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INSTALLATION AND MAINTENANCE INSTRUCTIONS

EVACUATED TUBE COLLECTOR

SOLAR-LUX 6/12

6 720 646 203-00.02TL

ROOF MOUNTING INSTALLATION

UK/IE
6 720 647 040 (2011/05) GB/IE
TABLE OF CONTENTS

TABLE OF CONTENTS

1 Key to symbols and safety instructions . . . . . . . 3 8 Installing the collectors . . . . . . . . . . . . . . . . . . 22


1.1 Explanation of symbols . . . . . . . . . . . . . . . 3 8.1 Installing the first collector . . . . . . . . . . . 22
1.2 General safety information . . . . . . . . . . . . 3 8.2 Installing the second collector . . . . . . . . . 23
8.3 Installing the collector sensor . . . . . . . . . 23
8.4 Installing the connection cover set
2 Product information . . . . . . . . . . . . . . . . . . . . . . 4 (accessory) . . . . . . . . . . . . . . . . . . . . . . . .24
2.1 Components and instructions . . . . . . . . . . 4
2.2 Correct use . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 EU Declaration of Conformity . . . . . . . . . . 5 9 Hydraulic connections . . . . . . . . . . . . . . . . . . . . 25
2.4 Standard delivery . . . . . . . . . . . . . . . . . . . 6
2.4.1 Mounting bracket . . . . . . . . . . . . . . . . . . . 6
2.4.2 Installation set . . . . . . . . . . . . . . . . . . . . . . 6 10 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4.3 Connection set (hydraulic connection) . . . 7 10.1 Checking the installation . . . . . . . . . . . . . 27
2.4.4 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . 7 10.2 Pressure filling, purging, venting . . . . . . . 27
2.5 Specification . . . . . . . . . . . . . . . . . . . . . . . 7 10.3 Adjusting the pre-charge pressure
2.6 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . 8 of the expansion vessel . . . . . . . . . . . . . .27
10.4 Determining and setting
the operating pressure . . . . . . . . . . . . . . .27
3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 10.5 Adjusting the flow rate . . . . . . . . . . . . . . 27
10.6 Insulating piping . . . . . . . . . . . . . . . . . . . 27

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

6 Installing the mounting brackets . . . . . . . . . . . 13


6.1 Determining distances . . . . . . . . . . . . . . 13
6.1.1 Vertical distances
for the mounting brackets . . . . . . . . . . . . 14
6.1.2 Horizontal distances
for the mounting brackets . . . . . . . . . . . . 14
6.2 Installing mounting brackets
pan tile roofs . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Installing mounting brackets
on plain tile roofs . . . . . . . . . . . . . . . . . . . 16
6.4 Installing mounting brackets
on slate shingle roofs . . . . . . . . . . . . . . . . 17

7 Installing the rails . . . . . . . . . . . . . . . . . . . . . . . 18


7.1 Installing the vertical rails . . . . . . . . . . . . 19
7.2 Installing horizontal rails
and retaining clips . . . . . . . . . . . . . . . . . . 20
7.3 Installing the retaining clips
to vertical rails . . . . . . . . . . . . . . . . . . . . . 21

2 6 720 647 040 (2011/05)


KEY TO SYMBOLS AND SAFETY INSTRUCTIONS

1 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS

1.1 EXPLANATION OF SYMBOLS DANGER OF BROKEN GLASS


WARNING SYMBOLS If the glass tubes are destroyed, there is a risk of injury
through falling glass.
Safety instructions in this document are
framed and identified by a warning triangle B Avoid installing in public areas where falling glass
which is printed on a grey background. could cause injury.

RISK OF BECOMING BURNED BY THE COLLECTORS


Electrical hazards are identified by a
If the collector and its installation material are left
lightning symbol surrounded by a warning
exposed to the sunlight for a long period, the parts will
triangle.
become hot.
Signal words indicate the seriousness of the hazard in B Care should be taken when working on the collector
terms of the consequences of not following the safety due to possible high temperatures.
instructions.
• NOTICE indicates possible damage to property or INSTALLATION
equipment, but where there is no risk of injury. Installation and maintenance may only be carried out by
• CAUTION indicates possible injury. a competent person. Do not alter the components.
• WARNING indicates possible severe injury. B Please read these instructions carefully.
• DANGER indicates possible risk to life. B Install the installation set only on roofs with sufficient
IMPORTANT INFORMATION load-bearing capacity. If necessary, consult a
structural engineer and/or roofer.
Notes contain important information in B Do not walk on the collectors. Do not subject them to
cases where there is no risk of personal loads from objects at single points or over the entire
injury or material losses and are identified surface area.
by the symbol shown on the left. They are
B After completing the installation, check that
bordered by horizontal lines above and
collectors and the installation set are securely
below the text.
positioned.
ADDITIONAL SYMBOLS
FUNCTION CHECKS
Symbol Meaning The user is responsible for ongoing maintenance and
safe upkeep of the system.
B a step in an action sequence
B Customer recommendation: Arrange a maintenance
Æ a reference to a related part in the
and inspection contract with a competent person.
document or to other related documents
B Only original spare parts must be used.
• a list entry
INSTRUCTING THE CUSTOMER
– a list entry (second level)
B Notify customers about how the appliance works and
Tab. 1 provide training on operating the entire system.
B Inform customers that they must not carry out any
1.2 GENERAL SAFETY INFORMATION
modifications or repairs.
DANGER OF FALLING WHEN WORKING ON THE ROOF B Hand over the installation instructions to the
B If there are not any general anti-fall safety devices, customer and point out that these instructions must
wear personal protective clothing and safety be kept and passed on to the next owner/user.
equipment.
B Take appropriate action to prevent accidents during
all work on roofs.
B Observe the health and safety regulations.

6 720 647 040 (2011/05) 3


PRODUCT INFORMATION

2 PRODUCT INFORMATION

2.1 COMPONENTS AND INSTRUCTIONS


The solar thermal system for DHW heating and/or central 1
heating backup comprises various components
(Æ Fig. 1). These have instructions for installation,
operation and maintenance. Some accessories have 2
separate instructions. The following topics are
described in the instructions for the components:

EVACUATED TUBE COLLECTORS (Æ FIG. 1, [1])


• Installing the mounting brackets. 3
• Fastening the collectors.
2 4
• Hydraulic connection for the collectors.
• Maintenance for the collectors.
3

SOLAR PUMP STATION (Æ FIG. 1, [2])


• Installing the solar pump station.
• Installing the piping.
• Commissioning the entire system.
4
• Maintenance for the solar pump station.
6720646203-01.1ST
• Maintenance for the entire system.
Fig. 2 Functional diagram of an evacuated tube
CYLINDER (Æ FIG. 1, [3]) collector, here: type Solar-Lux 6 = 6 tubes
• Positioning and installing the cylinder. (type Solar-Lux 12 = 12 tubes)
• Commissioning the cylinder. 1 Manifold
• Maintenance for the cylinder. 2 CPC mirror for optimum sunlight utilisation
3 Heat transfer medium tubes
SOLAR CONTROLLER (Æ FIG. 1, [4]) 4 Glass-glass evacuated tubes for optimum thermal insulation
(It is possible to replace a tube without having to drain the
• Installing the controller.
system).
• Operating the controller and the entire system.
REGARDING THESE INSTRUCTIONS

1 The evacuated tube collector is referred to in its short


form, collector, on the following pages. Roofing in the
form of pantiles, roof tiles etc. is designated uniformly as
roof tiles.

These instructions describe the installation of evacuated


tube collectors (including their hydraulic connection) for
4 the following roofing on pitched roofs:
3 • Pan tiles, plain tiles, tiles and slate shingles.
2

6720646203-35.1ST

Fig. 1 Schematic diagram of a solar thermal system

4 6 720 647 040 (2011/05)


PRODUCT INFORMATION

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)

B To determine the maximum wind speed, take into


account the following factors:
– the location of the solar thermal system,
– the geographic elevation,
– the topography
– the height of the building.
> 200 cm
If necessary, consult a building structural engineer.
20-30 cm
HEAT TRANSFER MEDIUM
To protect the collectors from frost and corrosion
damage, they should be operated with the Tyfocor
6720646203-49.1ST
Glycol LS. Do not add any other heat transfer medium.
Fig. 3
OTHER APPLICABLE INSTRUCTIONS AND IMPORTANT
NOTES
2.3 EU DECLARATION OF CONFORMITY
The installation and maintenance instructions for the
This product conforms in design and operation to the
solar pump station contain important information for
European Directives and the supplementary national
using evacuated tube collectors in the solar thermal
requirements. Its conformity is demonstrated by the CE
system. Please take particular note of the information on
designation. The Declaration of Conformity can be
the following topics.
requested from the manufacturer (see back cover for
• Do not carry out brazing close to evacuated tube address).
collectors.
• If system is used for central heating backup or covers
more than 60% of DHW needs, install a pre-cooling
vessel before the expansion vessel.
• Install the expansion vessel (EV) with a tee 20-30 cm
above the solar pump station in the return pipework
to the panel (Æ Fig. 3).
• Do not use any forms of soft soldering with these
collectors

6 720 647 040 (2011/05) 5


PRODUCT INFORMATION

2.4 STANDARD DELIVERY


B Check that the delivered packages are complete and
undamaged.

2.4.1 MOUNTING BRACKET 2.4.2 INSTALLATION SET

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)

Item 2 Hammer-head bolt 4 6 4 Item 5 Rail L=1300 mm 2 -- --


(with washer and nut
Item 5 Rail L=1953 mm 2 3 --
M10)
Item 5 Rail L=2007 mm -- 2 --
Item 3 Screw 8 x 120 12 18 12
Item 5 Rail L=2022 mm -- -- 2
Item 4 Wooden spacer 12 18 12
100 x 150 x 8 mm Item 6 L-shaped connector 4 6 --

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

3 x Solar-Lux 6 (or 1 x Solar-Lux 6 1 x Solar-Lux 12 or


2 x Solar-Lux 6 + 1 x Solar-Lux 12) 1 x Solar-Lux 6

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)

6 6 720 647 040 (2011/05)


PRODUCT INFORMATION

2.4.3 CONNECTION SET (HYDRAULIC 2.5 SPECIFICATION


CONNECTION)
Solar-Lux 6 Solar-Lux 12

Certificates
DIN

Width 0.70 m 1.40 m

Depth 0.10 m 0.10 m

1 2 Length 2.06 m 2.06 m

Collector connection, 15 mm 15 mm
flow and return

Absorber capacity 0.97 l 2.12 l

Aperture area 1.28 m2 2.57 m2


1000
Absorber area 1.29 m2 2.58 m2
6720646203-30.1ST

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.

2.4.4 COLLECTOR Number of glass tubes 6 12

Glass tube: Tube 1920 mm /


length/ ExternalØ / 47 mm / 37 mm
InternalØ
Tab. 7

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

between collectors Fig. 8 Pressure drop of collectors


Item 2 Collector Solar-Lux 6/12 1x 1 Pressure drop curve for Solar-Lux 12
comprising: evacuated tubes, 2 Pressure drop curve for Solar-Lux 6
CPC mirror, manifold
Tab. 6

6 720 647 040 (2011/05) 7


REGULATIONS

2.6 DATA PLATE 3 REGULATIONS


The data plate is mounted on the manifold and contains
all important information in the form of symbols. B Comply with all standards and guidelines applicable
to the installation and operation of the system in your
Symbol Meaning Explanation country and region.
These include, but are not limited to:
AG areagross Gross area
• The Health and Safety at Work Act 1974.
Aa areaaperture Projected mirror
• Control of substances hazardous to health regulations
area
(COSHH) 1994
AA areaabsorber Absorber area • The pressure equipment regulations 1999
Vf volumefluid Collector capacity • Construction (Design and Management) Regulation
(CDM) 2007
m mass Weight
• The Work at Height Regulations 2005
tstg temperaturestagnation Stagnation • Manual Handling Operations Regulations 1992
temperature, max.
• The Lifting Operations and Lifting Equipment
pmax pressuremaximum Operating pressure, Regulations (LOLER) 1999
max. • Reporting of injuries, diseases or dangerous
ppr pressureproof Test pressure occurrences regulations (RIDDOR) 1995
• Confined spaces regulations 1997
yprod yearproduction Production year
• Personal protective equipment at work regulations
Tab. 8 Data plate information 1992
• Electricity at work regulations 1989
• Provision and uses of work equipment regulations
(PUWER) 1998
• BS 6795:1986 Code of practice for solar heating
systems for swimming pools for swimming pool.
• BS5918: A code of practice for the installation of
DSHW systems for domestic hot water
• BS5546: 2000 Specification for installation of hot
water supplies for domestic purposes, using gas-fired
appliances of rated input not exceeding 70 kW.
• BS6700: 2006 Specification for design, installation,
testing and maintenance, of servicing supplying water
for domestic use within buildings and their curtilages.
• EN 12976: Thermal solar heating system and their
components (prefabricated systems).
• ENV 12977: Thermal solar heating system and their
components (bespoke systems).
• BS 6920: Suitability of non-metallic products for use
in contact with water intended for human
consumption with regards to their effect on the
quality of water
• BSEN 12831:2003: Heating systems in buildings.
Methods for calculation of the design heat load
• BS 8000-15: 1990: Workmanship on building sites.
Code of practice for hot and cold water services
(domestic scale)

8 6 720 647 040 (2011/05)


BEFORE INSTALLATION

4 BEFORE INSTALLATION

4.1 DETERMINING SPACE 4.2 PLANNING THE HYDRAULIC


REQUIREMENTS CONNECTION
These minimum space requirements must be available Before installing the collectors, please decide how the
on the roof. collectors will be arranged.

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

Fig. 9 Clearance dimensions for the collector array

• Dimension a: Use a formula, both are possible


3 2 6720646203-23.1ST
• Dimensions A and B: Æ Tab. 9
• Dimension C: At least 3 rows of tiles to ridge or Fig. 10 Connection in a single row, here: flow on the right
chimney 1 Collector sensor (always on the flow side)
• Dimension D: At least 0.5 m to the right and left of the 2 Flow pipe (to the cylinder)
collector array as well as to the ridge for connection 3 Return pipe (from the cylinder)

lines below the roof.

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)

6 720 647 040 (2011/05) 9


BEFORE INSTALLATION

4.3 OBSERVING GENERAL NOTES


We recommend that you engage the
services of a roofing company, as they are
experienced in working on roofs and will be
1
aware of the risk of falling.

• Familiarise yourself with the on-site conditions and


local regulations.
• Remove and replace broken roof tiles, shingles, etc.
• Always install collectors with the manifold on the top.

6720646203-44.1ST

4 Fig. 12 Permissible installation direction

• Arrange collectors optimally on the roof (Æ Fig. 13),


for example, in such a way that the collector array is
aligned with windows and doors. When doing so,
maintain the minimum clearances to the edge of the
roof (Æ Fig. 9).

6720646203-24.1ST
2 3 N

Fig. 11 Three-row connection (with shut-off valve), W O


here: flow on the left
S
1 Collector sensor (always on the flow side)
2 Flow pipe (to the cylinder)
3 Return pipe (from the cylinder)
4 Shut-off valve (accessory)

6720646203-08.1ST

Fig. 13 Aligning the collector array to the building's shape

10 6 720 647 040 (2011/05)


BEFORE INSTALLATION

• 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

4.5 LIGHTNING PROTECTION


The need for lightning protection may vary from region
to region.

B Familiarise yourself with the regional regulations to


6720646203-09.1ST

determine whether a lightning protection system is


necessary.
Fig. 14 Avoiding shade
The lightning conductor is often a requirement for
buildings higher than 20 m.

A lightning conductor must be installed by an electrician.

Where there is a lightning conductor system installed,


have the connection to the solar thermal system
checked.

4.6 INSTALLATION ORDER


To fasten the collectors to the roof, install in the
following order:

1. Determine distances for mounting brackets


2. Install mounting brackets.
3. Install rails and retaining clips.
4. Install collectors and collector sensor.
5. Connect piping to collectors.

6 720 647 040 (2011/05) 11


HANDLING

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.

NOTE: Collector damage through transport.


We recommend transporting the collector
to the roof in its transportation packaging.

WARNING: Risk of injury from broken glass.


B When handling the collectors, always
wear protective gloves and goggles.

B The belt loops at the top of the collector are for


assistance in handling the unit.

DANGER: Risk to life through inadequately


secured collectors during transport.
B Make sure that the collectors are
securely fastened during transportation.

12 6 720 647 040 (2011/05)


INSTALLING THE MOUNTING BRACKETS

6 INSTALLING THE MOUNTING BRACKETS


The collectors are connected to the supporting surface 6.1 DETERMINING DISTANCES
using mounting brackets. The distances are shown using
the example of the mounting bracket for roof tiles. The mounting bracket for roof tiles is shown
as an example in the figures. The distances
WARNING: Please refer to current health also apply to other mounting brackets.
and safety guidelines for working at height.
In order to install the mounting brackets, you must
determine the distances for them.
Please observe Fig. 16.
NOTE: Damage to the roofing by stepping – On pan tile roofs the tile valleys determine the true
on installed mounting brackets and distance between the mounting brackets.
installation set.
– The rafter spacing does not always match the
B To prevent damage to the roofing, do not required spacing for the mounting brackets. For
step on installed components. larger or smaller rafter spacing, you must install
supporting surfaces (braces) on site with adequate
PREASSEMBLY ON THE GROUND
load-bearing capacity.
In order make installation on the roof easier for you, we
– For multiple rows of collectors, you must choose
recommend that you preassemble the threaded
the distances for the mounting brackets such that
connections for all mounting brackets on the ground.
there is a minimum distance of 150 mm between
B Screw on hammer-head bolt with washer and nut M10 the collectors on the top and bottom.
to mounting bracket. – The mounting brackets must be positioned at right
angles to each other.

NOTE: Collector damage through


incorrectly positioned mounting brackets.
B Maintain the distance between the
mounting brackets (Æ Fig. 16).
B Always choose the largest possible
distance between two vertical mounting
6720646203-40.1ST
brackets (Æ Fig. 16, Dimension b).
Fig. 15 Preassembly of hammer-head bolts on the ground B A rafter width of at least 88 mm is
required to fasten the mounting brackets
with 3 screws. Provide for on-site
reinforcement in case of narrower
rafters.

B Define mounting bracket positions (Æ Fig. 16 to 20


and Æ Tab. 10).

6 720 647 040 (2011/05) 13


INSTALLING THE MOUNTING BRACKETS

6.1.1 VERTICAL DISTANCES FOR THE MOUNTING


BRACKETS

For roof batten spacing of 370 mm (Solar-Lux 6/12)


and 450/460/470 mm (Solar-Lux 6), the mounting
brackets must be installed at a distance from the
roof batten. This is the only way to achieve
dimension b.
x x
Dimension a - Dimension b - Dimension b -
Roof batten spacing for Solar-Lux 6 for Solar-Lux 12
320 mm - 340 mm 1520 mm - 0,65-0,8 m 0,65-0,8 m
1715 mm
6720646203-03.2ST

350, 430 mm 1715 mm - Fig. 18 3 x Solar-Lux 6 (or 1 x Solar-Lux 6 and 1 x


1760 mm Solar-Lux 12) for a standard snow load of
370, 470 mm 1895 mm 1520 mm -
1840 mm max. 1.5 kN/m2
380 mm - 420 mm 1520 mm -
1715 mm
360, 440, 450 mm 1760 mm -
1810 mm
460 mm 1810 mm
Tab. 10 Vertical distances for the mounting brackets

> 0,15 m

0,45 m 0,45 m
90°
0,26 m 6720646203-46.1ST

b Fig. 19 2 x Solar-Lux 6 (and others) for a standard snow


load of max. 2.0 kN/m2
90°
1,395 m
a

6720646203-33.1ST

Fig. 16 Distances to be maintained and rafter width

6.1.2 HORIZONTAL DISTANCES FOR THE


MOUNTING BRACKETS
Subject to the type of collector and regional standard
x x x x
snow load, you will have to take different distances into
account. 0,70-1,05 m 0,70-1,05 m
6720646203-26.1ST

Fig. 20 2 x Solar-Lux 12 (and others) for a standard


snow load of max. 2.0 kN/m2

The Dimension x stands for an identical


distance. The maximum difference between
these dimensions is 100 mm.

x x

0,70-0,93 m
6720646203-02.2ST

Fig. 17 2 x Solar-Lux 6 (or 1 x Solar-Lux 12) for a


standard snow load of max. 1.5 kN/m2

14 6 720 647 040 (2011/05)


INSTALLING THE MOUNTING BRACKETS

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

Fig. 21 Mounting brackets for roof tile roofs

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

6 720 647 040 (2011/05) 15


INSTALLING THE MOUNTING BRACKETS

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.

Positioning of the mounting brackets:


NOTE: Caution, to avoid roof leaks from
– The mounting bracket [1] must be in the middle of
fine, wind-driven snow in the area of the
the plain tile below it.
mounting bracket.
– The mounting bracket must protrude directly
B If there is a larger gap between the top
above the plan tile below it without touching this
and the bottom roof tiles, close this gap
tile.
using UV-resistant sealing tape.

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

16 6 720 647 040 (2011/05)


INSTALLING THE MOUNTING BRACKETS

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.

Positioning of the mounting brackets:


NOTE:
– The mounting bracket must protrude directly
B To avoid roof leaks on slate or shingle
above the panel below it without touching this
roofs, consult a roofer for advice and
panel.
assistance.
B Because the mounting bracket can rest B Mark the mounting bracket positions on the roof.
on the panel below, this panel must be B Screw mounting bracket [2] with 3 screws 8 x
reinforced on-site using a suitable 120 mm [1] to the rafter. Use a size SW13 spanner.
material. B Put panels back on.

13 6

6720646203-17.1ST

Fig. 23 Mounting brackets for slate shingle roofs

1 Mounting bracket
2 Screws 8 x 120 mm

6 720 647 040 (2011/05) 17


INSTALLING THE RAILS

7 INSTALLING THE RAILS


The mounting brackets and the collector are connected
by the rails and the retaining clips.

EXAMPLES OF HOW THE RAILS CAN BE USED

1 x Solar-Lux 6 2 x Solar-Lux 6 3 x Solar-Lux 6

1300 2007
2022

1953

1953
Tab. 11 Dimensions in mm

1 x Solar-Lux 12 1 x Solar-Lux 12* 1 x Solar-Lux 6 and 1 x Solar-Lux 12

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.

B Preassemble hammer-head bolts with L-shaped


connector: Æ Fig. 28
B Preassemble lower retaining clips with horizontal rail
(1300 mm or 2007 mm): Æ Fig. 28
B Preassemble upper retaining clips with vertical rail
(2022 mm): Æ Fig. 29

18 6 720 647 040 (2011/05)


INSTALLING THE RAILS

7.1 INSTALLING THE VERTICAL RAILS SOLAR-LUX 6: INSTALLING VERTICAL RAILS


FOR ROOF BATTEN SPACING OF 350-370 MM
ALIGNING THE RAILS AND 430-470 MM
When installing the rails, make sure that you align them For these distances between roof battens, it is
exactly (Æ Fig. 24): necessary to screw together the L-shaped connector
• perpendicular to the horizontal (use aid such as roof and the mounting bracket with the vertical rail.
batten [1])
Position of
• same overhang on top and bottom (dimension x).
Roof batten L-shaped Top, bottom of
spacing connector mounting bracket
350, 430, 440 mm A bottom only
360, 450 mm B bottom only
460 mm A top
B bottom
370, 470 mm B top and bottom
Tab. 13 Fastening the L-shaped connector to the
mounting bracket
B Screw rails as specified by Tab. 13 to L-shaped
connector and mounting bracket (Æ Fig. 26).

17

Fig. 24 Aligning the vertical rails

SOLAR-LUX 12: VERTICAL RAILS FOR ALL DISTANCES


BETWEEN ROOF BATTENS A
B Place top and bottom rails on mounting brackets and
B
screw on with hammer-head bolts (Æ Fig. 25). Use a
size SW17 spanner.

SOLAR-LUX 6: INSTALLING VERTICAL RAILS FOR


ROOF BATTEN SPACING OF 320-340 MM AND 380-
420 MM
B Place top and bottom rails on mounting brackets and
screw on with hammer-head bolts (Æ Fig. 25). Use a
6720646203-45.1ST
size SW17 spanner.
Fig. 26 Screwing to L-shaped connector and mounting
bracket (here: at position A)
17
CHECKING THE TIGHTNESS OF ALL HAMMER-HEAD
BOLTS
B Check the tightness of all hammer-head bolts [1].

6720646203-54.1ST

Fig. 27

6720646203-21.1ST

Fig. 25 Installing rails on mounting brackets

6 720 647 040 (2011/05) 19


INSTALLING THE RAILS

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

20-90 450-550 160- 450-550 160- 450-550 20-90


260 260
2007 6720646203-19.2ST

Fig. 28 Rails and clips, all dimensions in mm

1 Lower retaining clip


2 Upper retaining clip
3 Horizontal rail 2007 mm
4 Fastened hammer-head bolt
5 L-shaped connector for connecting the rails
6 Horizontal rail
7 Vertical rail

20 6 720 647 040 (2011/05)


INSTALLING THE RAILS

7.3 INSTALLING THE RETAINING CLIPS


TO VERTICAL RAILS
Horizontal rails are not installed for the 2022 mm vertical
rail. Therefore, you must install the upper and lower
retaining clips on the vertical rails.

PREASSEMBLY OF LOWER RETAINING CLIPS ON THE


GROUND
B Detach upper [1] and lower retaining clips [2] at the
designated breaking point.

Make sure that the hammer-head bolt is fastened


tightly [3].
B To fasten the lower retaining clips [2], push the
fastened hammer-head bolt into the rails up to the
stop. Tighten with a size SW17 spanner.

Do not fasten the upper retaining clips [1] to the


collector and the rail until after the collector has been
installed.

17

2
2022 mm

6720646203-27.1ST

Fig. 29

6 720 647 040 (2011/05) 21


INSTALLING THE COLLECTORS

8 INSTALLING THE COLLECTORS


Once the mounting brackets and the rails with the Wait to tighten the upper retaining clips until the
retaining clips have been installed, the collectors can be collectors are screwed to each other.
fastened. B Install the upper retaining clips [1 or 2] the same way
as the lower retaining clips [3].
DANGER: Risk to life through falling parts!
B During installation, secure the collectors
to prevent them falling.

WARNING: Risk of injury from broken glass.


B When handling the collectors, always
wear protective gloves and goggles. 1 2

NOTE: Collector damage from evaporation


in the solar circuit.
B Leave the sun protection film on the
collector until the collector has been 1
purged and filled. However, it must not
be exposed to the elements for more
than 4 weeks.
B Fit a suitable sun protection cover for
longer periods of time.
B Please observe all guidelines for working
3 6720646203-29.1ST
at height.
Fig. 30 Collector fastened to the horizontal rails
8.1 INSTALLING THE FIRST COLLECTOR 1 Upper retaining clip for horizontal rail
Align the first collector in such a way that during 2 Upper retaining clip if only vertical rails are available
3 Lower retaining clip
installation all collectors have the same overhang over
the rails to the right and left.

B Place the packed collector on the rails.


B Open the packaging at the bottom. The collector can
now slide into the lower retaining clips [3].
This clip must fully grip the collector profile.

B For the 1300 mm horizontal rail, push the outer edge


of the collector to the middle of the rail.
Once all the collectors are installed, the overhang on
the sides will be the same.

22 6 720 647 040 (2011/05)


INSTALLING THE COLLECTORS

8.2 INSTALLING THE SECOND 8.3 INSTALLING THE COLLECTOR


COLLECTOR SENSOR
The connection fitting (Æ Fig. 31) on the right-hand side The collector sensor is supplied with the solar pump
of the collector connects the two collectors. station, control or seperately as part of a first fix kit and
must be installed in the collector connected to the (hot)
B Place the second collector on the rails and push it
flow pipe (Æ page 9, 10).
towards the collector that is already installed.
B Align the collectors on the rails in such a way that the
NOTE: System damage through faulty
overhang on the right and left is the same.
sensor cable.
NOTE: Collector damage through over- B Protect the cable from possible damage.
tightening.
B Hold the connection nipple [4] using a The collector sensor must be correctly
size SW22 spanner. installed to ensure proper operation of the
B Tighten the nuts [2] using a size SW24 solar thermal system.
spanner.
B Push the collector sensor [1] 90 mm into the sensor
well (to the end-stop).
22 24

1 2 3 4 5 90 m
m

6720646203-28.1ST 1

6720646203-32.1ST
Fig. 32 Installing the collector sensor

Fig. 31 Connecting the collectors with each other


hydraulically

1 Left-hand collector
2 Union nut (already assembled)
3 Olive (already assembled)
4 ½ “ connection nipple
5 Right-hand collector

B Install all other connectors the same way.


B Tighten upper retaining clips with a size SW17
spanner (Æ Fig. 30).

CAUTION: Risk of scalding from fittings that


have not been tightened.
B Check that all fittings have been
tightened.

6 720 647 040 (2011/05) 23


INSTALLING THE COLLECTORS

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

Fig. 33 Top of collector at manifold: installing insulation


piece and cover

24 6 720 647 040 (2011/05)


HYDRAULIC CONNECTIONS

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).

NOTE: All roof work should be carried out


by qualified personnel to ensure water
tightness.

Feed sensor cable together with the flow


pipe through the roof.

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°.

NOTE: Collector damage through over


tightening. 6720646203-20.1ST

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

Fig. 35 Fitting for connection pipe and collector

1 Collector
2 Union nut (already assembled)
3 Olive (already assembled)
4 Connection pipe (already insulated)

6 720 647 040 (2011/05) 25


HYDRAULIC CONNECTIONS

INSTALLING THE SHUT-OFF VALVE (ACCESSORY)


For collector arrays consisting of several rows of To purge and vent a row of collectors,
collectors connected in parallel, each collector array always open the shut-off valve for this row
must be purged and vented separately. In order to do so, only. The other shut-off valves remain
each row of collectors requires a shut-off valve in the closed. Open all shut-off valves after purging
flow. and venting. Observe the additional notes
on pressure filling in the instructions for the
NOTE: Collector damage from overpressure. solar pump station as well as the filling
The piping between the collector and the station.
expansion vessel (EV) or safety valve must not
be shut off.

B Install the shut-off valve with the olive fittings (2


fittings supplied) in the flow of the collector.

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

26 6 720 647 040 (2011/05)


FINAL ACTIVITIES

10 FINAL ACTIVITIES

10.1 CHECKING THE INSTALLATION 10.4 DETERMINING AND SETTING THE


OPERATING PRESSURE
Once the following checks have been
performed, you can carry out the final After carrying out pressure filling and purging as well as
insulation activities. a pressure test (Æ solar pump station instructions), you
must determine and set the required operating
pressure. For information on how to proceed, please
Checks
refer to the instructions for the solar pump station.
1. Are all connection fittings tightened? 
The operating pressure is calculated from the
2. Are all threaded fittings on rails, 
static system head plus 2.0 bar (static system
mounting brackets and retaining clips
head = difference in head between the
tightened?
expansion vessel connection and the top edge
3. Is the collector sensor inserted up to the  of the collector; 1 metre difference in head
end-stop? corresponds to 0.1 bar).
Tab. 14 Example: 10 m difference in head
corresponds to 1.0 bar plus 2.0 bar = 3.0 bar.
10.2 PRESSURE FILLING, PURGING,
VENTING 10.5 ADJUSTING THE FLOW RATE
The solar thermal system must be filled by means of
Observe the information in the installation
pressure filling, purged and vented. Observe the notes
and maintenance instructions for the solar
on pressure filling in the installation instructions for the
pump station (chapter entitled "Adjusting
solar pump station as well as the filling station.
the flow rate").

NOTE: Collector damage from frost.


Flow rate in l/min
B Carry out pressure filling using LS heat
(for flow temperature of 20 °C)
transfer medium for purging and filling
the system. Solar-Lux 6 Solar-Lux 12
Do not use water because the collectors Number of collectors (l/min) (l/min)
cannot be drained!
1 -- 2.0

10.3 ADJUSTING THE PRE-CHARGE 2 2.0 4.0

PRESSURE OF THE EXPANSION 3 3.0 5.5


VESSEL 4 4.0 --
Before filling the solar thermal system, check the pre-
5 4.5 --
charge pressure of the expansion vessel.
6 5.5 --
The expansion vessel pre-charge pressure is Tab. 15 Flow rate to be adjusted for non-variable speed
calculated from the static system head plus solar controllers subject to the number and type
1.7 bar (static system head = difference in of collectors
head between the expansion vessel
connection and the top edge of the collector; 10.6 INSULATING PIPING
1 metre difference in head corresponds to
0.1 bar). ON-SITE INSULATION OF PIPING
Example: 10 m difference in head B Use insulation resistant to UV light and high
corresponds to 1.0 bar plus 1.7 bar = 2.7 bar. temperatures for outdoor piping.
B Use insulation resistant to high temperatures for
B Correct the pre-charge pressure of the expansion
indoor piping.
vessel, if necessary.
B Make the insulation bird-proof.

6 720 647 040 (2011/05) 27


REPLACING INDIVIDUAL TUBES

11 REPLACING INDIVIDUAL TUBES


You can tell when a tube is broken because the silver B Apply soapsuds or lubricant paste to the top of the
deposits in the bottom part of the tube will have turned tube.
white. B Turning the tube slightly, push it through the silicone
ring into the manifold.
WARNING: Risk of injury from broken glass. B Place the tube holder [2] on the end of the tube, push
B When handling the collectors, always it in between the notches in the aluminium profile and
wear protective gloves and goggles. engage it in the groove.
B Pull down the tube into the tube holder to the end-
stop.
1

2
3

6720646203-34.1ST

Fig. 38

1 Silicone ring
2 Tube holder
3 Release lever
4 Tube

REMOVING A MECHANICALLY DESTROYED TUBE


B Carefully remove broken glass without damaging the
surface of the CPC mirror.
B Remove tube holder [2] at the bottom.

REMOVING A TUBE IS NOT MECHANICALLY


DESTROYED
B To remove the tube holder [2] at the bottom,
– push up the tube 5 mm into the manifold and
– push down the two release levers [3] on the right
and left using your thumb and pointer finger.
B Lift the tube holder toward the manifold to release it.
B Lift the tube somewhat and turn it about the
longitudinal axis to pull it straight down and out.

INSTALLING THE TUBE


Install the new tube [4] the same way that you removed
the old tube.

Make sure that the silicone ring [1] fits tightly in the
manifold.

28 6 720 647 040 (2011/05)


ENVIRONMENTAL PROTECTION / DISPOSAL

12 ENVIRONMENTAL PROTECTION / DISPOSAL


Environmental protection is our principal policy.

Quality of performance, efficiency and environmental


protection are equally important objectives for us. All
legislation and regulations pertaining to the environment
are strictly observed. To protect the environment, we
use the best possible technology and materials.

DISPOSAL
At the end of their service life, materials should be
recycled in the most environmentally compatible
method of recycling.

6 720 647 040 (2011/05) 29


MAINTENANCE/INSPECTION

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.

Owner: Site location:

Maintenance and inspection work Page Maintenance/inspection

Date

1. Visual inspection of the collectors carried out (glass tubes   


fit tightly, appearance)?

2. Collector sensor is positioned correctly and is inserted 23   


into the sensor well to the end-stop?

3. Visual inspection of the installation system carried out?   

4. Visual inspection for leaks carried out at points where   


installation system meets the roof?

5. Visual inspection of pipe insulation carried out?   

Notes

The collector array has been serviced as specified by these   


instructions.

Date, stamp, Date, stamp, Date, stamp,


signature signature signature

Tab. 16

30 6 720 647 040 (2011/05)


NOTES

6 720 647 040 (2011/05) 31


WORCESTER, BOSCH GROUP:
TECHNICAL SUPPORT: 0844 892 3366
APPOINTMENTS: 0844 892 3000
SPARES: 01905 752571
LITERATURE: 0844 892 9800
TRAINING: 01905 752526
SALES: 01905 752640

Worcester, Bosch Group


Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. 0844 892 9900
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.

worcester-bosch.co.uk

6 720 647 040

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