SL-I-O Rev B.inddSL-I-O Rev B
This manual must only be used by a qualified heating installer/service technician. Read all instructions before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
WARNING:
2
Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parallel Basic and Expansion Sets . . . . . . . . . . . . . . . . . . 3 How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 2. LOCATION Array Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Handling and Storing . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Transportation Device . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3. ROOF ATTACHMENT INSTALLATION Roof Attachment Types . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Roof Attachment Quantities for SLV/SLH . . . . . . . . . . . . 11 Roof Attachment Spacing - SLV . . . . . . . . . . . . . . . . . . . 12 Roof Attachment Spacing - SLH . . . . . . . . . . . . . . . . . . . .13 Installation of Roof Attachment Types . . . . . . . . . . . . 14-30 4. COLLECTOR INSTALLATION SLV Parallel Mounting Instructions . . . . . . . . . . . . . . 31-33 SLV Inclined Mounting Instructions . . . . . . . . . . . . . . 34-37 SLV Non-South Facing Mounting Instructions . . . . . . 38-41 SLH Parallel Mounting Instructions . . . . . . . . . . . . . . 42-43 SLH Inclined Mounting Instructions . . . . . . . . . . . . . . 44-45 SLH Non-South Facing Mounting Instructions . . . . . . 46-48 SLV/SLH A-Frame Dimensions . . . . . . . . . . . . . . . . . . . . 49
5. HYDRAULIC CONNECTIONS SLV/SLH Connections Kits . . . . . . . . . . . . . . . . . . . . . . . 50 Hydraulic Expansion Kits . . . . . . . . . . . . . . . . . . . . . . . . . 50 Pressure Drop Charts . . . . . . . . . . . . . . . . . . . . . . . . 51-53 6. SYSTEM START-UP Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Final Checks Before Starting the System . . . . . . . . . . . . 54 Filling, Flushing, and Bleeding . . . . . . . . . . . . . . . . . . . . . 55 Clamp Ring Screw Connections . . . . . . . . . . . . . . . . . . . 56 Flat Seal Screw Connections . . . . . . . . . . . . . . . . . . . . . . 56 Operation, Multi-function Ball Valve & Check Valve . . . . 56 7. MAINTENANCE Fluid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fluid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 System Design Considerations . . . . . . . . . . . . . . . . . . . . 57 Freezing and Boiling Points of Aqueous Solutions . . . . . 58 Solar Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pump / Control Function . . . . . . . . . . . . . . . . . . . . . . . . . 58 Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Contents
1 Introduction SLV collectors are designed for vertical mounting while SLH collectors are designed for horizontal mounting. Suitable mounting systems are available for various types of roofing. Thanks to its low weight and optimum dimensions, the collector may be installed in no time at all. The internal piping is easy to install and the collectors can quickly be connected in a few simple actions.
Area of use: On roof mounting, parallel and inclined, on tiles, plain tiles, slate, Spanish tiles, tin roofing, flat roofs, and as a freestanding unit
Technical data
SLV/SLH Collectors Type Vertical Horizontal Gross area 27.45 ft2 27.45 ft2
Aperture surface area 25.40 ft2 25.40 ft2
Absorber surface area 25.51 ft2 25.51 ft2
External Dimensions (L x W)1 7'-1" x 3'-10" 3'-10" x 7'-1" Weight Ratings 102 lbs. 102 lbs. Heat transport medium capacity approximately 0.55 gal. 0.55 gal.
SLV/SLH Collectors Installation & Operation Manual
3
Substructure SLV SLH
4
6. Inlet connections Copper pipes, 18 mm x 0.8 mm.
7. Outlet connections Copper pipes, 18 mm x 0.8 mm.
8. Absorber coils 8 mm copper, serpentine arrangement.
9. Hydraulic connection kit Connection set with stainless steel corrugated pipe. For connecting the collector supply and return flow to the riser. The corrugated pipes are included with substructure kits in lengths of 3'-3" or 9'-9" depending on the chosen inclination.
10. Sensor well For measuring the collector outlet temperature directly in the fluid. The sensor well has to be installed on the outlet connection as shown on the collector label. The sensor must be inserted up to the end of the sensor well.
11. Plug This plug is used on the end collector of each array to complete the water flow path.
How it works... 1. Housing Powder coated (RAL7016) aluminum frame structure with rear aluminum wall.
2. Cover Prismatic solar safety glass, .15" thick, for maximum light transmission. 3. Insulation 1.57" mineral wool emission free, non-flammable.
4. Absorber Full surface absorber, laser welded with highly-selective PVD coating (PVD = Physical Vapor Deposition), serpentine flow. 5. Collector seal Aluminum profile system with double temperature and UV- resistant silicone seals, emission free.
1 Introduction
NOTICE SLV collector shown for illustration purposes only.
5
1 Introduction (continued)
Have your collector(s) serviced/inspected by a qualified service technician, at least annually.
Failure to comply with the above could result in severe personal injury, death or substantial property damage.
When calling or writing about the collector – Please have the collector model and serial number.
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Factory warranty (shipped with the collector) does not apply to collectors improperly installed or improperly operated.
WARNING
NOTICE
Before getting started on your installation be sure to carefully read the preparation instructions in this section.
• You must comply with local regulations, laws and standards of the local governing authority.
• The collector frame must be capable of withstanding the local snow and wind loads and permit the correct anchoring of the collectors in accordance with all applicable local regulations.
• The load bearing capacity of the roofing and the frame shall be specially checked or analyzed by a structural engineer.
• The number of mounting brackets specified by the Lochinvar/TiSun manuals and parts sheets is based on an average collector load bearing per square foot. The maximum permissible collector loading per square foot may be calculated from the number of mounting brackets, taking into consideration the permissible loading on the mounting brackets. If a higher collector wind and snow loading (including snow sliding off the roof) per square foot is required, additional mounting brackets will have to be used. Roof pitches in excess of 30° also represent increased loading; additional mounting brackets must also be used for this variant.
• The mounting substructure must be capable of withstanding the local snow and wind loads and permit correct anchoring of the collectors.
• To avoid damage to the collectors and mounting frames from snow sliding off the roof, additional snow guards must be placed in sufficient numbers around the collectors and above the collectors. • The collectors must be linked with a lightning arrester system and/or the building’s ground system by a licensed electrician. • Hydraulic connection of the collectors must be performed according to Lochinvar/TiSun specifications. • The collector connections must not be damaged, soiled or misaligned. Take care during transport, installation, and connection of the modules. Do not remove the header protection caps at the top and bottom connections of the collector until just before installation. • When connecting the modules to the riser, the Hydraulic Connection Kit (corrugated pipe) supplied must be installed. Otherwise, the warranty is invalidated. • Always connect the collector outlet and inlet flow to each other diagonally, please follow the connection examples (see FIG.’s 1-2 and 1-3 on page 6). • Insert the brass support sleeve in the copper pipe before fixing the clamping ring threaded connection. • Do not twist the headers when screwing the connections together. Hold threaded connection in the desired position and tighten clamping ring union nut to torque. • Roof penetrations for solar piping must be adequately sealed against water ingress. • Use only the original sensor well supplied. • Use only high temperature and glycol pipe sealing materials.
CAUTION
CAUTION
6
WARNING Only authorized solar companies familiar with our products may handle them.
WARNING There is a risk of injury when handling collectors and mounting accessories as these have sharp edges.
Dismantling and Disposal • The units are dismantled in the reverse sequence of installation.
• The roofing shall be properly sealed after the mounting brackets have been removed.
• Materials shall be disposed of in an environmentally conscious manner.
WARNING The collector becomes very hot in the sunlight. There is a burn risk.
WARNING Comply with all safety regulations and applicable OSHA requirements.
WARNING Check the load bearing capacity and stability of the substructure onto which the collector is to be installed and will need to be accessed during the installation process.
• Check the materials for any damage sustained in transport and describe any damage in writing on the packing slip where necessary. This is important for processing any needed freight or delivery damage claims.
• Carefully read through the relevant installation instructions before starting the installation and follow each step.
• Use only the original mounting components.
• Stainless steel screws may not be used again once they have been removed (because of the possibility of breaking).
• Any conversion or modification of the Lochinvar/TiSun product not expressly approved in writing by the manufacturer shall void the warranty.
• No liability can be accepted for damage resulting from failure to observe the installation instructions.
NOTICE
1 Introduction
WARNING A properly sized expansion tank must be used to avoid damage to the Solar Thermal System.
Be sure to install the sensor well in the side of the collector marked with the sensor sticker (see FIG. 1-1).
NOTICE
Figure 1-1 Sensor Sticker
If copper pipe is being used, all joints MUST BE brazed, no soldering allowed.
WARNING
7
Array options The diagrams must be selected taking the overall system into account (type, dimensions and length of the connecting lines, solar pump station, heat exchanger, etc.,). In the event of further connection, the pressure drop must be calculated and the pump output tested separately (FIG.’s 2-1 and 2-2).
Legend: A = Inlet B = Sensor C = Outlet D = Plug E = Balancing Valve
Figure 2-1 SLH Array Options
Figure 2-2 SLV Array Options
2 Location
8
2 Location Installation positions
Figure 2-3 SLV Parallel Installations Figure 2-4 SLV Inclined Installations
Figure 2-5 SLV Non-South Facing Installations Figure 2-6 SLH Parallel Installations
Figure 2-7 SLH Inclined Installations Figure 2-8 SLH Non-South Facing Installations
9
2 Location (continued) Handling and storing
Figure 2-9 Transportation Connection Points and Positioning
What to avoid • Collectors are to be located such that eventual sliding of snow and ice does not endanger any person. • The collectors have a large surface exposed to wind. Therefore, be aware of possible wind hazards when using a crane for installation (the collector may flip over quickly). In this case immediately stop the crane operation and protect the collector against swinging (hazard of collector breakage).
CAUTION
NOTICE • See FIG. 2-9 for crane transportation connection points and positioning.Transportation device
• The SL transportation device is only suitable for Lochinvar/TiSun SLV and SLH collectors. • Note clamp positions for manual and crane installation • Examine transportation device and clamp for correct seating and good grip before lifting the collectors. Tightening torque for star knob is 11 ft./lbs. • Collector installation by two (2) persons requires four (4) transportation devices (2 sets) • Collector installation by crane requires two (2) transportation devices (1 set) • General local installation and safety regulations and laws apply for installation by person or cranes.
SLV
SLH
SLV/SLH
11 ft./lbs.
11 ft./lbs.
• Only loosen the crane connection when the collectors are completely secured to the substructure. • Pay special attention to roof work near an electric grid. If need be, the installer must take security precautions such as isolation or covering of electrical devices. • Inspect the roof surface in the area of the installation for cracks, water leakage, and roofing material quality and uniformity. This is especially important if the roof is more than 10 years old. • Inspect the roof for sags and other abnormalities. A sag or deep depression in the roof may indicate a structural weakness in the support system that may require correction. • Check that all rafters, trusses and other materials are in suitable condition.
• Installation of LOCHINVAR/TiSun SLV/SLH collectors are only allowed for qualified installer. • Local instructions, laws and standards are to be followed. • Collectors are to be located so falling snow and ice will not endanger any person or property. • Use personal protection equipment (helmet, belt, security shoes) when on the roof. • Secure tools and materials against fall. • It is forbidden to stand or walk under a hanging load. • Danger area has to be restricted. • Avoid rotating movements of the load through wind. Secure load before lifting. • Use ladders properly and check stability.
WARNING
CAUTION
10
SLV/SLH Collectors Installation & Operation Manual
3 Roof Attachment Installation Roof attachment types Table 3A Roof Attachments - Parts
SOLAR ROOF MOUNTS Installation Type
See Page DescriptionParallel Inclined Free-
standing
Stainless steel attachment for universal heavy duty installations, on parallel and inclined roofs and freestanding installations on sufficiently anchored bases.
SRM20002 BOLT, SINGLE
HANGER LT COM
X X X 14 Stainless steel attachment for universal installations on parallel and inclined roofs, and freestanding installations on sufficiently anchored bases.
SRM20003 ANCHOR,
RAFTER, STD ROOF TILE
X X - 17 Stainless steel attachment for parallel and inclined installations on various types of tiled roofs. Standard installations for tile heights of up to 1.5". Package is complete with fasteners and spacers.
SRM20004 ANCHOR,
RAFTER, TALL ROOF TILE
X X - 17 Stainless steel attachment for parallel and inclined installations on various types of tiled roofs. Standard installations for tile heights of up to 2". Package is complete with fasteners and spacers.
SRM20005 HOOK, FLAT TILE X - - 19
Stainless steel attachment for parallel installations on plain tile, slate, and flat cement tiled roofs with pitches in excess of 30 degrees.
SRM20006 CLAMP, JOINT X X - 21 Stainless steel attachment for parallel and inclined installations on jointed tin, galvanized, or copper roofs. Additional securing cables (Lochinvar Part # SRM20012) are required for inclined installations.
SRM20007 PLATE,
FLANGE, SHINGLE, STD.
X X X 23 Galvanized steel attachment for parallel, inclined and freestanding installations on asphalt or elastomer roofs.
SRM20008
PLATE, FLANGE, SHINGLE, RAISED
- X X 25 Galvanized steel attachment for inclined and freestanding installations on asphalt or elastomer roofs. Also recommended for flat roofs.
SRM20009
CONCRETE W/ ADJ
- X X 29 Galvanized steel attachment for inclined or freestanding installations with 2.75" height adjustment. For use in applications with no more than a 5 degree inclination.
SRM20010 BOLT,
ANCHOR, CONCRETE
- X X 29 Galvanized steel attachment for inclined or freestanding installations with no height adjustment. For use in applications with no more than a 5 degree inclination.
SRM20012 KIT, UNIV
CABLE SECURING
- X - 22 Stainless steel cable set for securing collectors on jointed roofs. Kit includes cable, turnbuckle, hardware for attachment to frame, and joint clamp (SRM20006).
SRM20013 ATTACHMENT, ROOF CORR
METAL X X - 26 Stainless steel attachment for parallel and inclined installations
on profiled and corrugated roofs.
SRM20014 ATTACHMENT, ROOF WAVE
SM X X - 28
Galvanized steel attachment for installations on concrete corrugated roofs with 5 corrugations per meter. For parallel and inclined installations.
SRM20015 ATTACHMENT, ROOF WAVE
LG X X - 28
Galvanized steel attachment for installations on concrete corrugated roofs with 8 corrugations per meter. For parallel and inclined installations.
SRM20016 ROOF HOOK,
TILE ROOF, LT COMM.
X - - 18 Stainless steel attachment for parallel installations on various types of tiled roofs with an inclination greater than 30 degrees.
11
Roof attachment quantities for SLV/SLH snow loading 3 Roof Attachment Installation (continued)
SRM: 20001, 20003, 20004, 20006, 20007, 20013, 20014, 20015 SRM: 20002, 20005, 20016
area load up to 32 lb/sq-ft
area load up to 64 lb/sq-ft
area load up to 16 lb/sq-ft
area load up to 32 lb/sq-ft
SLV 1x SLV 4 4 4 4 2x SLV 6 8 6 8 3x SLV 8 12 8 12 4x SLV 10 16 10 16 5x SLV 12 20 12 20 6x SLV 14 24 14 24
SLH 1x SLH 4 4 4 4 2x SLH 8 8 8 8 3x SLH 12 12 12 12 4x SLH 16 16 16 16 5x SLH 20 20 20 20 6x SLH 24 24 24 24
Pa ra
area load up to 32 lb/sq-ft
area load up to 64 lb/sq-ft
area load up to 16 lb/sq-ft
area load up to 32 lb/sq-ft area load up to 64 lb/sq-ft
SLV 1x SLV 4 4 4 4 6 2 2x SLV 6 8 6 8 10 2 3x SLV 8 12 8 12 14 2 4x SLV 10 16 10 16 18 3 5x SLV 12 20 12 20 22 4 6x SLV 14 24 14 24 26 4
SLH 1x SLH 4 4 4 4 6 2 2x SLH 8 8 8 8 10 2 3x SLH 12 12 12 12 14 2 4x SLH 16 16 16 16 18 3 5x SLH 20 20 20 20 22 4 6x SLH 24 24 24 24 26 4
In cl
in ed
(2 0,
4 0°
, 6 0°
SLV/SLH Collectors Installation & Operation Manual
12
3 Roof Attachment Installation SLV Roof attachment spacing
Figure 3-1 SLV Parallel Spacing
x = 2” - 8” y: 20° = 79” - 88.5” 40° = 74.5” - 84.25” 60° = 61.5” - 71”
48” 47.5”
48” 47.5”
Figure 3-2 SLV Inclined Spacing
x = 2” - 8” y: 20° = 79” - 88.5” 40° = 74.5” - 84.25” 60° = 61.5” - 71”
x 48”
3 Roof Attachment Installation (continued)
13
(< 4
Figure 3-4 SLH Parallel Spacing
(< 4
4 ”)
w = 55” - 71” y: 20° = 41.25“ - 51” 40° = 36.5“ - 46.5” 60° = 31“ - 41” z = 86.25” - w
Figure 3-5 SLH Inclined Spacing
w = 55” - 71” y: 20° = 41.25“ - 51” 40° = 36.5“ - 46.5” 60° = 31“ - 41” z = 86.25” - w
(< 4”) (< 4”)
SLH Roof attachment spacing
Single hanger bolt for universal fastening #SRM20002
The universal fixture is for parallel and inclined installation on various roof types and freestanding installation on sufficiently anchored frames.
Figure 3-7 Kit #SRM20002 - Single Hanger Bolt Kit Components
• The hanger bolt must be screwed into a support capable of bearing the required static load (generally rafters). • Install the hanger bolt using a field supplied anchoring adapter. • The roofing must be capable of withstanding the pressure needed to compress the gasket. • Beware of linear expansion in sheet metal (each hanger bolt is a fixed point in the sheet metal that prevents a linear expansion and can cause lifting of the sheet).
CAUTION
HANGER BOLT PLATE (1X)
Figure 3-8 Pre-Drill 9mm Hole Into Substructure
PRE-DRILL 9MM HOLE PERPENDICULAR TO THE ROOF (APPROX. 4 IN. DEEP)
INSTALL HANGER BOLT
6. Slide the hanger bolt seal over the machine threads until the seal is touching the roof’s surface (FIG. 3-9A).
7. Slide the washer (M12) on top of the hanger bolt seal (FIG. 3-9A).
8. Thread the hex nut with flange (flange side down) onto the washer, compressing the washer and hanger bolt seal to the roof (see FIG. 3-9B).
9. Install the second hex nut with flange (flange side up) until the hex nut reaches the desired substructure height (FIG. 3-9B).
10. Slide the hanger bolt plate onto the flange of the hex nut installed in Step 9 (FIG.’s 3-9A and 3-9B).
11. Install the remaining hex nut with flange (flange side down) to the top of the hanger bolt plate. Tighten and secure both hex nuts (top and bottom) to the hanger bolt plate.
12. Make certain all hanger bolt plates are facing the same direction.
Install single hanger bolt
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13 of this manual).
4. Pre-drill a 9mm hole, a minimum of 4 inches deep into the roof substructure (see FIG. 3-8), perpendicular to the roof.
5. Install the hanger bolt into the pre-drilled hole until the threads are level with the roof’s surface.
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-7).
Installation of roof attachment types The solar thermal collectors are capable of being mounted to several different types of roofing with a wide variety of mounting hardware available from Lochinvar.
SLV/SLH Collectors Installation & Operation Manual
15
3 Roof Attachment Installation (continued)
13. Slide the square disk onto the hex bolt (see FIG. 3-10).
14. Install the hex bolt with square disk attached into the opening of the hanger bolt plate as shown in FIG. 3-10.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
15. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 14 (FIG. 3-10).
16. Repeat Steps 4 - 15 until installation is complete.
Figure 3-10 Install Hex Bolt
SQUARE DISK
HEX BOLT
Double hanger bolt for universal fastening #SRM20001
Universal fixture for parallel and inclined installation on various roof types and freestanding installations on sufficiently anchored frames. Two hanger bolts are to be installed on the roof as vertically as possible with a spacing of 4 3/4" to 6 3/4". The two are connected by an intermediate plate.
• The hanger bolt must be screwed into a support capable of bearing the required static load (generally rafters). • Install the hanger bolt using a field supplied anchoring adapter. • The roofing must be capable of withstanding the pressure needed to compress the gasket. • Beware of linear expansion in sheet metal that prevents a linear expansion and can cause lifting of the sheet.
CAUTION
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-11).
HANGER BOLT (M12) (2X)
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
SLV/SLH Collectors Installation & Operation Manual
Figure 3-9A Install Hanger Bolt Components
4”
16
Figure 3-12 Pre-Drill 9mm Holes Into Substructure
PRE-DRILL TWO (2) 9MM HOLES PERPENDICULAR TO THE ROOF (APPROX. 4 IN. DEEP)
INSTALL HANGER BOLT(S)
6. Slide the hanger bolt seals over the machine threads until the seal is touching the roof’s surface (FIG. 3-13A).
7. Slide the washer (M12) on top of the hanger bolt seal (FIG. 3-13A).
8. Thread the hex nut with flange (flange side down) onto the washer, compressing the washer and hanger bolt seal to the roof see (3-13B).
9. Install the second hex nut with flange (flange side up) until the hex nut reaches the desired substructure height (FIG. 3-13B).
10. Slide the hanger bolt plate onto the flange of the hex nut installed in Step 9 (FIG.’s 3-13A and 3-13B).
11. Install the remaining hex nut with flange (flange side down) to the top of the double hanger bolt plate. Tighten and secure both hex nuts (top and bottom) to the double hanger bolt plate.
12. Make certain all double hanger bolt plates are facing the same direction.
Install double hanger bolt
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Pre-drill two 9mm holes, a minimum of 4 inches deep into the roof substructure (see FIG. 3-12), perpendicular to the roof with a spacing of 4 3/4" to 6 3/4".
5. Install the hanger bolts into the pre-drilled holes until the threads are level with the roof’s surface.
13. Slide the square disk onto the hex bolt (see FIG. 3-14).
14. Install the hex bolt with square disk attached into the opening of the double hanger bolt plate as shown in FIG. 3-14.
Note: Do not tighten hex bolts until ready to install on the collector substructure.
15. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 14 (FIG. 3-14).
16. Repeat Steps 4 - 15 until installation is complete.
Figure 3-14 Install Hex Bolt(s) HEX BOLT
SQUARE DISK
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
SLV/SLH Collectors Installation & Operation Manual
Figure 3-13A Install Double Hanger Bolt Components
MIN. 4 IN.
HEX NUT W/FLANGE
HANGER BOLT
Figure 3-13B Compress Washer Hanger Bolt Seal DOUBLE HANGER BOLT PLATE
HEX NUT FLANGE UP
NUT
WASHER
SEAL
17
• The anchors must be screwed into a support capable of bearing the required static load (generally rafters or concrete). • Complies with the requirements of DIN1055. • Roof batten height at least 1". • The gap between rafter anchor and top edge of the tile must be at least 3-5mm. Under no circumstances may the rafter anchor be in contact with the tile (if the overall height of roof batten and tile do not match, the lower height must be packed out).
3 Roof Attachment Installation (continued) Rafter anchor for standard and tall roof tiles #SRM20003 & #SRM20004
The rafter anchor is used for parallel and inclined mounting on tiled roofs with a roof pitch of at least 15° and an area loading greater than 6 lb/ft2. Can be used for various types of roofing tiles.
CAUTION
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-15).
RAFTER ANCHOR (1X)
WOOD SCREW (2X)
WASHER (M8) (1X)
HEX NUT (M8) (1X)
SQUARE DISK (1X)
SPACER PLATE (3X)
Install rafter anchor
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Number two (2) tiles, one above the other. The upper tile will be removed to install the rafter anchor.
5. Mark the edge of the upper tile on the lower tile to ensure proper alignment upon assembly.
6. Using the rafter anchor as a template, pre-drill two (2) 6 mm holes, approximately 4 inches deep into the roof substructure (see FIG. 3-16), perpendicular to the roof.
Figure 3-16 Pre-Drill 6mm Holes Into Roof Substructure
USE RAFTER ANCHOR AS A TEMPLATE
PRE-DRILL TWO (2) 6MM HOLES APPROX. 4” DEEP PERPENDICULAR TO THE ROOF
7. To achieve the recommended 3 - 5 mm clearance above the tile, place spacer plate(s) (provided in the kit) between the rafter anchor and the roof substucture if necessary (FIG. 3-17).
8. Place the rafter anchor on the spacer plate (if used).
9. Place the heavy duty washers over the holes pre-drilled in Step 6.
10. Install the wood screws through the washers and rafter anchor into the roof substructure.
Note: It may be necessary to grind the upper tile to assure a better fit (FIG. 3-18).
SLV/SLH Collectors Installation & Operation Manual
18
Tiled roof hook #SRM20016
The tiled roof hook is only used for the mounting of collector modules parallel to the roof line (SLV and SLH) on tiled roofs with a roof pitch of at least 15°. The hooks are hung over the tiles. Should the underlying roof batten be too thick, the lower part of the top hook is cut off. To ensure that the hook cannot be lifted, a hole is drilled through the tile and the hook held by the screw provided in the kit.
3 Roof Attachment Installation
11. Slide the square disk onto the hex bolt (see FIG. 3-17).
12. Install the hex bolt with square disk attached into the opening of the rafter anchor as shown in FIG. 3-17.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
13. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 12.
14. Repeat Steps 4 - 13 until installation is complete.
15. Replace tiles removed in Step 4.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
Figure 3-17 Install Rafter Anchor
HEX BOLT
COLLECTOR SUBSTRUCTURE
RAFTER ANCHOR
Figure 3-18 Grind Tile (if necessary)
IF NECESSARY, GRIND THE TILE FOR A BETTER FIT
Figure 3-19 Kit #SRM20016 - Tiled Roof Hook Kit Components
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-19).
TILED ROOF HOOK (1X)
Install tiled roof hook
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
SLV/SLH Collectors Installation & Operation Manual
Flat tile hook #SRM20005
The flat tile hook is only used for parallel installation on plain tiled roofs (generally steep roofs with a pitch of over 30°), the hooked ends are hung over the roof battens and screwed in place, an inclined collector installation is not possible here.
3 Roof Attachment Installation (continued) 4. Number two (2) tiles, one above the other. The top tile will be removed to install the tiled roof hook.
5. Remove the top tile from the roof (set aside for reassembly).
6. Place the tiled roof hook over the roof batten of the bottom tile.
7. Using the roof hook as a template, drill a 6 mm hole through the tile (holes on the tiled roof hook are pre-drilled), see FIG. 3-20.
8. Secure the tiled roof hook to the roof substructure using the screw(s) provided in the kit (FIG. 3-20).
9. Replace the tile removed in Step 5.
Note: It may be necessary to grind the tile to assure a better fit (FIG. 3-21).
Figure 3-20 Drill 6 mm Hole Into Roof Substructure
DRILL 6 MM HOLE
TILED ROOF HOOK
COLLECTOR SUBSTRUCTURE
HEX BOLT SQUARE DISK
10. Slide the square disk onto the hex bolt (see FIG. 3-21).
11. Install the hex bolt with square disk attached into the opening of the tiled roof hook as shown in FIG. 3-21.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
12. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 11.
13. Repeat Steps 4 - 12 until installation is complete.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
Figure 3-22 Kit #SRM20005 - Flat Tile Hook Kit Components
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-22).
FLAT TILE HOOK (1X)
HEX NUT (M8) (1X)
HEX BOLT (M8) (1X)
WASHER (M8) (1X)
SQUARE DISK (1X)
METAL SHEET (1X)
20
3 Roof Attachment Installation Install flat tile hook
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Number two (2) tiles, one above the other. The top tile will be removed to install the flat tile hook.
5. Remove the top tile from the roof (set aside for reassembly).
6. Place the tiled roof hook over the roof batten of the bottom tile (FIG. 3-23).
7. Place the metal sheet provided in the kit under the flat tile hook (FIG. 3-23). Using the nails provided in the kit, secure the metal sheet to the roof substructure (FIG. 3-23).
8. Secure the tiled roof hook to the roof substructure using the screw provided in the kit (FIG. 3-23).
9. Replace the tile removed in Step 5.
Note: It may be necessary to grind the tile to assure a better fit (FIG. 3-24).
Figure 3-23 Install Flat Tile Hook and Metal Sheet
HOOK FLAT TILE HOOK ONTO ROOF BATTEN
USE THE NAILS AND WOOD SCREW TO SECURE THE METAL SHEET AND FLAT TILE HOOK TO ROOF SUBSTRUCTURE
NAIL NAIL
WOOD SCREW
Figure 3-24 Grind Tile(s) (if necessary) / Install Hex Bolt
COLLECTOR SUBSTRUCTURE
HEX BOLT
SQUARE DISK
FLAT TILE HOOK
10. Slide the square disk onto the hex bolt (see FIG. 3-24).
11. Install the hex bolt with square disk attached into the opening of the flat tile hook as shown in FIG. 3-24.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
12. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 11.
13. Repeat Steps 4 - 12 until installation is complete.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
21
3 Roof Attachment Installation (continued) Joint clamp #SRM20006
The joint clamp is only used for parallel and inclined mounting on folded-seam tin roofs with galvanized or coated sheet steel, or copper, reference the Universal Cable Securing Kit on page 22 .
• Not recommended for titanium-zinc sheet due to danger of cracks at low temperature. • Do not reuse any stainless steel screws as there is a risk of breakage.
CAUTION
JOINT CLAMP 2 (1X)
HEX NUT (M8) (1X)
HEX BOLT (M8) (1X)
WASHER (M8) (1X)
SQUARE DISK (1X)
JOINT CLAMP 1 (1X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-25).
Install joint clamp
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Assemble joint clamp as shown in FIG. 3-26 (be sure to loosely assemble the screws on the joint clamp assembly).
5. Place the joint clamp assembly at the appropriate location on the joint of the tin roof.
6. Tighten the screws on the joint clamp to 26 ft./lbs.
Figure 3-26 Assemble / Install Joint Clamp & Hex Bolt
ASSEMBLE JOINT CLAMP INSTALL ON THE TIN ROOF JOINT
JOINT
SQUARE DISK
7. Slide the square disk onto the hex bolt (see FIG. 3-26).
8. Install the hex bolt with square disk attached into the opening of the joint clamp as shown in FIG. 3-26.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
9. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 8.
10. Repeat Steps 4 - 9 until installation is complete.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
22
3 Roof Attachment Installation Universal cable securing kit #SRM20012
For securing inclined collectors on tin joint roofs comprising a guy cable, turnbuckle and hardware for collector frames and joint clamp for guy cable tensioning. Material: stainless- steel.
Joint clamp for cable set is required for mounting the guy cable set on joint tin roofs with galvanized or coated sheet steel or sheet copper (one in each guy cable set). The guy cable set is fastened to the joint clamp. Note: The joint clamp can also be used with a 1" pipe provided on site as an additional snow guard above the collector (does not replace the snow guard system provided on site which is a requirement).
• Not recommended for titanium- zinc sheet due to danger of cracking at low temperatures. • Do not reuse any stainless steel screws as there is a risk of breakage.
CAUTION
Install cable securing kit
1. Install the anchor bracket on the A-frame using the hex bolt, square disk, washer, and hex nut.
2. Assemble the joint clamp as shown in FIG. 3-29 (be sure to loosely assemble the screws on the joint clamp assembly).
3. Place the joint clamp assembly at the appropriate location on the joint of the tin roof.
Figure 3-29 Assemble Joint Clamp
ASSEMBLE JOINT CLAMP LOOSELY AND PLACE ON JOINT
Figure 3-27 Kit #SRM20012 - Universal Cable Securing Kit Components
JOINT CLAMP PART 2 (1X)
HEX BOLT W/FLANGE (2X)
HEX BOLT (M10) (1X)
HEX NUT (M8) (2X)
NUT (2X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-27).
Figure 3-28 Attach Cable Fastening Bracket to A-Frame
ATTACH CABLE FASTENING BRACKET TO THE A-FRAME, USING THE HEX BOLT SQUARE DISK, WASHER AND HEX NUT
CABLE FASTENING BRACKET INSTALLED ON A-FRAME
SLV/SLH Collectors Installation & Operation Manual
Flange plate shingle (standard) #SRM20007
The standard flange shingle plate is used for parallel and inclined installations on asphalt and elastomer roofs.
3 Roof Attachment Installation (continued) 4. Choose a cable orientation to ensure proper degree of angle (see FIG. 3-30).
5. Install the steel cable on the A-frame bracket using the pin and pin clip provided in the kit (see FIG. 3-31).
6. Attach the steel cable to the joint clamp (fashioned after the cable orientations in FIG. 3-30).
Figure 3-31 Install Steel Cable on A-frame
INSERT PIN
CABLE INSTALLED ON ANCHOR BRACKET
Extend turnbuckle to its fullest extent. NOTICE
7. Before tightening the joint clamp, set the angle of the cable to greater than or equal to 30°, but less than or equal to 45° (see FIG. 3-32).
8. Tighten the joint clamp.
9. Use the turnbuckle to tighten the cable.
Figure 3-32 Cable Angle
Figure 3-30 Cable Orientations
• The plates must be screwed into a support capable bearing the required load (generally rafters or concrete). • Once installed, the plates must be sealed to the roof sheet material (see FIG. 3-36), and only then can the collector be fitted.
CAUTION
Figure 3-33 Kit #SRM20007 - Flange Shingle Plate (Standard) Kit Components
PLATE FLANGE (STD) (1X)
SQUARE DISK (1X)
SCREW (M10) (4X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-33).
23
24
3 Roof Attachment Installation Install flange plate shingle (standard)
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Caulk (field supplied) around the perimeter of the flange plate (FIG. 3-34).
5. Using the flange plate as a template, place the flange plate on the roof and drill four (4) 6 mm holes as shown in FIG. 3-35. Install the larger screws provided in the kit into the 6mm holes securing the flange plate to the roof (caulk around screws before tightening).
6. Install the four (4) remaining smaller screws in the perimeter of the flange plate as shown in FIG. 3-35 (caulk around screws before tightening).
7. Cover flange plate with roofing material, sealing it to the roof (FIG. 3-36).
Figure 3-34 Caulk Around Perimeter of Flange Plate
CAULK AROUND THE PERIMETER OF THE FLANGE PLATE ~ Ø 5 mm
Figure 3-35 Drill Holes and Attach Flange Plate
COLLECTOR SUBSTRUCTURE
FLANGE PLATE
PRE-DRILL FOUR (4) 6MM HOLES - USE THE LARGER SCREWS TO SECURE THE
FLANGE PLATE
8. Slide the square disk onto the hex bolt (see FIG. 3-35).
9. Install the hex bolt with square disk attached into the opening of the flange plate as shown in FIG. 3-35.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
10. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 9.
11. Repeat Steps 4 - 10 until installation is complete.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
Figure 3-36 Cover Flange Plate with Roofing Material
COVER FLANGE PLATE WITH ROOFING MATERIAL, SEALING IT TO THE ROOF
2”
3 Roof Attachment Installation (continued) Flange plate shingle (raised) #SRM20008
The raised flange shingle plate is used for inclined installations on asphalt and elastomer roofs; also suitable for flat roofs.
• The plates must be screwed into a member capable of bearing the required static load (generally rafters or concrete). • Once installed, the panels must be sealed to the roof sheet material (FIG. 3-40), and only then can the collector be fitted.
CAUTION
Figure 3-37 Kit #SRM20008 - Flange Plate Shingle (Raised) Kit Components
FLANGE PLATE RAISED (1X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-37).
Install flange plate shingle (raised)
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Caulk (field supplied) around the perimeter of the flange plate (FIG. 3-38).
5. Using the flange plate as a template, place the flange plate on the roof and drill four (4) 6 mm holes as shown in FIG. 3-34. Install the larger screws provided in the kit into the 6mm holes securing the flange plate to the roof (caulk around screws before tightening).
6. Install the four (4) remaining smaller screws in the perimeter of the flange plate as shown in FIG. 3-39 (caulk around screws before tightening).
7. Cover flange plate with roofing material, sealing it to the roof (FIG. 3-40).
Figure 3-38 Caulk Around Perimeter of Flange Plate
CAULK AROUND THE PERIMETER OF THE FLANGE PLATE ~ Ø 5 mm
SLV/SLH Collectors Installation & Operation Manual
26
COLLECTOR SUBSTRUCTURE
FLANGE PLATE
PRE-DRILL FOUR (4) 6 MM HOLES - USE THE LARGER SCREWS TO SECURE THE
FLANGE PLATE
8. Slide the square disk onto the hex bolt (see FIG. 3-39).
9. Install the hex bolt with square disk attached into the opening of the flange plate as shown in FIG. 3-39.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
10. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 9.
11. Repeat Steps 4 - 10 until installation is complete.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
Corrugated metal roof attachment #SRM20013
The corrugated metal roof attachment is used for parallel and inclined mounting on profiled or corrugated sheet metal roofs. The console is mounted above the mounting screws of the profiled or corrugated sheet metal. The two sealing screws are first screwed onto the underlying mounting screw of the sheet. The sealing is done before the console is mounted using the sealing pads supplied. The sections are fixed to the section connectors on the console.
• The console must be ordered to fit the relevant profiled or corrugated sheet metal. • The mounting screws supplied with the console must be appropriate in type and length for the particular roof construction.
CAUTION
Figure 3-41 Kit #SRM20013 - Corrugated Metal Roof Attachment Kit Components
HEX NUT (M10) (1X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-41).
SLV/SLH Collectors Installation & Operation Manual
Figure 3-40 Cover Flange Plate with Roofing Material
COVER FLANGE PLATE WITH ROOFING MATERIAL, SEALING IT TO THE ROOF
2”
Install metal roof attachment
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Attach the rubber seals provided in the kit to each end of the metal roof attachment as shown in FIG. 3-42.
5. Place the metal roof attachment on top of an existing fixing point of the metal roof (FIG. 3-43).
6. Using the metal roof attachment as a template pre-drill two (2) 6.5 mm holes into the top of the metal roof attachment (see FIG. 3-43).
7. Install hex bolts into pre-drilled holes as shown in FIG. 3-44.
8. Install the four (4) self tapping screws provided in kit into each side of the metal roof attachment (FIG. 3-44).
9. Insert the stud (all thread) into the center of the roof attachment.
Figure 3-42 Install Rubber Seals
INSTALL SEALING PADS
METAL ROOF ATTACHMENT
PRE-DRILL 6.5 MM HOLES
INSTALL STUD (ALL THREAD)
INSTALL HEX BOLTS & STUD
INSTALL SELF TAPPING SCREWS
10. Attach the profile connector to the stud using the washers and hex nuts provided in the kit (FIG. 3-45).
11. Drill a 6.5 mm hole into the horizontal bar.
12. Place the horizontal bar into the profile conrector installed in Step 10.
13. Using the remaining bolts and washers secure the horizontal bar into the profile connector.
Figure 3-45 Install Profile Connector
ATTACH PROFILE CONNECTOR
METAL ROOF ATTACHMENT
28
Wave roof attachment #SRM20014 & #SRM20015
The wave roof attachment is for parallel and inclined mounting on corrugated cement roofs. The wave roof attachment is screwed to the load-bearing wooden frame using mounting screws and then sealed with caulk. The horizontal bars are then screwed to the angle bracket that has been bolted to the wave roof attachment.
3 Roof Attachment Installation
• Various sizes: Profile 5 corrugations per meter; profile 8 corrugations per meter. • The wood screws must be screwed into a member capable of bearing the required static load (generally rafters). Longer wood screws are necessary if the roof construction is higher (e.g. roof insulation).
CAUTION
Figure 3-46 Kit #SRM20014 & #SRM20015 - Wave Roof Attachment Kit Components
WAVE ROOF ATTACHMENT (1X)
HEX BOLT (M8) (1X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-46).
Install wave roof attachment
1. Determine roof type. Inspect the structural integrity of the roof and the durability of the roof materials.
2. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
3. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
4. Using the wave roof attachment as a template, place the wave roof attachment on the roof and pre-drill a 6 mm hole as shown in FIG. 3-47.
5. Caulk (field supplied) inside the 6 mm hole pre-drilled in Step 4 (FIG. 3-47).
6. Place the wave roof attachment, angle bracket and washer over the 6 mm hole on the roof (FIG. 3-48). Insert the screw through the washer and angle bracket into the 6 mm hole securing the wave roof attachment to the roof (caulk around screws before tightening) (FIG. 3-47).
Figure 3-47 Pre-Drill 6 mm Hole and Seal
PRE-DRILL A 6 MM HOLE AND SEAL
SEAL
29
Figure 3-48 Attach Wave Roof Attachment Assembly and Hex Bolt
HEX BOLT SQUARE DISK
ATTACH WAVE ROOF ATTACHMENT ASSEMBLY (WASHER, ANGLE BRACKET AND SCREW) TO THE ROOF
7. Slide the square disk onto the hex bolt (see FIG. 3-48).
8. Install the hex bolt with square disk attached into the opening of the wave roof attachment as shown in FIG. 3-48.
Note: Do not tighten hex bolt until ready to install on the collector substructure.
9. Thread the hex nut (M8) and washer (M8) onto the bottom of the hex bolt installed in Step 8.
10. Repeat Steps 4 - 9 until installation is complete.
Install hex bolt onto collector substructure (reference Section 4 - Collector Installation)
Anchor bolts for concrete with or without height adjustment
Anchor bolts are used for inclined and freestanding mounting on concrete. The anchor bolt is inserted at least 2 1/4" into the 10 mm hole pre-drilled in the concrete. The aluminum profile with a 10.5 mm clearance hole is threaded over the bolt and fixed with a washer and nut.
• There are two (2) models of concrete anchor bolts, one with adjustment and one without. The adjustable dimensions are up to 2 3/4". • The anchor bolt may have a maximum deviation from vertical of 5°.
CAUTION
ANCHOR BOLT W/ADJUSTMENT (1X)
HEX NUT (M10) (3X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-49).
Install anchor bolt
1. Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11.
2. Determine collector connection points (spacing). Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout (reference the Roof Attachment Spacing Section on pages 12 and 13).
3. Pre-drill a 10 mm hole a minimum of 3 inches into the concrete (FIG. 3-50).
4. Place the anchor bolt into the pre-drilled hole using a field supplied hammer.
5. Use the washer and nut provided in the kit to secure the anchor bolt to the concrete as shown in FIG. 3-50.
SLV/SLH Collectors Installation & Operation Manual
30
m in
. 2 1
22 ft./lbs.
USE THE WASHER AND NUT TO SECURE THE ANCHOR BOLT TO THE CONCRETE
6. Place the second nut and washer on the anchor bolt at the desired height (if using the anchor bolt with adjustments).
7. Drill a 10.5 mm hole in the horizontal bar (see FIG. 3-51).
8. Place the horizontal bar onto the anchor bolt and use the remaining washer and nut to secure the horizontal bar to the substructure as shown in FIG. 3-51.
Figure 3-51 Attach Horizontal Bar
ATTACH HORIZONTAL BAR DRILL 10.5 MM HOLE
22 ft./lbs.
2 1/
3 Roof Attachment Installation
31
SLV parallel mounting instructions 4 Collector Installation
1. Install roof attachment (see the Roof Attachment Section on pages 14 - 30 of this manual).
2. Assemble horizontal bars into one continuous bar. Slide the pin into the hole on the end of the horizontal bar and slide the next horizontal bar onto the pin as shown in FIG. 4-3. Assemble the plate assembly using the hex bolts, square disks, washer and nuts provided in the kit. Slide the plate assembly so that it straddles the intersection of the horizontal bars.
3. Repeat Step 2 until all horizontal bars have been assembled.
4. Slide both top and bottom horizontal bars onto the pre- installed hex bolt, square disk, washer and nut of every roof attachment point (FIG. 4-3).
SLV/SLH Collectors Installation & Operation Manual
Figure 4-1 SLV Parallel Basic Kit Components
SQUARE DISK (4X)
SINGLE GROOVE ATTACHMENT (4X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG.’s 4-1 and 4-2).
Figure 4-2 SLV Parallel Expansion Kit Components
SQUARE DISK (6X)
ASSEMBLE PLATE ASSEMBLY
SLIDE PIN INTO HORIZONTAL BAR(S)
48.1 IN.
STEPS TO ASSEMBLE HORIZONTAL BARS
CAUTION Make certain the plate assembly is not facing the roof attachment or the collector (FIG. 4-3).
32
SLV/SLH Collectors Installation & Operation Manual
5. Tighten the hex bolts making sure the horizontal bars are even and perpendicular to each other (FIG. 4-4).
Figure 4-4 Install Horizontal Bars
6. Slide the spacers onto the horizontal bar (FIG. 4-3).
7. Slide the metal bracket hook onto the bottom horizontal bar, to the center of each collector (see FIG. 4-5).
Figure 4-5 Install Metal Bracket Hook
SLIDE METAL BRACKET HOOK(S) ONTO HORIZONTAL BAR(S)
8. Slide the first collector onto the metal bracket hook until the collector slides into the bracket channel (FIG. 4-6).
Figure 4-6 Install Collector on Metal Bracket Hook
SLIDE COLLECTOR ONTO METAL BRACKET HOOK
9. Place the collector at the end of the horizontal bar, be sure to leave room for the single groove attachment assembly (bolt, square disk, grooved aluminum plate, washer and nut).
10. Attach the collector to the horizontal bars using the single groove attachment assembly (bolt, square disk, grooved aluminum plate, washer and nut) provided in the kit (FIG. 4-7).
Figure 4-7 Attach Collector
ATTACH COLLECTOR USING THE SINGLE GROOVE ATTACHMENT ASSY (BOLT, SQUARE DISK, GROOVED ALUMINUM PLATE, WASHER, AND NUT)
11. Install support sleeves into all four (4) hydraulic connections on each collector (FIG. 4-8).
Figure 4-8 Install Support Sleeves
INSTALL SUPPORT SLEEVES INTO HYDRAULIC CONNECTIONS
33
12. Install the compression ring and the union of the Hydraulic Expansion Kit (FIG. 4-9).
4 Collector Installation (continued)
SLIDE PRE-INSTALLED SPACER TO THE EDGE OF THE 1ST COLLECTOR
INSTALL HYDRAULIC
EXPANSION KIT
Figure 4-9 Install Compression Ring and Union
INSTALL COMPRESSION RING AND UNION OF THE HYDRAULIC EXPANSION KIT ONTO THE OUTLET OF THE 2ND COLLECTOR
13. Install the Hydraulic Expansion Kit onto the inner ports of the first collector (if you have multiple collectors) (FIG. 4-10).
Note: Reference Section 5 - Hydraulic Expansion Kits on page 50 of this manual for details on how to install the expansion kit.
14. Slide the pre-installed spacer to the edge of the first collector (FIG. 4-10). Do not tighten at this time. Spacer has to be in the vertical position.
15. Repeat Step 8 on page 32 with the second collector. Position the collector against the loosely placed spacer installed in Step 14.
Note: Repeat Steps 11 - 15 for all subsequent collectors on the array (maximum of 6 collectors).
16. Twist spacers (horizontal position) to lock collectors into position and tighten (FIG. 4-11).
Figure 4-11 Twist Spacers and Lock Collectors
TWIST SPACERS TO LOCK COLLECTORS INTO POSITION AND TIGHTEN SPACERS
17. After all collectors have been positioned, lock the last collector using the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) provided in the kit (FIG. 4-12).
Figure 4-12 Lock Collectors
WASHER, AND NUT)
18. Tighten all hydraulic connections (see Section 5 - Hydraulic Connection Kits) to complete the installation (4-13).
Figure 4-13 Tighten All Hydraulic Connections TIGHTEN ALL HYDRAULIC
CONNECTIONS
SLV/SLH Collectors Installation & Operation Manual
34
SLV inclined mounting instructions
1. Install roof attachment (see the Roof Attachment Section on pages 14 - 30 of this manual).
2. Assemble horizontal bars into one continuous bar. Slide the pin into the hole on the end of the horizontal bar and slide the next horizontal bar onto the pin as shown in FIG. 4-16. Assemble the plate assembly using the hex bolts, square disks, washer and nuts provided in the kit. Slide the plate assembly so that it straddles the intersection of the horizontal bar.
3. Repeat Step 2 until all horizontal bars have been assembled.
4. Slide both top and bottom horizontal bars onto the pre- installed hex bolt, square disk, washer and nut of every roof attachment point (FIG. 4-16).
Figure 4-14 SLV Inclined Basic Kit Components
SQUARE DISK (12X)HEX NUT (M8) (12X)
WASHER (M8) (12X) HEX BOLT (M8) (12X)
HYDRAULIC CONNECTION (2X)
SENSOR WELL (1X)
A-FRAME (2X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG.’s 4-14 and 4-15).
Figure 4-15 SLV Inclined Expansion Kit Components
SQUARE DISK (10X)HEX NUT (M8) (10X)
WASHER (M8) (10X) HEX BOLT (M8) (10X)
METAL BRACKET (2X)
A-FRAME (1X)
OF THE HORIZONTAL BAR(S)
SLIDE PIN(S) INTO HORIZONTAL BAR(S)
STEPS TO ASSEMBLE
SLV/SLH Collectors Installation & Operation Manual
5. Tighten the hex bolts making sure the horizontal bars are even and perpendicular to each other (FIG. 4-17).
Figure 4-17 Install Horizontal Bars
CAUTION Make certain the plate assembly is not facing the roof attachment or the collector (FIG. 4-16).
6. Assemble the U-shaped profile connector using the bolt, square disk, washer and nut provided in the kit (FIG. 4-18).
7. Slide the U-shaped profile connector onto the horizontal bars using the square disk, hex bolt, hex nut and washer positioning the connectors as shown in FIG. 4-18.
Figure 4-18 Assemble and Install U-Shaped Profile Connector
ASSEMBLE U-SHAPED PROFILE CONNECTOR(S) AND
SLIDE ONTO HORIZONTAL BAR(S)
x = 3.9 - 7.9 in.
8. Assemble A-frame (reference page 49). Unfold and place the bar into the U-shaped profile connector, attach the A-frame using the hex bolt, square disk, washer and nut provided in the kit (FIG. 4-19).
Figure 4-19 Assemble A-Frame
INSTALL ASSEMBLED A-FRAME INTO U-SHAPED PROFILE CONNECTOR
9. Place the assembled A-frame into the lower U-shaped profile connectors and then into the top U-shaped profile connectors (FIG. 4-20).
ASSEMBLE A-FRAME
36
Figure 4-21 Install Metal Bracket, Spacer(s), and Single Groove Attachment Assembly
PLACE ASSEMBLED METAL BRACKET
TIGHTEN BOTTOM METAL BRACKET
OUTER A-FRAMES
INSTALL SPACER
10a. Install the metal bracket, spacer(s) and single groove attachment assembly (bolt, square disk, grooved aluminum plate, washer and nut) as shown below in FIG. 4-21.
10b. Install the end hook on the A-frame using the hex bolt provided in the kit.
11. Slide the first collector onto the metal bracket until the collector slides into the bracket channel (FIG. 4-22).
Figure 4-22 Install Collector INSTALL THE COLLECTOR ONTO THE METAL BRACKET
12. Assemble the single groove attachment assembly (square disk, hex bolt, aluminum grooved plate, washer and nut). Slide the single groove attachment assembly onto the top outer A- frames. Repeat for all A-frames (FIG. 4-23).
Figure 4-23 Install Single Groove Attachment Assembly
INSTALL SINGLE GROOVE ATTACHMENT ASSEMBLY (HEX BOLT, SQUARE DISK, ALUMINUM GROOVED PLATE, WASHER, AND NUT)
13. Install support sleeves into all four (4) hydraulic connections on each collector (FIG. 4-24).
Figure 4-24 Install Support Sleeves
INSTALL SUPPORT SLEEVES INTO HYDRAULIC CONNECTIONS
14. Install the compression ring and the union of the Hydraulic Connection Kit (FIG. 4-25).
Figure 4-25 Install Compression Ring and Union
INSTALL COMPRESSION RING AND UNION OF THE HYDRAULIC EXPANSION KIT ONTO THE OUTLET OF THE 2ND COLLECTOR
4 Collector Installation (continued)
TWIST SPACERS TO LOCK COLLECTORS
INTO POSITION AND TIGHTEN
USING THE SINGLE GROOVE
DISK, AND NUT)
SECURE THE TOP OF THE INNER COLLECTOR’S METAL BRACKET HOOK
37
Figure 4-26 Install Hydraulic Expansion Kit INSTALL HYDRAULIC
EXPANSION KIT
15. Install the Hydraulic Expansion Kit onto the inner ports of the first collector (if you have multiple collectors) (FIG. 4-26).
Note: Reference Section 5 - Hydraulic Expansion Kits on page 50 of this manual for details on how to install the expansion kit.
16. Slide the pre-installed spacer to the edge of the first collector. Do not tighten at this time. Spacer has to be in the vertical position.
17. Repeat Step 11 on page 36 with the second collector. Position the collector against the loosely placed spacer installed in Step 16.
Note: Repeat Steps 13 - 17 for all subsequent collectors on the array (maximum of 6 collectors).
18. Twist spacers (horizontal position) to lock collectors into position and tighten (FIG. 4-27).
19. Secure the top of the outer collector using the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) and the metal bracket hook (FIG. 4-27).
20. Tighten all hydraulic connections (see Section 5 - Hydraulic Connection Kits) to complete the installation (FIG. 4-28).
Figure 4-28 Tighten All Hydraulic Connections TIGHTEN ALL HYDRAULIC
CONNECTIONS
38
Figure 4-31 Steps to Assemble Horizontal Bars
STEPS TO ASSEMBLE HORIZONTAL BARS
SLIDE PLATE ASSEMBLY ONTO HORIZONTAL BAR(S)
SLIDE PIN(S) INTO HORIZONTAL BAR(S)
SLIDE THE SQUARE DISK, HEX BOLT, WASHER
AND NUT ONTO EVERY ROOF ATTACHMENT POINT OF THE HORIZONTAL BAR(S)
48.1”
48.1” 47.6”
1. Install roof attachment (see the Roof Attachment Section on pages 14 - 30 of this manual).
2. Assemble horizontal bars into one continuous bar. Slide the pin into the hole on the end of the horizontal bar and slide the next horizontal bar onto the pin as shown in FIG. 4-31. Assemble the plate assembly using the hex bolts, square disks, washer and nuts provided in the kit. Slide the plate assembly so that it straddles the intersection of the horizontal bar.
3. Repeat Step 2 until all horizontal bars have been assembled.
4. Slide both top and bottom horizontal bars onto the pre- installed hex bolt, square disk, washer and nut of every roof attachment point (FIG. 4-31).
SLV/SLH Collectors Installation & Operation Manual
4 Collector Installation
SQUARE DISK (12X)HEX NUT (M8) (12X)
WASHER (M8) (12X) HEX BOLT (M8) (12X)
HYDRAULIC CONNECTION (2X)
A-FRAME (2X)
SQUARE DISK (2X)
WASHER (2X)
SQUARE DISK (10X)HEX NUT (M8) (10X)
WASHER (M8) (10X) HEX BOLT (M8) (10X)
SUPPORT SLEEVE (4X) HYDRAULIC
WASHER (2X) DIAGONAL SUPPORT (1X)
Installation instructions
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG.’s 4-29 and 4-30).
39
SLV/SLH Collectors Installation & Operation Manual
5. Tighten the hex bolts making sure the horizontal bars are even and perpendicular to each other (FIG. 4-32).
Figure 4-32 Install Horizontal Bars
CAUTION Make certain the plate assembly is not facing the roof attachment or the collector (FIG. 4-31).
6. Assemble the U-shaped profile connector using the bolt, square disk, washer and nut provided in the kit (FIG. 4-33).
7. Slide the U-shaped profile connector onto the horizontal bars using the square disk, hex bolt, hex nut and washer positioning the connectors as shown in FIG. 4-33.
4 Collector Installation (continued)
ASSEMBLE U-SHAPED PROFILE CONNECTOR(S) AND
SLIDE ONTO HORIZONTAL BAR(S)
x = 3.9 - 7.9 in.
8. Assemble A-frame (reference page 49). Unfold and place the bar into the U-shaped profile connector, attach the A-frame using the hex bolt, square disk, washer and nut provided in the kit (FIG. 4-34).
Figure 4-34 Assemble A-Frame
INSTALL ASSEMBLED A-FRAME INTO U-SHAPED PROFILE CONNECTOR
9. Place the assembled A-frame into the lower U-shaped profile connectors and then into the top U-shaped profile connectors (FIG. 4-35).
ASSEMBLE A-FRAME
40
Figure 4-36 Install Metal Bracket Hook, Spacer(s), and Single Groove Attachment Assembly
ASSEMBLE BOLT, SQUARE
DISK, GROOVED ALUMINUM
OUTER A-FRAMES
INSTALL SPACER
4 Collector Installation
11. Before installing the first collector, install two (2) side support brackets and end hook using the square disk, hex bolt, washer and nut provided in the kit (FIG. 3-36). Install the diagonal supports by drilling four (4) 7mm holes. Measure and cut the support to size (see FIG. 4-37).
Figure 4-37 Install Diagonal Supports
MEASURE AND CUT TO SIZE
Figure 4-38 Install Collector INSTALL COLLECTOR
SIDE SUPPORT BRACKETS
ATTACH COLLECTOR USING THE BOLT, SQUARE DISK, GROOVED ALUMINUM CONNECTOR, WASHER, AND NUT
SLV/SLH Collectors Installation & Operation Manual
10a. Install the metal bracket, spacer(s) and single groove attachment assembly (bolt, square disk, grooved aluminum plate, washer and nut) as shown below in FIG. 4-36.
10b. Install the end hook on the A-frame using the hex bolt provided in the kit.
12. Slide the first collector onto the metal bracket hook until the collector slides into the side support brackets (FIG. 4-38).
Note: Be sure to install the bottom collector first for ease of installation.
13. Assemble the single groove attachment assembly (square disk, hex bolt, aluminum grooved plate, washer and nut). Slide the single groove attachment assembly onto the top outer A-frames. Repeat for all A-frames (FIG. 4-39).
41
4 Collector Installation (continued) 14. Install support sleeves into all four (4) hydraulic connections on each collector (FIG. 4-40).
Figure 4-40 Install Support Sleeves
INSTALL SUPPORT SLEEVES INTO HYDRAULIC CONNECTIONS
15. Install the compression ring and the union of the Hydraulic Expansion Kit (if used) (FIG. 4-41).
Figure 4-41 Install Compression Ring and Union
INSTALL COMPRESSION RING AND UNION OF THE HYDRAULIC EXPANSION KIT ONTO THE OUTLET OF THE 2ND COLLECTOR
Figure 4-42 Install Hydraulic Connection Kit
INSTALL HYDRAULIC EXPANSION KIT
16. Install the Hydraulic Expansion Kit onto the outlet of the second collector (FIG. 4-42).
17. Slide the pre-installed spacer to the edge of the first collector. Do not tighten at this time. Spacer has to be in the vertical position.
SLV/SLH Collectors Installation & Operation Manual
18. Repeat Step 12 on page 40 with the second collector. Position the collector against the loosely placed spacer installed in Step 16.
Note: Repeat Steps 14 - 18 for all subsequent collectors on the array (maximum of 6 collectors).
19. Twist spacers (horizontal position) to lock collectors into position and tighten (FIG. 4-43).
20. Secure the top of the outer collector using the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) and the metal bracket hook (FIG. 4-43).
Figure 4-43 Secure Top of Collector
TWIST SPACERS TO LOCK COLLECTORS
INTO POSITION AND TIGHTEN
SECURE THE TOP OF THE OUTER COLLECTOR USING THE SINGLE GROOVE ATTACHMENT
(HEX BOLT, WASHER, ALUMINUM GROOVED CONNECTOR, SQUARE
DISK, AND NUT) SECURE THE TOP OF THE INNER COLLECTOR’S METAL BRACKET HOOK
21. Tighten all hydraulic connections (see Section 5 - Hydraulic Connection Kits) to complete the installation (FIG. 4-44).
Figure 4-44 Tighten All Hydraulic Connections TIGHTEN ALL HYDRAULIC
CONNECTIONS
42
Figure 4-45 SLH Parallel Basic Kit Components
SQUARE DISK (2X)
HEX BOLT (M8) (2X)
SQUARE DISK (2X)
HEX BOLT (M8) (2X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG.’s 4-45 and 4-46).
Figure 4-47 Install Vertical Bars INSTALL VERTICAL BARS
INSTALL SUPPORT BRACKETS
1. Install roof attachment (see the Roof Attachment Section on pages 14 - 30 of this manual).
2. Install vertical bars (horizontally leveled) as shown in FIG. 4-47.
3. Install support brackets on the bottom of the vertical bars (FIG. 4-47).
4. Repeat Steps 2 and 3 until all vertical bars have been installed.
5. Slide the collector into the support brackets installed in Step 3 (FIG. 4-48).
Figure 4-48 Install Collector
43
SLIDE THE SINGLE GROOVE ATTACHMENT (BOLT, SQUARE DISK, ALUMINUM
GROOVED CONNECTOR, WASHER, AND NUT) INTO THE TOP END OF THE A-FRAMES
Figure 4-50 Install Support Sleeves
INSTALL SUPPORT SLEEVES INTO HYDRAULIC CONNECTIONS
8. Install the Hydraulic Expansion Kit onto the outlet of the second collector (FIG. 4-52).
Figure 4-51 Install Compression Ring and Union
6. Install the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) into the top of the vertical bar(s) (FIG. 4-49).
4 Collector Installation (continued)
7. Install support sleeves into all four (4) hydraulic connections on each collector (FIG. 4-50).
8. Install the compression ring and the union of the Hydraulic Expansion Kit (FIG. 4-51).
INSTALL COMPRESSION RING AND UNION OF THE HYDRAULIC EXPANSION KIT ONTO THE OUTLET OF THE 2ND COLLECTOR
Figure 4-52 Install Hydraulic Expansion Kit
INSTALL HYDRAULIC EXPANSION KIT
9. Repeat Step 5 on page 42 with the second collector (FIG. 4-53).
Figure 4-53 Install Collector and Lock in Place SLIDE THE 2ND COLLECTOR INTO POSITION USING THE COMPRESSION FITTINGS
AND UNION TO LOCK INTO PLACE
10. Secure the top of the second collector using the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) (FIG. 4-54).
Figure 4-54 Secure Top of Collector / Tighten Hydraulic Connections
SECURE THE TOP OF THE 2ND COLLECTOR USING THE
SINGLE GROOVE ATTACHMENT
TIGHTEN ALL HYDRAULIC CONNECTIONS
11. Tighten all hydraulic connections (see Section 5 - Hydraulic Connection Kits) to complete the installation (FIG. 4-54).
Be sure to check and tighten ALL connections. NOTICE
SLV/SLH Collectors Installation & Operation Manual
44
WASHER (M8) (2X)
HYDRAULIC CONNECTION (2X)
A-FRAME (2X)
WASHER (M8) (2X)
SUPPORT SLEEVE (4X)
HYDRAULIC EXPANSION (2X)
A-FRAME (2X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG.’s 4-55 and 4-56).
1. Install roof attachment (see the Roof Attachment Section on pages 14 - 30 of this manual).
2. Install A-frames (horizontally leveled) as shown in FIG. 4-57.
3. Repeat Step 2 until all A-frames have been installed.
Figure 4-57 Install A-frames
4 ”)
w = 55” - 71” y: 20° = 41.25“ - 51” 40° = 36.5“ - 46.5” 60° = 31“ - 41” z = 86.25” - w
INSTALL SUPPORT BRACKETS
4. Slide the collector into the support brackets (FIG. 4-58).
Figure 4-58 Install Collector
SLIDE COLLECTOR ONTO SUPPORT BRACKETS
5. Install the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) into the top end of the A-frames (FIG. 4-59).
SLV/SLH Collectors Installation & Operation Manual
45
SLIDE THE SINGLE GROOVE ATTACHMENT (BOLT, SQUARE DISK, ALUMINUM
GROOVED CONNECTOR, WASHER, AND NUT) INTO THE TOP END OF THE A-FRAMES
Figure 4-60 Install Support Sleeves
INSTALL SUPPORT SLEEVES INTO HYDRAULIC CONNECTIONS
Figure 4-61 Install Compression Ring and Union
Figure 4-62 Install Hydraulic Expansion Kit INSTALL HYDRAULIC
EXPANSION KIT
SLIDE THE 2ND COLLECTOR INTO POSITION USING THE COMPRESSION FITTINGS
AND UNION TO LOCK INTO PLACE
10. Secure the top of the second collector using the single groove attachment assembly (hex bolt, square disk, aluminum grooved plate, washer and nut) (FIG. 4-64).
Figure 4-64 Secure Top of Collector / Tighten Hydraulic Connections
SECURE THE TOP OF THE 2ND COLLECTOR USING THE
SINGLE GROOVE ATTACHMENT
TIGHTEN ALL HYDRAULIC CONNECTIONS
11. Tighten all hydraulic connections (see Section 5 - Hydraulic Connection Kits) to complete the installation (FIG. 4-64).
4 Collector Installation (continued)
6. Install support sleeves into all four (4) hydraulic connections on each collector (FIG. 4-60).
7. Install the compression ring and the union of the Hydraulic Expansion Kit (FIG. 4-61).
INSTALL COMPRESSION RING AND UNION OF THE HYDRAULIC EXPANSION KIT ONTO THE OUTLET OF THE 2ND COLLECTOR
8. Install the Hydraulic Expansion Kit onto the outlet of the second collector (FIG. 4-62).
9. Repeat Step 4 on page 44 with the second collector (FIG. 4-63).
SLV/SLH Collectors Installation & Operation Manual
Be sure to check and tighten ALL connections. NOTICE
46
SLH non-south facing mounting instructions
1. Install roof attachment (see the Roof Attachment Section on pages 14 - 30 of this manual).
2. Assemble A-frame (reference page 49). Unfold and place the vertical bar into the U-shaped profile connector, attach the A-frame using the hex bolt, square disk, washer and nut provided in the kit (FIG. 4-67).
4 Collector Installation
SQUARE DISK (3X)
WASHER (3X)
A-FRAME (2X)
SQUARE DISK (2X)
A-FRAME (2X)
WASHER (2X)
Unpacking and checking parts
When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG.’s 4-65 and 4-66).
SLV/SLH Collectors Installation & Operation Manual
Installation instructions
w = 55” - 71” y: 20° = 41.25“ - 51” 40° = 36.5“ - 46.5” 60° = 31“ - 41” z = 86.25” - w
(< 4”) (< 4”)
SLV/SLH Collectors Installation & Operation Manual
3. Place the assembled A-frame on the roof attachments (FIG. 4-68).
4. Slide the single groove attachment assembly (hex bolt, aluminum square plate, square disk, washer and nut) onto the top of every A-frame (FIG. 4-68).
5. Install the metal bracket hook and secure it with the single groove attachment assembly (see FIG. 4-68).
Figure 4-68 Install Single Groove Attachment Assembly
ASSEMBLE BOLT, SQUARE
DISK, GROOVED ALUMINUM
ATTACHMENT
6. Install diagonal supports by drilling four (4) 7mm holes. Measure and cut the supports to size (see FIG. 4-69).
Figure 4-69 Install Diagonal Supports
INSTALL DIAGONAL SUPPORTS (CUT TO FIT IF NECESSARY)
7. Slide the lowest collector into the metal bracket hook (FIG. 4-70).
8. Secure the collector to the A-frame using the single groove attachment assemblies (hex bolt, aluminum square plate, square disk, washer and nut) (FIG. 4-70).
Figure 4-70 Install Collector SECURE COLLECTOR TO A-FRAME USING THE SINGLE GROOVE ATTACHMENT ASSEMBLY
SLIDE LOWEST COLLECTOR INTO THE METAL BRACKET HOOK
INSTALL HYDRAULIC CONNECTION KIT
9. Install support sleeves into all four (4) hydraulic connections on each collector (FIG. 4-71).
Figure 4-71 Install Support Sleeves INSTALL SUPPORT SLEEVES INTO
WATER CONNECTIONS
Figure 4-72 Install Compression Ring and Union
10. Install the compression ring and the union of the Hydraulic Expansion Kit (FIG. 4-72).
INSTALL COMPRESSION RING AND UNION OF THE HYDRAULIC EXPANSION KIT ONTO THE OUTLET OF THE 2ND COLLECTOR
48
11. Install the Hydraulic Expansion Kit onto the outlet of the second collector (FIG. 4-70).
12. Install the top collector. Tighten the single groove attachment assemblies (FIG. 4-73).
4 Collector Installation
AND TIGHTEN SINGLE GROOVE ATTACHMENT
13. Tighten all hydraulic connections to complete the installation (FIG. 4-74).
Figure 4-74 Tighten Hydraulic Connections
TIGHTEN HYDRAULIC CONNECTIONS
NOTICE
49
SLV/SLH Collectors Installation & Operation Manual
Dimensions
SLV/SLH Collectors Type Tilt A B C SLV 20° 86.2 inches 27.2 inches 90.6 inches SLV 40° 86.2 inches 53.2 inches 86.2 inches SLV 60° 86.2 inches 73.2 inches 73.2 inches SLH 20° 48.1 inches 14.2 inches 53.2 inches SLH 40° 48.1 inches 27.2 inches 48.4 inches SLH 60° 48.1 inches 38.6 inches 42.9 inches
SLV/SLH Collectors Installation & Operation Manual
50
5 Hydraulic Connections Hydraulic connection kits The hydraulic connection kits are used to connect the collector to the main pipework. The hydraulic connections kits consist of two (2) flexible corrugated stainless steel pipe with insulation, sensor well, plug and support sleeves.
Hydraulic expansion kits
The hydraulic expansion kits are hydraulic connections between collectors in one array. The hydraulic expansion kits consist of two (2) nipples with compression rings and unions.
Note: Hydraulic connections and expansion kits are included with the substructure material.
Figure 5-1 Hydraulic Connection Details
All joints must be brazed if using copper pipe. Soldering is not acceptable. WARNING
Figure 5-2 Connection Diagram_SLV (vertical) Figure 5-3 Connection Diagram_SLH (horizontal)
SLV/SLH Collectors Installation & Operation Manual
5 Hydraulic Connections (continued)
Figure 5-4 Pressure Drop Chart - 1 Collector
0.268 0.34 0.268 0.94 0.537 0.95 0.537 1.61 0.866 1.63 0.866 2.21 1.155 2.86 1.155 3.68 1.444 4.81 1.444 5.75 1.733 7.48 1.733 8.46
SLV - 1 COLLECTOR SLH - 1 COLLECTOR
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
GPM
1 - SLV
1 - SLH
FE E
T O
F H
E A
D Flow (GPM) Flow (GPM) Pressure Drop (FT OF HEAD)Pressure Drop (FT OF HEAD)
Pressure drop charts up to 6 collectors
Figure 5-5 Pressure Drop Chart - 2 Collectors
Flow (GPM) Pressure Drop (FT OF HEAD) Flow (GPM) Pressure Drop (FT OF HEAD) 0.268 0.70 0.268 1.04 0.537 1.82 0.537 1.84 0.866 3.17 0.866 3.08 1.155 4.81 1.155 4.88 1.444 6.95 1.444 7.23 1.733 9.50 1.733 9.94
SLV - 2 COLLECTORS SLH - 2 COLLECTORS
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
GPM
D
51
NOTICE Recommended flow is .01 GPM per square foot of collector area in each array.
SLV/SLH Collectors Installation & Operation Manual
Figure 5-6 Pressure Drop Chart - 3 Collectors
Flow (GPM) Pressure Drop (FT OF HEAD) Flow (GPM) Pressure Drop (FT OF HEAD) 0.268 0.80 0.268 1.10 0.537 2.04 0.537 2.07 0.866 3.54 0.866 3.51 1.155 5.35 1.155 5.69 1.444 7.59 1.444 8.26 1.733 10.47 1.733 11.14
SLV - 3 COLLECTORS SLH - 3 COLLECTORS
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
10.00 11.00 12.00
GPM
Figure 5-7 Pressure Drop Chart - 4 Collectors
Flow (GPM) Pressure Drop (FT OF HEAD) Flow (GPM) Pressure Drop (FT OF HEAD) 0.268 0.90 0.268 1.17 0.537 2.26 0.537 2.31 0.866 3.92 0.866 3.98 1.155 5.87 1.155 6.39 1.444 8.23 1.444 9.30 1.733 11.48 1.733 12.58
SLV - 4 COLLECTORS SLH - 4 COLLECTORS
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
10.00 11.00 12.00 13.00
FE ET
O F
H EA
Figure 5-8 Pressure Drop Chart - 5 Collectors
Flow (GPM) Pressure Drop (FT OF HEAD) Flow (GPM) Pressure Drop (FT OF HEAD) 0.268 1.00 0.268 1.34 0.537 2.44 0.537 2.62 0.866 4.32 0.866 4.77 1.155 6.39 1.155 7.62 1.444 8.90 1.444 11.09 1.733 12.34 1.733 14.65
SLV - 5 COLLECTORS SLH - 5 COLLECTORS
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
10.00 11.00 12.00 13.00 14.00 15.00
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
GPM
Figure 5-9 Pressure Drop Chart - 6 Collectors
Flow (GPM) Pressure Drop (FT OF HEAD) Flow (GPM) Pressure Drop (FT OF HEAD) 0.268 1.12 0.268 1.51 0.537 2.68 0.537 3.02 0.866 4.73 0.866 5.61 1.155 6.97 1.155 9.03 1.444 9.58 1.444 12.83 1.733 13.22 1.733 17.18
SLV - 6 COLLECTORS SLH - 6 COLLECTORS
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
GPM
Start-up
6 System Start-up
Check/control water chemistry
Do not use petroleum-based cleaning or sealing compounds in the system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.
CAUTION
Test/replace freeze protection fluid
1. For systems using freeze protection fluids, follow fluid manufacturer’s instructions.
2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer’s instructions.
Freeze protection
1. Determine freeze protection fluid quantity using system water content, following fluid manufacturer’s instructions. Remember to include expansion tank water content.
2. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.
4. The freeze protection set points may be lowered when freeze protection fluid is used (see the Lochinvar Solar Differential Control Manual).
Glycol
Aqueous solutions of Dowfrost HD fluid are designed to provide freeze/burst and corrosion protection, as well as efficient heat transfer, in water-based, closed-loop heating and air-conditioning systems.
Dowfrost HD fluid has an operating temperature range of -50°F to 325°F; with fluid freeze protection to below -60°F and system burst protection to below -100°F. The fluid contains corrosion inhibitors that are specially formulated for HVAC systems to keep pipes free of corrosion without fouling.
Thermal protection
In heated water systems, a warning instruction must be provided by the operator near the expansion tank, if persons are endangered by excessive surface temperatures.
WARNING The expansion tank may be hot, ensure scalding does not occur.
WARNING Failure to heed these instructions, especially the safety instructions, can result in the destruc