TUBO II C, TUBO II T Flat roof and façade installation Application
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TECHNICAL DOCUMENTATION
TUBO II C, TUBO II T
Flat roof and façade installation
Application Advantage
• Solar heating support and water heating • Very high efficiency and yields in the winter half-year
• Process heat • Low weight with 18 kg (T) and 18 kg (C)
• Single and multi-family houses • Modular system: needs-based fields through small
• On-roof installation (see other document) modules that can be optically connected to a field
• Flat roof / façade installation • Low space requirement on the roof
• High reliability through proven components
• Very good ecological balance due to low embodied
carbon
• Good integration and shapely design due to very flat
design
• Consolar grants a 5-year warranty
TDMA722EN_TUBOII_flat-roof_2017_11_20_2017_03_14_obps
6.1 Fitting telescopic rails ..........................................14
Content 6.1.1 Selecting mounting holes .....................................14
1 Key to symbols and safety instructions ... 3 6.1.2 Fitting telescopic rails ..........................................14
1.1 Key to symbols .....................................................3 6.2 Collector support clearances ................................14
1.1.1 Warnings ............................................................3 6.3 Fitting the collector supports on a flat roof ............15
1.1.2 Important information ...........................................3 6.3.1 Base anchor .......................................................16
1.2 General safety instructions ....................................3 6.3.2 Ballast troughs ....................................................16
2 Information about the collector and its 6.3.3 Securing with ropes ............................................16
accessories.............................................. 3
7 Façade installation ................................ 17
2.1 Collector ..............................................................3
8 Horizontal installation .......................... 18
2.1.1 Specifications .......................................................4
9 Fitting the profile rails ........................... 19
2.2 Product data for energy consumption .....................5
9.1 Connecting profile rails .......................................19
2.3 Determined use ....................................................5
9.2 Installing the profile rails .....................................19
2.4 Accessories ..........................................................6
9.3 Aligning the profile rails ......................................19
2.5 EU Declaration of Conformity ................................6
9.4 Fitting the anti-slip protectors ...............................19
2.6 Components and technical documentation ..............6
10 Installing the collectors ......................... 20
2.7 Scope of delivery .................................................6
10.1 Collector installation ...........................................20
2.7.1 Collector installation set ........................................7
10.1.1 Fit one-sided collector clamps on the left ..............20
2.7.2 Connection set .....................................................8
10.1.2 Placing the first collector on the profile rails .........20
2.7.3 Collector with interconnection set ...........................8
10.1.3 Inserting a double sided collector clam ................21
3 Regulations ............................................ 9
10.1.4 Fitting the second collector .................................21
3.1 Validity of regulations ...........................................9
10.1.5 Fitting single sided collector clamps on the right
3.2 Standards, regulations, directives ..........................9 hand side .........................................................22
4 Transport................................................. 9 10.2 Prepare the collector temperature sensor ..............22
5 Before installation ................................ 10 11 Hydraulic connection ............................ 23
5.1 General notes ....................................................10 12 Final steps ............................................ 24
5.2 Collector layout ..................................................10 12.1 Flushing, venting and leak testing ........................24
5.3 Collector angle of incidence ................................12 12.2 Checking the installation .....................................24
5.3.1 Determining the range of incidence ......................12 12.3 Install intermediate reflector (accessories) .............24
5.3.2 Determining the angle of incidence and angle of 12.4 Installing the end cap and intermediate panel .......25
inclination on pitched roofs ................................12
12.5 Insulating the connection lines and pipework ........25
5.4 Space required on roof .......................................12
12.6 Removing the collector film ..................................25
5.4.1 Determining the clearance between rows of
13 Cleaning the collectors .......................... 26
collectors ..........................................................12
14 Environmental protection and disposal... 26
5.4.2 Determining the space required ...........................13
15 Maintenance/inspection......................... 26
5.5 Lightning protection ............................................14
5.6 Required tools and materials ...............................14
5.7 Installation sequence ...........................................14
6 Fitting the collector supports.................. 14
2Key to symbols and safety instructions
1 Key to symbols and safety Collector storage
The collectors and the installation material may cause burns
instructions when exposed to solar radiation.
>> Protect the collectors and installation material from solar
exposure.
1.1 Key to symbols
>> Store the collectors in dry conditions; if stored outside,
use a rain cover.
1.1.1 Warnings
>> Do not stand on the collectors.
Warnings in this document are identified by
a warning triangle printed against a grey Work on the roof
background. Keywords at the start of a warning There is a danger of falling when working on the roof if
indicate the type and seriousness of the ensuing measures are not taken to prevent accidents.
risk if measures to prevent the risk are not taken.
>> If there is not any independent anti-fall safety device,
wear personal protective equipment or safety equipment.
The following keywords are defined and can be used in this
document: >> Observe accident prevention regulations.
• NOTICE indicates a situation that could result in dama- Load bearing capacity of the roof
ge to property or equipment. >> Only install collectors on roofs with sufficient load bea-
• CAUTION indicates a situation that could result in ring capacity.
minor to medium injury. >> If in doubt, consult a structural engineer and/or roofer.
• WARNING indicates a situation that could result in
severe injury or death. Handover to the user
• DANGER indicates a situation that will result in severe When handing over the solar system, explain the operating
injury or death. conditions to the user.
>> Explain the operation—with particular emphasis on all
1.1.2 Important information safety-related actions.
This symbol indicates important information >> Explain that conversions and repairs must only be carried
where there is no risk to people or property. out by an approved contractor.
>> Point out the need for inspections and maintenance for
safe and environmentally-compatible operation.
>> The installation and operating instructions must be given
1.2 General safety instructions to the user for safekeeping. This involves:
These installation instructions are intended for gas fitters --Keeping the instructions in a visible place, protected
and plumbers. from heat, water and dust.
>> Read the installation instructions (collector, solar pump --Passing them on to subsequent owners/users.
station, solar controller, etc.) before installation.
>> Observe safety instructions and warnings. 2 Information about the collector
>> Observe national and regional regulations, technical
rules and guidelines.
and its accessories
>> Keep a record of any work carried out.
The vacuum tube collectors TUBO II C (with CPC-reflector)
and T (without CPC-reflector) are referred to as „collectors“
Determined use for short in these instructions.
The collectors are designed to produce heat in solar thermal
systems. The installation set is exclusively designed for the 2.1 Collector
safe installation of collectors.
The vacuum tube collector has six twin-wall glass tubes with
>> Only operate collectors in fail-safe sealed unvented solar
vacuuminsulated interiors. A temperature sensor is installed
systems (exclusion of oxygen). on each collector which is accessible after the cover [6] is
>> Only operate collectors with suitable solar controllers. removed.
>> Do not place objects on top of the collector.
3Key to symbols and safety instructions
TUBO C (with TUBO T (without 2.1.1 Specifications
reflector) reflector)
Collector angle greater than 24° less than 25° TUBO C TUBO T
Tab. 1 Recommended use
Certificates
(CE marking, Solar Keymark)
1 3 Length 1947 mm
2
Width 624 mm
Height 85 mm
Collector connection (nominal
DN 15
diameter)
Absorber capacity (VFl) 0,851
4 Total collector area (gross
1,22 m2
5 area, AGr)
6 Absorber area (net area, AAb) 1,07 m2 0,39 m2
Maximum heat output (Pmax) at
650 W1) 362 W
6720816962-03.1ST
1000 W/m2
Fig. 1 TUBO II C Aperture area (area on which
0,98 m2 2) 0,46 m2
[1] CPC (not in TUBO II T); [2] Pipe register; [3] Vacuum tube; the usable sunlight falls, AAp)
[4] Collector connection, flow (hot, red transport protection);
[5] Collector connection, return (cold, blue transport protec- Net weight excluding pa-
18 kg
tion); [6] Access to the collector temperature sensor ckaging (m)
permissible collector operating
1 10 bar
pressure (pmax)
permissible collector angle 25-90° 0-90°
Tab. 2 Technical data
1) Additional 66 W per intermediate reflector
2) Additional 0.1 m2 between two collectors (accessory: intermedi-
ate reflector)
2
5 3
1947
4 6720816962-06.1ST
Fig. 2 Collector hydraulic system and data plate
[1] Data plate on the outside of the collector casing; [2] Pipe
register; [3] Flow to the cylinder [4] Collector temperature
sensor, pre-mounted; [5] Return from the cylinder
624
85
6 720 818 573-03.1T
Fig. 3 Collector dimension
4Key to symbols and safety instructions
mbar >> Only remove the protective film from the collector after
commissioning.
400
>> Commission the solar system with 4 weeks of fitting the
350
collectors.
300
Permissible types of roof
250
These instructions describe the installation of collectors on
200 flat roofs and walls.
150 >> Only use the installation set on such roofs.
100
Permissible roof slopes (see Tab. 1, page 4)
50 >> Install the installation set with flat roof frames only on flat
0 roofs or those with a shallow pitch up to 25 °.
0 10 20 30 40 50 60 70
V [l/h] 6720816963-40.1 ST
Collector supports and profile rails
Fig. 4 Collector pressure drop (measured with heat transfer medium >> When installing collectors on a flat roof: Never use
LS at 50 °C) the collector supports to secure other parts of the roof
structure.
2.2 Product data for energy consumption >> When installing collectors on a wall: only mount the pro-
The following product data satisfy the requirements of file rails on walls with sufficient load-bearing capacity.
the EU Regulations No. 811/2013 and No. 812/2013,
Permissable loads
813/2013 and 814/ 2013 supplementing Directive
2010/30/EU. >> Only install collectors in locations with lower values than
those shown in the following. If required, consult a struc-
Product data Symbol Unit TUBO C TUBO T tural engineer.
Collector The installation set is suitable for the following maximum
Asol m2 0,98 0,46
aperture area loads:
Collector • maximum snow load on the floor after DINEN 1991-1-
efficiency % 61 64 3: 2.0 kN/m2
col
(∆T=40 K) • maximum wind speed to corresponding to DIN EN
1991-1 -4 of up to 129 km/h (corresponding to a
Zero-loss 1)
0,663 0,787 backpressure of 0.8 kN/m2)
efficiency 0
>> To determine the maximum wind speed, take into account
First-order W/
a1 1)
0,782 2,99 the following factors:
coefficient (m2K)
--Location of the thermal solar system
Second-order W/
a2 1)
0,012 0,015 --Geographical height of the terrain
coefficient (m2K2)
--Topography (terrain/buildings)
Incidence
--Height of building
Angle Mo- IAM 1,00 1,27
The maximum snow load is calculated using regional zones
difier
(snow load zones) and the ground level elevation.
Tab. 3 Performance data
1) Reference: Aperture area >> Find out the local snow load (see relevant local data).
With angled roofs: Prevent an accumulation of snow above
2.3 Determined use or on the collector:
>> Fit a snow guard above the collector.
The installation set is exclusively designed for the safe
mounting of collectors. - or -
>> Never modify components. >> Regularly clear snow build-up.
To prevent additional snow loads, see also: „Height diffe-
Collector protection
rentials in roofs“ on page 10.
>> To protect the collectors against damage through frost
and corrosion, operate them with LS solar heat transfer
medium.
5Key to symbols and safety instructions
Other applicable instructions and important information 2.6 Components and technical documentation
The installation and maintenance instructions for the solar A thermal solar system is designed to heat domestic hot
pump station include vital information regarding the use of water (DHW) and can also provide central heating backup
vacuum tube collectors in a solar thermal system. Observe where required. It is made up of various components which
particularly the information on the following subjects: also include installation instructions. Further instructions
• Never braze pipework near the collectors. may be found with the accessories.
• If the system is used for central heating backup or
covers more than 60 % of the DHW demand, install an 1
intermediate vessel upstream of the expansion vessel.
• Install the expansion vessel (EV) in the return line cor-
responding to the technical documentation of the solar
pump station.
4
• Flush and fill the system with LS solar heat transfer me-
dium under pressure (never use water, as the collectors
3
2
cannot be drained). Consequently, there is no need for
an air vent valve above the roof.
• Depending on the storage type, the volumetric flow rate
for Consolar solar systems should be set to between
15 and 25 l / h per m2 of collector surface area (see
the technical documentations of the Consolar storage
tanks).
• Adjust the following values according to the installation 6720816962-05.1ST
and maintenance instructions of the solar pump station: Fig. 5 Components of a solar system
--Pre-charge pressure for the expansion vessel [1] Collectors; [2] Solar pump station with expansion vessel,
temperature and safety equipment; [3] Solar cylinder; [4] Solar
--Operating pressure. controller
• The clearance between the solar pump station (expan-
sion vessel connection) and the bottom edge of the
2.7 Scope of delivery
collector array must be at least 2 m.
>> Check that the delivered material is complete and unda-
• The minimum pipe length (single length) between the
maged.
solar pump station (expansion vessel connection) and
the collector array must be at least 10 m.
2.4 Accessories
The pricelist includes a current and complete overview.
2.5 EU Declaration of Conformity
The design and operation of the collectors conform to the
European Directives and supplementary national require-
ments. Its conformity is demonstrated by the CE marking.
The Declaration of Conformity can be requested from the
manufacturer (see the back cover for the address).
6Key to symbols and safety instructions
2.7.1 Collector installation set
1 2 3 4 5
7
6
6720816963.01-1.ST
Fig. 6 Installation set for 4 collectors (grey: expansion for 2 collectors)
Installation set, standard version1) for Installation set, expansion for
No. Component
2 collectors 3 collectors 2 collectors 3 collectors
1 Single-side collector clamp 4 4 - -
2 Screw M8 × x 20 and nut M8 4 4 4 4
3 Double-sided collector clamp 2 4 4 6
4 Horizontal profile rail2) 2 2 2 2
5 Profile rail joiner - - 2 2
6 Collector brace 2 2 2 2
7 Anti-slip protector 4 6 4 6
Tab. 4 Number of components per set
1) Per collector row
2) For 2 collectors: 1254 mm long, for 3 collectors: 1874 mm long
7Key to symbols and safety instructions
2.7.2 Connection set
7
6
8
5 9
1
10 2
4 3
6720816963-02.1ST
Fig. 7 1 on-roof connection set and 2 interconnection sets
2.7.3 Collector with interconnection set
No. Connection set for 1 row of collectors Qty
1 Hydraulic plug-in connector 2
2 Elbow with compression fitting 18 mm 2 8
9
3 Clips 4
4 Cap 2
5 Cover (1 x left, 1 x right) 2 10
6 Installation and maintenance instructions 1
7 5 mm Allen key 1
Tab. 5 Connection set
6720816963-35.1ST
Fig. 8 Collector and individual parts in the packaging
No. Collector with interconnection set Qty
8 Intermediate panel 1
9 Hydraulic plug-in connector 2
10 Clip 2
Tab. 6 Individual parts in the collector packaging
8Regulations
WARNING: Risk of injury through
3 Regulations glass splinters.
>> When handling collectors, always wear safety
gloves and goggles.
3.1 Validity of regulations
The collector transport protection contains im-
>> Observe updated regulations or supplements. These
portant components (see Fig. 8, page 8).
regulations also apply at the time of installation.
3.2 Standards, regulations, directives >> Only remove the transport packaging after the collector
Observe all standards and guidelines applicable to the has been installed.
installation and operation of the system in your country and >> Dispose of shipping packaging by environmentally res-
region. ponsible means.
Technical regulations applicable in Germany for the instal-
lation of collectors:
• Rooftop installation:
--DIN 18338, VOB, Part C1): Roof covering and roof
sealing work
--DIN 18339, VOB, Part C: Plumbing work
--DIN 18451, VOB, Part C: Scaffolding work
--DIN EN 1991: Actions on structures
• Connection of thermal solar systems:
--EN 12976: Thermal solar systems and components
(preassembled systems)
--EN 12977: Thermal solar systems and components 6720816962-43.1ST
(custom built systems)
Fig. 9 Use two people to carry the collector
--DIN 1988: Technical Regulations for Drinking Water
NOTICE: Collector damage from im-
Installations (TRWI) proper transport.
• Electrical connection: >> Do not connect any straps, belts, etc. to the
--DIN EN 62305 Part 3 / VDE 0185-305-3: Protection collector connections.
against lightning, injury and structural damage
1) VOB: German Construction Contract Procedures, Part C: General
>> To make it easier to transport the collectors and the instal-
technical specifications in construction contracts (ATV)
lation materials, the following assembly aids, which have
4 Transport sufficient loadbearing capacity, can be used:
--Lifting belt
DANGER: Risk to life by falling from --Roofing ladder or equipment for sweeping chimneys
roof! --Lean-to lift
>> Never use a ladder to move components to --Scaffolding
the roof because the installation material and
collectors are heavy and difficult to handle.
>> Whilst working on the roof, take all necessary
precautions against a possible fall.
>> If there are no general anti-fall safety devices
available, wear personal protective equip-
ment.
WARNING: Risk of injury through
falling parts!
>> During transport, secure the collectors and
installation materials to prevent them falling.
9Before installation
>> Prevent shading of the collector array through adjacent
5 Before installation buildings, trees, other collector rows, etc.
5.1 General notes
WARNING: Risk of burns due to hot
parts!
If the collector and installation material are ex-
posed to solar exposure for prolonged periods
of time, they may cause burns!
>> Protect yourself with personal protective
equipment.
6720816963-04.1ST
>> Protect the collector and installation material
Fig. 11 Avoid shading
from solar exposure.
We recommend that you engage the services of Height differentials in roofs
a roofing contractor, as they are experienced in Where there are height differentials in the roof, snow loads
working on roofs and will be aware of the risk must be prevented from sliding down from a roof slope of
of falling. > 15°. The length of the additional load through sliding
snow loads results from the height differential (see Fig. 12):
>> Obtain information about on-site conditions and local ls = 2 × h
regulations.
>> Avoid installing collectors within the ls area below height
>> Arrange collectors in the optimal position on the roof. For
differentials.
this, pay particular attention to the following:
>> In case of installation below a height differential:
--Align the collector array facing as close to south as
--Fit a snow guard to the higher roof area.
possible (see Fig. 10).
--Observe additional loads during the installation.
--Align the collector array so that it is in line with win-
dows, doors etc. (see Fig. 10).
--Avoid potential shading (see Fig. 11.
--Prevent height differentials (see Fig. 12).
--Hydraulic connection to the pipework (see chapter 11,
page 23).
--Take the space required on the roof into account (see
chapter 5.4, page 12).
--Align the collector array on angled roofs parallel to the
ridge (no side slopes).
W
N
6720816963-05.1ST
Fig. 12 Collector arrangement with changes in height
[1] Additional loads through sliding snow; [2] Standard snow
load; [ ] Roof pitch; [h] Height differential; [ls] Length of the
additional load
5.2 Collector layout
Refer to the technical guide for stores and controller for
S
6720816963-03.1ST detailed information on designing the system hydraulics
Fig. 10 Collector arrangement and components.
>> Plan the routing of the collector sensor lead so that the
collector temperature sensor can be used in the collector
to which the flow [3] has been connected.
10Before installation
1
2
3
6720816962-09.1ST
6720816962-12.1ST
Fig. 13 Permissible layout and orientation
Fig. 17 Maximum of 14 collectors, with connections on the same side
[1] Collector temperature sensor always in the collector to on the right or left (2 rows)
which the flow has been connected; [2] Return (cold, from the
storage tank, blue transport protection); [3] Flow (hot, to the
storage tank, red transport protection)
1
6720816962-10.1ST
Fig. 14 Maximum of 14 collectors, connection on the same side, right
or left (1 row)
6720816962-13.1ST
Fig. 18 Maximum of 14 collectors, connection on the same side, right
or left (2 rows)
1) Shut-off valve for pressure (separate for each collector
row)
6720816962-27.1ST
1
Fig. 15 Maximum of 14 collectors, connection on alternate sides (1 row)
6720816962-28.1ST
Fig. 19 Maximum of 14 collectors per row (connected in parallel)
1) Control valve for hydraulic balancing (separate for each
6720816962-11.1ST collector row) and shut-off valve for pressure filling
Fig. 16 Maximum of 14 collectors, connection on the same side, right
or left (2 rows)
11Before installation
5.3.2 Determining the angle of incidence and angle of
inclination on pitched roofs
On roofs with a slight inclination towards the south:
1 Angle of inclination [2] = Angle of incidence [1] - Roof
slope [3]
On roofs with a slight inclination towards the north:
Angle of inclination [2] = Angle of incidence [1] + Roof
slope [3]
6720816962-29.1ST
Fig. 20 Maximum of 14 collectors per individual field (connected in 1
parallel) 45°
[1] Control valve for hydraulic balancing (separate for each 2 45°
30°
field) and shut-off valve for pressure filling 30°
15° 15°
5.3 Collector angle of incidence
3 6720816963-07.1ST
The collectors’ angle of incidence depends on the relevant
application and on the roof pitch. The angle of inclination Fig. 22 Angle of incidence on pitched roofs
of the collector support is subject to the application, roof [1] Collector angle of incidence (absolute angle to the horizon-
tal plane); [2] Angle of inclination of the collector support; [3]
pitch and angle of incidence.
Roof slope (maximum 25 °)
5.4 Space required on roof
5.4.1 Determining the clearance between rows of collec-
tors
The minimum clearance X between the collector rows results
from the collector angle of incidence.
Angle of Angle of
Clearance X Clearance X
incidence incidence
6720816963-06.1ST
30° 4,88 m 50° 6,26 m
Fig. 21 Collector angle of incidence
35° 5,26 m 55° 6,34 m
) Angle of incidence
40° 5,59 m 60° 6,50 m
5.3.1 Determining the range of incidence
45° 5,88 m
The different areas of application of solar thermal systems
provide various angles of incidence that ensure an optimum
Tab. 8 Clearance between the rows of collectors at minimum solar
solar yield depending on season.
altitude of 17 °
Application Range of incidence >> Obtain clearance X from the Tab. 8, or use a formula
Domestic Hot Water 30-45° from Fig. 23, page 13.
DHW + central heating 45-60° >> For arrays comprising several rows, maintain clearance X
DHW + swimming pool 30-45° to prevent shading from occurring (see Fig. 23, Sei-
DHW + central heating + swim- te 13).
45-60°
ming pool
Tab. 7 Angle of incidence
>> Determining the range of incidence according to appli-
cation.
12Before installation
l>b
sin
tan + cos
L
6720816963-33.1ST
6720816963-18.1ST
Fig. 25 Clearances to be maintained to the building edge (a); the
Fig. 23 Prevent shading, flat roof installation lesser value may be used
) Angle of incidence
β) Minimum solar altitude
X) Clearance between collector rows
5.4.2 Determining the space required C
DANGER: Risk of death from coll-
ectors that cannot withstand high
winds!
B
>> Maintain the minimum clearance to the edge A 6720816963.28-1.ST
of the roof and roof structures.
Fig. 26 Collector array dimensions
The clearances to be maintained (see Fig. 24 und Fig. 25) Number of Number of
to the edge of the roof (a) and to roof structures (b) can be Dim. A Dim. A
collectors collectors
found in DIN EN 1991-1-4 and Code of Practice 61 of the
1 0,73 m 8 5,13 m
BDH (Federal Association of the German Heating Industry).
2 1,36 m 9 5,76 m
d1 ื 3xh d1 < 3 x h
a = 0,15 x d1 a = 0,45 x h b = 0,5 x l12 + l22 3 1,99 m 10 6,39 m
a ื1m a ื 0,04 x d1 b = hA
a ื1m 4 2,62 m 11 7,02 m
5 3,25 m 12 7,65 m
l2 l1 hA 6 3,87 m 13 8,28 m
b 7 4,50 m 14 8,91 m
Tab. 9 Space requirement
Angle of inclination Dim. B Dim. C
d2
d1 30° 0,73 m 1,16 m
d1 < d2
6720816963-23.1ST
35° 1,36 m 1,30 m
Fig. 24 Clearances to be maintained to the roof edge (a) and roof
structures (b); in the case of (b), the smallest value should be 40° 1,99 m 1,44 m
used
45° 2,62 m 1,56 m
50° 3,25 m 1,67 m
55° 3,87 m 1,77 m
60° 4,50 m 1,83 m
Tab. 10 Dim. B and C
13Before installation
in the upper rail.
5.5 Lightning protection
>> Check regional regulations as to whether a lightning 30° 1
protection system is required.
35°
Lightning protection is frequently required for buildings
higher than 20 m, for example. 40°
>> Have a qualified electrician install the lightning protec- 45°
tion.
50°
>> If a lightning protection system is installed, check whether
the thermal solar system is included in this system. 55°
60°
5.6 Required tools and materials 6720647803-09.1T
Fig. 27 Fitting telescopic rails
• 27 and 30 mm open-ended spanner for connecting the
pipework
6.1.2 Fitting telescopic rails
• Material for pipe insulation
>> Push telescopic rails together. [1.]
• Screwdriver with Torx bit T15
>> Secure telescopic rails with M8 × 20 screw in the selected
holes. [2.]
5.7 Installation sequence
To fasten the collectors to the roof with the collectors sup- 1. 2.
ports, install in the following order:
1. Determine the collector angle of incidence.
2. Determine the space requirement for the collector array.
3. Fit telescopic rails.
4. Fit collector supports.
5. Install the profile rails.
6. Install the collectors and prepare the collector tempera-
ture sensor.
7. Connect the pipework to the collectors.
6720647803-12.1T
8. Install the intermediate panel. Fig. 28 Installing the telescoping rail
6 Fitting the collector supports 6.2 Collector support clearances
DANGER: Risk to life by falling from
roof!
>> Whilst working on the roof, take all necessary
precautions against a possible fall.
>> If there are no general anti-fall safety devices
available, wear personal protective equip-
ment.
6.1 Fitting telescopic rails
>> From the determined angle of incidence (see chapter 5.3,
page 12), determine the angle of inclination of the 980
6720816963.12-1.ST
collector support. Fig. 29 Basic version for 2 collectors, details in mm
6.1.1 Selecting mounting holes
>> Select holes in accordance with the determined angle of
inclination (see chapter 5.3, page 12) of the collector.
>> Select hole [1] in the lower rail and a corresponding hole
14Before installation
6.3 Fitting the collector supports on a flat roof
The following details refer to a single collector. The infor-
mation is based on DIN EN 1991, Part 4 „Load assump-
tions for structural components“ and Code of Practice 61
of the BDH (Federal Association of the German Heating
Industry)
The installation may take 3 different forms:
• Base anchor (on-site fixing)
• Ballast troughs (with concrete slabs, gravel and similar)
980
6720816963.11-1.ST
• Securing with ropes plus ballast troughs
Fig. 30 Standard version for 3 collectors, dimensions in mm NOTICE: Damage to the roof from
incorrect form of stabilisation!
>> Consider the roof statics when selecting the
form of stabilisation.
NOTICE: Damage to the roof and the
collectors through inadequate fixing
on pitched roofs!
>> On pitched roofs, provide adequate fixings
for the collector supports on site.
NOTICE: Roof leaks through punctu-
980 268 980 ring the roof membrane!
6720816963.10-1.ST
>> To protect the roof membrane, put down
Fig. 31 Standard version for 2 collectors and expansion for 2 collec-
conventional protective mats.
tors, dimensions in mm
>> Put down profiles, collector supports and
additional installation materials only on pro-
tective mats.
When using ballast troughs with gravel, a
ballast weight of up to 80 kg per ballast trough
is feasible.
980 589 980
6720816963.09-1.ST
Fig. 32 Standard version for 2 collectors and expansion for 3 collec-
tors, dimensions in mm
980 899 980
6720816963.37-1.ST
Fig. 33 Standard version for 3 collectors and expansion for 3 collec-
tors, dimensions in mm
15Before installation
Ballast without additional
Base anchor Ballast secured with ropes [kg]
securing [kg]
Speed pressu-
Wind speed Number and type Weight3) in ballast trough with Weight3) in ballast trough with Rope tensi-
re q1)
of screws2) an angle of incidence of a an angle of incidence of a on force
30° 45° 60° 30° 45° 60°
0,50 kN/m2 102 km/h 2x M8/8.8 130 150 161 82 90 101 2 kN
0,60 kN/m2 111 km/h 2x M8/8.8 162 188 200 110 119 129 2 kN
0,70 kN/m2 120 km/h 2x M8/8.8 180 228 243 139 149 160 2 kN
0,80 kN/m2 129 km/h 2x M8/8.8 231 266 282 168 178 187 3 kN
Tab. 11 Values for stabilizing a collector, weight in kg
1) The velocity pressure is determined by the regional wind zone, territorial category and building height (see technical guide or consult a structural
engineer) 2) Per collector brace 3) Weight without intermediate reflector (with intermediate reflector: Weight plus 18 %)
6.3.1 Base anchor
The following describes by way of example how to secure >> Between two collector supports, hook 4 ballast troughs
the installation onto the double T-beams. [2] onto the bottom profile [1] and into each other [3].
>> Ensure that the substructure is set up (on site) so that the >> Place ballast (concrete slabs, gravel or similar) into the
collectors can withstand the snow loads and wind forces ballast troughs (weight: see Tab. 11, page 16).
affecting them.
>> Ensure that the solar system is stabilized by its attach-
ment, and that the roof is not damaged.
NOTICE: Damage to the thermal solar
system through structural modifica-
tions on the collector supports.
>> Never drill through the collector support profi-
les or make structural changes.
>> Position the collector supports in accordance with the
determined spacing (see chapter 6.2, page 14).
>> Transfer the hole dimensions from the lower profile [2] to 6720816963.13-1.ST
the double T-beams and pre-drill the necessary holes. Fig. 35 Collector supports with ballast troughs
>> Secure the profile to the double T-beams [3] using screws
6.3.3 Securing with ropes
(see Tab. 11, page 16), nuts and washers [1].
Secure with ropes corresponding to Tab. 11, page 16.
>> Use a wire rope [1] on site to fasten each collector sup-
port at the back to the screw from the lower profile.
>> Insert ballast troughs (see chapter 6.3.2, page 16).
>> Anchor the wire ropes at a suitable point on the roof.
6
112
6720816963-34.1ST
Fig. 34 Collector supports on double T-beams, dimension in mm
6.3.2 Ballast troughs
>> Position the collector supports in accordance with the
6720816963.14-1.ST
determined spacing (see chapter 6.2, page 14).
Fig. 36 Collector supports secured with ropes
16Façade installation
7 Façade installation
Installation on a façade is only permissible if the following
apply:
• Snow load: max. 5.0 kN/m2
1664 mm ±1
• Wind speed: max. 129 km/h
DANGER: Risk to life by falling from
roof!
>> Whilst working on the roof, take all necessary
precautions against a possible fall.
>> If there are no general anti-fall safety devices
available, wear personal protective equip- 6720816963-08.1ST
ment.
DANGER: Risk to life through falling
1
1137-1557 mm
collectors in case of unsuitable
façade!
3
>> Install profile rails supports only on a solid 8 7 6 5 4 2
façade that is impervious to wind.
Fig. 37 Installing the profile rails using double ended screws set
>> Prior to installation, check the load-bearing [1] horizontal profile rails; [2] vertical profile rails
capacity of the wall where the collectors are
to be installed and its foundations. If required, Accessories
consult a structural engineer. [3] screw M8 × 20 (2 screws for 1 retaining block); [4] re-
taining block; [5] nut M12; [6] washer; [7] sealing washer if
Spacing of double ended screws: see chapter 6.2, required; [8] double ended screws M12
page 14.
On-site attachment
Conncect and align profile rails: see chapter 9, page 19.
>> Note the indicated forces per collector!
Slots for double ended screws: see Fig. 42, page 19 >> Secure the profile rails on site.
The mounting of the profile rails horizontally can be done
with the double ended screws set or engineered on site. FGd = 0,54 kN
Securing with the double ended screw set
>> For the double ended screws M12 [8], use suitable
1664 mm ±1
anchors (on site).
>> Fasten each vertical profile rail [1] with 2 double ended FWo = 2,60 kN
screws M12 [8] side by side onto the façade.
>> Fasten the vertical profile rail [1] at the top and at the
bottom to the retaining block with 2 screws M8 × 20 [3].
6720816963-39.1ST
Fig. 38 Mounting the profile rails to the façade on site
Continue with chapter „9.3 Aligning the profile rails“ on
page 19.
17Horizontal installation
8 Horizontal installation 1 2
DANGER: Risk to life by falling from
> 10 mm
roof!
>> Whilst working on the roof, take all necessary
precautions against a possible fall.
>> If there are no general anti-fall safety devices
>100 mm
available, wear personal protective equip-
ment.
6720816963-29.1ST
NOTICE: Roof leaks through punctu-
ring the roof membrane! 1664 mm ±1
>> To protect the roof membrane, put down Fig. 39 Example: On-site installation on double-T beams
conventional protective mats. >> Use suitable anchors for the double ended screws and the
>> Only put down installation materials on pro- roof type.
tective mats.
3
>> Have a roofer make sure that the roof is
sealed. 1
NOTICE: Damage to the roof from
±1
incorrect form of stabilisation!
2
mm
>> Consider the roof statics when selecting the
64
4
16
form of stabilisation.
5
6
The collector type TUBO II T is suitable for horizontal instal- 7
>100 mm
57
lation. The substructure can be installed on site, that is, on
-15
8
37
double-T beams, or with the double ended screw installati-
11
on set. 6720816963-38.1ST
>> Make sure that each collector is weighted with at least Fig. 40 Installing the profile rails using double ended screws
49 kg.
[1] Horizontal profile rail; [2] Vertical profile rail
>> Make sure that the anti-slip protector [2] can be installed
on the profile rails [1]. If required, adjust the height.
Accessories
[3] Screw M8 × 20 (2 screws for 1 retaining block); [4] Re-
Note the positions of the anti-slip protectors see Fig. 44, taining block; [5] M12 nut; [6] Washer; [7] Sealing washer if
page 19! required; [8] M12 double ended screw
Connect and the line the profile rails: see chapter 9, Continue with chapter „9.3 Aligning the profile rails“ on
page 19. page 19.
Distances of double ended screws: see chapter 6.2,
page 14.
18Fitting the profile rails
9 Fitting the profile rails 9.3 Aligning the profile rails
It is important for the subsequent collector
9.1 Connecting profile rails installation that the profile rails are accurately
aligned.
If there are more than 3 collectors, you need to connect the
profile rails.
>> Level the profile rails horizontally and with the stated
>> Push the profile rails as far as they will go into the plug-in clearance. Use a spirit level.
connector. >> Align sides of the upper and lower profile rails with each
>> To lock, tighten both fitted threaded pins in the plug-in other.
connector using a 5 mm Allen key. >> Check that they are at right angles. Measure the diago-
nals or place a roof batten, for example, at the ends of
the profile rails.
>> Tighten screws M8.
6720816962-19.1ST
Fig. 41 Connecting profile rails
6720816963.16-1.ST
Fig. 43 Align the profile rails and collector supports
9.2 Installing the profile rails
Only use the slots marked with the arrows to install the 9.4 Fitting the anti-slip protectors
profile rails. Only use the slots marked with the arrows to fit the anti-slip
>> Secure the profile rails with screws M8 × 20 to the coll- protectors.
ector supports. Do not yet tighten the screws so that the >> Push the collector clamp into the profile rail and let it click
profile rails can be aligned. into the slot.
6720816963.15-1.ST
Fig. 42 Installing profile rails for 2 or 3 collectors click!
Fig. 44 Fitting the anti-slip protectors
6720816963-19.1ST
19Installing the collectors
>> Push the collector clamp into the profile rail and let it click
10 Installing the collectors into the slot.
click
DANGER: Risk to life by falling from
roof!
>> The installation on the roof must be performed
by at least 2 people.
WARNING: Risk of injury through
glass splinters.
>> When handling collectors, always wear safety
gloves and goggles.
WARNING: Risk of injury through
falling collectors!
>> Secure the collectors against falling during click
6720816963.20-1.ST
handling and installation.
Fig. 45 Fitting the collector clamp
>> After completing installation, check that the
installation set and collectors are securely 10.1.2 Placing the first collector on the profile rails
positioned.
WARNING: Risk of injury through
NOTICE: Lack of seal from damaged falling collectors.
O-rings! >> Ensure that the collector profile engages in the
>> Do not use mineral oil-containing lubricants antislip protectors.
(such as thread sealing compound). The
collector connections are sufficiently lubricated >> Remove the top and bottom packaging cover.
at the plant. >> Remove the interconnection set.
10.1 Collector installation
The plastic parts on the collector tensioners do
not have any support function. They are simply
intended to make installation easier.
>> Observe the information in chapter 5.2, page 10
concerning the collector layout.
10.1.1 Fit one-sided collector clamps on the left
Fit the single sided collector clamp on the 6720816962-45.1ST
opposite side only after the final collector has Fig. 46 Remove the packaging cover
been installed.
20Installing the collectors
>> Place the collector onto the profile rails and allow it to >> Remove the transport packaging on the rear.
slide into the anti-slip protectors.
6720816963-32.1ST
Fig. 49 Remove the transport packaging
10.1.3 Inserting a double sided collector clam
6720816963.17-1.ST >> Place the collector clamp on the profile rail and push up
Fig. 47 Let the collector slide into the anti-slip protectors to the collector.
NOTICE: Glass breakage from twisted
clamp.
To prevent the clamp from twisting:
>> Hold/brace the clamp when screwing in.
>> Carefully push the collector to the left against the collector
clamp and level horizontally. [1.]
>> Counterhold the clamp! [2.]
>> Tighten the screw of the collector clamp with a 5 mm
Allen key. [3.]
The clamp must engage in the recesses of the collector
profile. When the screw is tightened, the plastic guide
breaks at the predetermined cut-off points.
6720816963.22-1.ST
3. Fig. 50 Place the collector clamp
10.1.4 Fitting the second collector
1. If supply connection is on the left side of the
collector field, the collector temperature sensor
must be prepared before the second collector
is installed (see Fig. 55, page 23).
1.
2.
6720816963.21-1.ST
Fig. 48 Fasten the first collector
6720816962-49.1ST
Fig. 51 If the flow is from the left, first prepare the temperature
sensor (see Fig. 55, page 23)
>> Place the second collector onto the profile rails and allow
21Installing the collectors
it to slide into the anti-slip protectors.
10.1.5 Fitting single sided collector clamps on the right
>> Remove the interconnection set from the transport protec- hand side
tion.
>> Push the collector clamp into the profile rail and let it click
>> Remove caps from the collector connections.
into the slot. [1.]
>> Insert the hydraulic plug-in connector into the collector.
>> Counterhold the clamp. [2.]
[1.]
>> Tighten the screw of the collector clamp with a 5 mm
>> Push the second collector as far as it goes to the first
Allen key. [3.]
collector. [2.]
The clamp must engage in the recesses of the collector
>> Push the clips over both plug-in connectors. [3.] profile. When the screw is tightened, the plastic guide
breaks at the pre-determined cut-off points.
3.
1.
3.
2.
1. 3.
1. 2.
6720816963-25.1ST
Fig. 54 Fitting the collector clamp
6720816962-23.1ST
10.2 Prepare the collector temperature sensor
Fig. 52 Connect the first and second collector to each other A temperature sensor is installed in each collector and is
>> Tighten the screw of the double-sided collector clamp with
accessible on the right side of the collector.
a 5 mm Allen key. >> In regard to using the right collector temperature sensor,
The clamp must engage in the recesses of the collector note the instructions in chapter 5.2, page 10.
profile. NOTICE: System failure through faulty
sensor lead!
>> Protect the sensor lead against possible dama-
ge, e.g. from rodents.
>> Removing the cover.
>> Carefully pull the sensor cable out a maximum of 1 m up
to the red mark.
6720816962-24.1ST
Fig. 53 Fastening the double sided collector clamp
CAUTION: Risk of injury and leaks
through escaping solar heat transfer
medium as a result of unsecured plu-
gin connectors.
>> Secure hydraulic collector connection with
clips.
>> Fit all other collectors in the same way.
22Hydraulic connection
11 Hydraulic connection
NOTICE: Collector damage through
leaks!
Connecting rigid pipework to the collector may
1m lead to leaks due to thermal expansion.
>> Install the piping allowing for adjustment
(on-site).
Connecting the pipework
NOTICE: Collector damage through
1 twisted pipes!
>> When tightening the screw fittings, hold the
6720816962-36.1ST
angle with a 24 mm open-ended spanner.
Fig. 55 Carefully pull out the collector temperature sensor
>> Remove transport protection (red, blue) from the collector
1) Feed, left side: Pull out the collector sensor cable up to the
red mark, and guide it through the opening (only install connections.
the second collector after this is done) >> Push the plug-in connectors and pipe bend into the coll-
ector connections. [1.]
>> Secure pipe bend with a clip. [2.]
>> Push pipe into the 18 mm compression fitting and tighten
the union. [3.]
2.
1.
3.
6720816963.24-1.ST
Fig. 56 Connect pipe work (in this case, same-side connection)
[1] Flow to storage tank (hot, red transport protection); [2] Re-
turn from the storage tank (cold, blue transport protection)
23Final steps
Install the caps
WARNING: Risk of injury from unse- 12 Final steps
cured caps!
>> Make sure that each cap is secured with a
12.1 Flushing, venting and leak testing
clip.
>> Flush the system with Tyfocor LS.
>> Remove transport protection (red, blue) from the collector >> Check all connections for leaks.
connections. >> High system pressure increases reliability. 2.5-4 bar are
>> Push caps with O-rings onto the collector connection. [1.] recommended: This results in about 2-3 bar on the roof
>> To secure the connection, push clips over the caps and and thus an evaporation temperature of over 120 °C (at
collector connections. [2.] 2 bar). (Form CON-SOLARSTATION: 2.5 bar).
Make sure that the clips are properly seated. Commission the solar thermal system in
accordance with the details in the solar pump
station installation and maintenance instructions.
2.
12.2 Checking the installation
Checks
Profile rails connected to collector supports and
1.
screws tightened?
1. 2. Anti-slip protectors fitted?
3. Collector clamps fitted and screws tightened?
Are the pipe bends secured with clips, and has
4.
the correct seat of the clips been checked?
6720816963-27.1ST
Are the free collector connections sealed with
Fig. 57 Install the caps (in this case, same-side connection) 5.
caps and secured with clips?
6. Correct collector temperature sensor selected?
Tightness test carried out and all connections
7. checked for leaks (see solar pump station
instructions)?
Tab. 12 Checks
12.3 Install intermediate reflector (accessories)
Scope of delivery: 1 × Intermediate reflector, 2 × Clip
>> To make the protective film of the intermediate reflector
easier to remove after installation, the protective film can
be removed slightly at one place.
>> Place the intermediate reflector between the collectors.
24Final steps
T15 click
1. 2.
3.
6720816963-26.1ST
Fig. 58 Inserting the intermediate reflector 6720816963.31-1.ST
>> Carefully press in the intermediate reflector from top to Fig. 60 Installing the intermediate panel and end cap
bottom. (1.-6.)
>> Use a clip to secure the intermediate reflector at the top
12.5 Insulating the connection lines and pipework
and bottom. (7.)
>> Thermally insulate the pipework in the entire solar circuit
7. click
in accordance with regulations.
>> Thermally insulate the external pipework using material
1.
2. which is resistant to UV rays, weather influences and high
3. temperatures (150 °C).
4. >> Insulate internal pipework with high temperature-resistant
5. (150 °C) material.
6. >> Protect the insulation against damage from birds if
7. required.
click
6720816963-36.1ST 12.6 Removing the collector film
Fig. 59 Installing the intermediate reflector between the collectors In order for the film to be removed residue-free, do not
leave the film on the collector for more than 4 weeks after
installation.
12.4 Installing the end cap and intermediate panel
If the system cannot be commissioned after 4
Only install the intermediate panel and end cap after the
weeks:
hydrostatic test has been performed.
>> Cover the collectors at the installation site.
>> Insert the intermediate panel from below into the collector
profile. [1.] >> Remove the film after commissioning the solar system.
>> Press it forward until it audibly locks into place. [2.]
>> Fix the end cap with a Torx T15. [3.]
6720816963.30-1.ST
Fig. 61 Removing the collector film
25Cleaning the collectors
13 Cleaning the collectors Disposing of collectors
At the end of their service life, collectors may be returned to
the manufacturer. Materials will be recycled using the most
DANGER: Risk to life through falling!
environmentally responsible processes.
>> Whilst working on the roof, take all necessary
precautions against a possible fall.
>> If there are no general anti-fall safety devices
15 Maintenance/inspection
available, wear personal protective equip-
DANGER: Risk to life through falling!
ment.
>> Whilst working on the roof, take all necessary
At a roof inclination of 15 ° and steeper, the collector is precautions against a possible fall.
generally self-cleaning. >> If there are no general anti-fall safety devices
>> In the case of more stubborn contamination, clean the available, wear personal protective equip-
collector with water. Do not use a high-pressure cleaner! ment.
>> Make sure that the drain holes in the collector profile are The installation and maintenance instructions of
open and that water can drain out. the solar pump station include details regar-
ding the maintenance of the entire system. Also
observe these details.
Use the table as a copy template so that you will have
documentation available even after the third service.
>> After approximately 500 hours of operation, check
(inspect) the collector array for the first time. Then check
them every 1-2 years. Immediately remedy all faults
6720816962.48-1.ST
(maintenance).
Fig. 62 The drain holes in the collector profile must be open
>> Fill out the report and tick off the tasks performed.
14 Environmental protection and
disposal User:
System location.:
Environmental protection is one of our principal policies.
Quality of products, efficiency and environmental protec-
tion are equally important objectives for us. Statutory and
other regulations concerning environmental protection are
strictly applied. To protect the environment, we use the best
possible technology and materials, subject to economic
considerations.
Removing collectors
DANGER: Risk to life through falling!
>> Whilst working on the roof, take all necessary
precautions against a possible fall.
>> If there are no general anti-fall safety devices
available, wear personal protective equip-
ment.
>> Drain the pipework.
>> Undo the collector clamps on the side and in between
collectors.
>> Remove the plug-in connectors and connection pipes.
>> Use lifting gear to transport the collectors (see chapter 4,
page 9).
26Cleaning the collectors
Maintenance and inspection tasks Page Maintenance/inspection
Date:
Visual inspection of collectors carried out (safe
1.
seating, visual impression)?
2. Correct collector temperature sensor selected. 22
Visual inspection of the installation system
3.
carried out?
Visual inspection for leaks carried out at the
4.
joints between the installation and the roof?
Visual inspection of pipework insulation
5. 24
carried out?
Visually inspect the glass tubes. Cleaning in
6. 26
the case of severe contamination.
Visually inspect the drain holes in the collector
7. 26
profile. Clean if water cannot drain.
Remarks:
The collector array has been serviced as
specified by these instructions.
Date, stamp, Date, stamp, Date, stamp,
signature signature signature
Tab. 13 Maintenance and inspection tasks
Replacing the collector temperature sensor
Since a temperature sensor is in each collector, you can
use the temperature sensor of the adjacent collector while
servicing (see chapter 10.2, page 22)
27Consolar Solare Energiesysteme GmbH Kasseler Straße 1a, 60486 Frankfurt Gewerbestraße 7, 79539 Lörrach Fon +49 (0)7621 42228-500 Fax +49 (0)7621-42228-31 info@consolar.de • www.consolar.com Subject to alterations and errors.
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