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Greenskies Solar-Lux 6-12 On Roof Installation and Servicing Instructions
Greenskies Solar-Lux 6-12 On Roof Installation and Servicing Instructions
SOLAR-LUX 6/12
UK/IE
6 720 647 040 (2011/05) GB/IE
TABLE OF CONTENTS
TABLE OF CONTENTS
4 Before installation . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Determining space requirements . . . . . . . 9 11 Replacing individual tubes . . . . . . . . . . . . . . . . 28
4.2 Planning the hydraulic connection . . . . . . 9
4.3 Observing general notes . . . . . . . . . . . . . 10
4.4 Tools and accessories required . . . . . . . 11 12 Environmental protection / disposal . . . . . . . . 29
4.5 Lightning protection . . . . . . . . . . . . . . . . 11
4.6 Installation order . . . . . . . . . . . . . . . . . . . 11 13 Maintenance/inspection . . . . . . . . . . . . . . . . . . 30
5 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 PRODUCT INFORMATION
6720646203-35.1ST
2.2 CORRECT USE • Use an electrical solar filling station to pressure fill
The installation set and the mounting brackets are with the heat transfer medium Tyfocor LS to purge
intended only for the safe attachment of collectors to and fill the system (do not use water because the
pitched roofs. collectors cannot be drained). This means that there
is no need to have an air vent valve up on the roof.
The collectors are for DHW heating and can be used to
• For the required expansion vessel pre-charge
make a contribution to space heating in certain
pressure setting and the operating pressure and flow
circumstances with specially designed systems.
rate settings for the vacuum tube collector system,
They may only be operated in combination with suitable
please see the chapter entitled "Final activities"
solar controllers in intrinsically safe, sealed unvented
(Æ page 27).
solar thermal systems. These systems must be equipped
with a suitable, adequately sized expansion vessel. In addition to the notes from the solar pump station
instructions, please also observe the following:
PERMISSIBLE ROOF PITCH
• The distance between the solar pump station
The self-cleaning effect for the glass tubes and CPC
(Expansion vessel connection) and the bottom edge
mirror will only work if the roof has a pitch of at least
of the collector array must be at least 2 m (Æ Fig. 3).
15°.
• The minimum pipe length between the solar pump
The maximum roof pitch is 65°. station (expansion vessel connection) and the
collector array must be at least 5 m. For systems
PERMISSIBLE LOADS
utilising more than 18 tubes, a minimum of 10 metres
The installation set is suitable for the following: is requires.
• a standard snow load of 1.5 kN/m2 or 2.0 kN/m2
(Æ Tab. 4, page 6)
1 5 2
2
L
6
3
4 7
6720646203-05.1ST
6720646203-06.1ST
Fig. 4 Standard delivery for mounting brackets for roof Fig. 5 Standard delivery for installation set
tiles (different mounting brackets subject to
roofing) Solar-Lux
6 6 12
Solar-Lux
(2 x) (3 x) (1 x)
6 6 12
Item 2 Hammer-head bolt 24 36 6
(2 x) (3 x) (1 x)
(with washer and nut
Item 1 Mounting bracket 4 6 4 M10)
Tab. 2 Standard delivery for mounting brackets for roof Item 7 Upper/lower retaining 4 6 2
tiles subject to number of collectors clips
Tab. 3 Installation set subject to number of collectors
1300 2007
2022
1953
1953
Standard snow load: max. 1.5 kN/m2 Standard snow load: max. 1.5 kN/m2 Standard snow load: max. 2.0 kN/m2
Tab. 4 Using the rails (Item 5) and maximum standard snow load (dimensions in mm)
Certificates
DIN
Collector connection, 15 mm 15 mm
flow and return
Fig. 6 Standard delivery for connection set Gross area 1.45 m2 2.86 m2
Net weight 24 kg 43 kg
Item 1 Connection pipe, fully assembled 2x
Permissible operating 10 bar 10 bar
(incl. stainless steel corrugated pipe,
pressure for collector
insulation and compression fitting
(pmax)
for connection to the piping)
Test pressure (ppr) 13 bar 13 bar
Item 2 Installation and maintenance 1x
instructions Stagnation 301 °C 301 °C
Tab. 5 temperature, max.
1 mbar
180
160
140
1
120
2
100
80
60
6720646203-31.1ST 40
20 2
Fig. 7 Collector with connection nipple 0
0 1 2 3 4 5 6 7 8
Item 1 Connection nipple as connector 1x l/min 6720646552-16.1ST
4 BEFORE INSTALLATION
DANGER: Risk of fatal injury from collectors The collector sensor [1] must be fitted in
that cannot withstand peak wind and the collector connected to the flow pipe [2].
suction values.
B Maintain the minimum clearance to the
MAXIMUM NUMBER OF COLLECTORS PER ROW:
edge of the roof.
• Solar-Lux 6: 6 collectors
• Solar-Lux 12: 3 collectors
a= h
10 HERE ARE TWO EXAMPLES OF AN HYDRAULIC
b ARRANGEMENT FOR THE EVACUATED TUBE
C, a a= b COLLECTORS:
10
1
a
a
h
6720646203-10.1ST
Solar-Lux 6 Solar-Lux 12
Number of Dimension Dimension Dimension Dimension
collectors* A B A B
1 0.70 m 2.06 m 1.40 m 2.06 m
2 1.40 m 4.27 m 2.80 m 4.27 m
3 2.10 m 6.48 m 4.20 m 6.48 m
4 2.80 m -- 5.60 m --
5 3.50 m -- 7.00 m --
6 4.20 m -- 8.40 m --
Tab. 9 Space requirements (* for dimension B:
collectors arranged one above the other)
6720646203-44.1ST
6720646203-24.1ST
2 3 N
6720646203-08.1ST
• Avoid shade from adjacent building, trees, etc. 4.4 TOOLS AND ACCESSORIES
(Æ Fig. 14). REQUIRED
• Cordless screwdriver for pre-drilling
• 6 mm, 9 mm for pre-drilling
• Spanner, sizes SW13, 17, 22, 24, 30
• Hammer (for roof tiles and connection set)
• Phillips screwdriver (for connection set)
• Ventilation tiles to pass piping through the roof
(optional)
• Material for pipe insulation
5 HANDLING
The collectors and the installation materials are heavy B To make it easier to transport the collectors and the
and difficult to handle. Please observe the following installation material, use the following aids with
notes, since working on the roof can also be dangerous. sufficient load-bearing capacity:
– Mobile hoist or crane
DANGER: Risk to life through falls or falling – Lifting belt
parts!
– Roofing ladder or equipment for sweeping
B Do not use a ladder to move components chimneys
to the roof because the installation
– Scaffolding
material and collectors are heavy and can
be difficult to handle. B Dispose of transportation packaging using the most
B Take appropriate action to prevent environmentally friendly method of recycling.
accidents during all work on roofs.
B Take precautions against a possible fall.
B Always wear personal protective clothing
and safety equipment.
B At least 2 people must carry out
installation on the roof.
B During transport, secure the collectors
and installation material to prevent them
falling.
B After completing installation, check that
the installation set and collectors are
securely positioned.
> 0,15 m
0,45 m 0,45 m
90°
0,26 m 6720646203-46.1ST
6720646203-33.1ST
x x
0,70-0,93 m
6720646203-02.2ST
6.2 INSTALLING MOUNTING BRACKETS B If required, use wooden spacer [5] supplied for height
PAN TILE ROOFS compensation (pre-drill 9 mm).
B Depending on the distances (Æ page 14), remove B Carefully remove the roof tiles' rain guards and
2-3 roof tiles from a row in the area of the rafters. profiles [2, 4] in the area of the mounting brackets.
B Screw mounting bracket with 3 screws 8 x 120 mm
Positioning of the mounting brackets:
[3] to the rafter. Use a size SW13 spanner.
– The mounting bracket must be in the tile valley.
B Put the roof tiles back on.
– The mounting bracket must protrude directly
above the roof tile below it without touching this
NOTE: Caution, care should be taken to
tile.
avoid roof leaks from fine, wind-driven snow
B Mark the mounting bracket positions on the roof. in the area of the mounting bracket.
B Place mounting bracket [1] on rafter and pre-drill B If there is a larger gap between the top
using a 6 mm drill bit to fasten with the screws [3]. and the bottom roof tiles, close this gap
using UV-resistant sealing tape.
1 13 6 9
1.
2
2. 3 3.
6720646203-07.1ST
1 Mounting bracket
2 Top roof tile
3 Screws 8 x 120 mm
4 Bottom roof tile
5 Wooden spacer 100 x 150 x 8 mm
6.3 INSTALLING MOUNTING BRACKETS B To make room for the mounting bracket, shorten the
ON PLAIN TILE ROOFS plain tile at the top edge if necessary and/or make a
recess in the roof batten lying above.
NOTE: To avoid roof leaks on plain tile roofs, B Mark the mounting bracket positions on the roof.
consult a roofer for advice and assistance.
B Pre-drill rafter with 6 mm drill bit.
B Consult a roofer for advice and
B If required, use wooden spacer [4] supplied for height
assistance.
compensation (pre-drill 9 mm).
B Depending on the distances determined (Æ page 14) B Screw mounting bracket with 3 screws 8 x 120 mm
remove 2-3 plain tiles from a row in the area of the [2] to the rafter. Use a size SW13 spanner.
rafters. B Trim adjacent plain tiles [3] and roof them.
13 6 9
1 1.
2
2.
3.
6720646203-11.1ST
3
Fig. 22 Mounting brackets for plain tile roofs
1 Mounting bracket
2 Screws 8 x 120 mm
3 Plain tiles, trimmed
4 Wooden spacer 100 x 150 x 8 mm
6.4 INSTALLING MOUNTING BRACKETS B Depending on the distances determined (Æ page 14),
ON SLATE SHINGLE ROOFS remove several panels in the area of the rafters.
13 6
6720646203-17.1ST
1 Mounting bracket
2 Screws 8 x 120 mm
1300 2007
2022
1953
1953
Tab. 11 Dimensions in mm
1300 2007
2022
1953
1953
Tab. 12 Dimensions in mm
* recommended for the combination 2 x Solar-Lux 12 and 1 x Solar-Lux 6
PREASSEMBLING ON THE GROUND
In order make installation on the roof easier for you, we
recommend that you preassemble the following parts on
the ground using a size SW17 spanner.
17
6720646203-54.1ST
Fig. 27
6720646203-21.1ST
7.2 INSTALLING HORIZONTAL RAILS AND Do not fasten the upper retaining clips [2] to the
RETAINING CLIPS collector and the top rail until after the collector has
been installed.
Horizontal rails are not always required
(Æ Tab. 11 and 12, page 18). INSTALLING THE RAILS
When installing the rails, make sure that you align them
exactly (dimension x: same overhang on the right and
PREASSEMBLY OF LOWER RETAINING CLIPS ON THE left).
GROUND
Make sure that the hammer-head bolt [4] is fastened
B Detach upper [2] and lower [1] retaining clips at the
tightly.
designated breaking point.
B Using the L-shaped connector [5], 4 hammer-head
B Install lower retaining clips [1] on the bottom rail at
bolts, 4 washers and 4 nuts, connect the horizontal
the distances indicated and screw on with a nut and
rail [6] to the vertical rail [7].
washer.
Use a size SW17 spanner.
17
7 x
90°
x
90°
1
5
1953
2
90°
1
20-90 450-550 160- 450-550 20-90
260
4
1300
17
2
2022 mm
6720646203-27.1ST
Fig. 29
1 2 3 4 5 90 m
m
6720646203-28.1ST 1
6720646203-32.1ST
Fig. 32 Installing the collector sensor
1 Left-hand collector
2 Union nut (already assembled)
3 Olive (already assembled)
4 ½ “ connection nipple
5 Right-hand collector
8.4 INSTALLING THE CONNECTION The new connection plugs hold together the two
COVER SET (ACCESSORY) collector frames, maintaining the correct dimensions.
To improve the appearance of the area between two 1. Remove the original plugs from the collector frame
connectors, you can install the connection cover set as profiles.
an accessory. 2. Inserting the new connection plugs into the profiles.
3. Drive the metal pin into the plug with the hammer.
STANDARD DELIVERY
• 1 x insulation piece (45 mm wide, 19 mm thick) with
self-adhesive closure
• 1 x cover (70 mm wide)
• 1 x securing bar (8 x 10 x 80 mm) with screw
(4.2 x 19 mm)
• 2 x connection plug with metal pin
TOOL
Screwdriver (Phillips), hammer
1.
INSTALLATION
The collectors must be exactly aligned prior to
installation.
1. Place the insulation piece over the fitting from below
and seal using the self-adhesive tab.
2. Push the cover onto the insulation.
3. Fasten the cover to the back side of the collector with
the securing bar.
2. 3.
6720646203-42.1ST
2.
Fig. 34 Bottom of collector: exchanging the plugs
1.
3. 6720646203-41.1ST
9 HYDRAULIC CONNECTIONS
Refer to the "Solar pump station" instructions for B Connect piping below the roof to the 15 mm olive
information on laying the pipes between the fitting of the connection pipe (use size SW30
components (collectors, solar pump station, solar spanner).
cylinder).
CONNECTING PIPEWORK
The hydraulic connection to the piping under the roof is
made using the 1 m long flexible connection pipes. They
can be bent a maximum of 90°.
B Hold connection pipe [4] using a size Fig. 36 Assembled connection pipe and roof outlet
SW24 spanner.
B Use a second size SW24 spanner to
tighten the nuts [2].
24 24
1 2 3 4
6720646203-36.1ST
1 Collector
2 Union nut (already assembled)
3 Olive (already assembled)
4 Connection pipe (already insulated)
6720646203-24.1ST
2 3
Fig. 37 Three-row connection (with shut-off ball valve),
here: flow on the left
1 Collector sensor
2 Flow pipe (to the cylinder)
3 Return pipe (from the cylinder)
4 Shut-off valve
10 FINAL ACTIVITIES
2
3
6720646203-34.1ST
Fig. 38
1 Silicone ring
2 Tube holder
3 Release lever
4 Tube
Make sure that the silicone ring [1] fits tightly in the
manifold.
DISPOSAL
At the end of their service life, materials should be
recycled in the most environmentally compatible
method of recycling.
13 MAINTENANCE/INSPECTION
The collector array must be inspected at regular
DANGER: Risk to life through falls and
intervals (inspection). Defects must be remedied
falling parts!
immediately (maintenance). We recommend conducting
B Take appropriate action to prevent the first maintenance/inspection after about
accidents during all work on roofs. 500 operating hours, and then at intervals of 1-2 years.
B Take precautions against a possible fall.
Use the table to make copies to ensure that activities are
B Always wear personal protective clothing
documented after the third time maintenance is
and safety equipment.
conducted.
B Fill out the report and tick off the tasks performed.
Date
Notes
Tab. 16
worcester-bosch.co.uk