the pan tile overlay Fig 59 Item 1 according to the calculated position and fasten to the roof bat ten B Lay the cut pan tiles Fig 59 Item 3 10 7 2 Side pan tiles B Cut pan tiles to dim X Table 5 page 17 and lay i USER NOTE Fasten cut pan tiles with suitable brackets if necessary available from a roofing spe cialist CAUTION BUILDING DAMAGE from...

Page 41: ...nts snow and rain proof 11 2 Insulating the connection and header pipes Insulation of header pipes For the insulation of internal pipework use only high temperature resistant insulating materials i USER NOTE If you are venting the solar heating sys tem with an automatic air vent valve ac cessory you must close the ball valve after the venting procedure see pump station installation instructions ...

Page 42: ...ollector and drill pilot hole for a screw p 25 8 Fasten clamp with screw and washer p 25 9 Drill hole for the double sided clamp on the left collector side between two collectors p 25 10 Push underlay plate under collector and screw in the double sided clamp a little p 25 11 Push corrugated pipe connectors onto the connections on the first collector and secure with clips p 25 12 Push second collec...

Page 43: ...6 720 613 057 2006 04 43 ...

Page 44: ... 752556 TRAINING 01905 752526 SALES 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 6 720 613 057 2006 04 ...