Consolar TUBO II C User manual

TECHNISCHE DOKUMENTATION
Application
• Solar heating support and water heating
• Process heat
• Single and multi-family houses
• On-roof installation
• Flat roof / façade installation (see other document)
Advantage
• Very high efficiency and yields in the winter half-year
• Low weight with 18 kg (T) and 18 kg (C)
• Modular system: needs-based fields through small
modules that can be optically connected to a field
• 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
TUBO II C, TUBO II T
On-roof installation
TDMA721EN_TUBOII_on-roof_2018_02_01_2018_03_14_obps

2
Content
1 Key to symbols and safety instructions . 3
1.1 Key to symbols ....................................................3
1.1.1 Warnings ...........................................................3
1.1.2 Important information ..........................................3
1.2 General safety instructions ...................................3
2 Information about the collector and its
accessories ............................................. 3
2.1 Roof connection ...................................................3
2.2 Collector .............................................................4
2.2.1 Technical data .....................................................5
2.3 Product data for energy consumption ....................6
2.4 Determined use ...................................................6
2.5 Accessories .........................................................7
2.6 EU Declaration of Conformity ...............................7
2.7 Components and technical documentation .............7
2.8 Scope of delivery .................................................7
2.8.1 Collector installation set .......................................8
2.8.2 Connection set .....................................................9
2.8.3 Collector with interconnection set ..........................9
3 Regulations ......................................... 10
3.1 Validity of regulations ........................................10
3.2 Standards, regulations, directives .......................10
4 Transport ............................................. 10
5 Before installation ............................... 11
5.1 General Notes ...................................................11
5.2 Collector layout .................................................11
5.3 Space required on roof ......................................13
5.4 Lightning protection ...........................................13
5.5 Required tools and materials ..............................13
5.6 Installation sequence ..........................................13
6 Installing the roof connection ................ 14
6.1 Determining clearances ......................................14
6.2 Mounting roof hook as rafter anchor ...................15
6.3 Fitting the roof hooks with roof tiles .....................16
6.4 Fitting special roof hooks for slate/shingles ..........17
6.5 Fitting double ended screws on sheet metal roofs .17
6.6 Fitting double ended screws on corrugated roofs ..17
7 Fitting the profile rails........................... 18
7.1 Install the profile rails vertically ...........................18
7.2 Waagerechte Profilschienen montieren ................19
7.3 Fitting the anti-slip protectors ..............................20
8 Installing the collectors ......................... 20
8.1 Collector installation ..........................................20
8.1.1 Fit one-sided collector clamps on the left ..............20
8.1.2 Placing the first collector on the profile rails .........21
8.1.3 Inserting a double sided collector clamp ..............21
8.1.4 Fitting the second collector .................................21
8.1.5 Fitting single sided collector clamps on the right hand
side .................................................................22
8.2 Prepare the collector temperature sensor for connec-
tion .................................................................22
9 Hydraulic connection ........................... 23
10 Final steps ........................................... 24
10.1 Flushing, venting and leak testing .......................24
10.2 Checking the installation ....................................24
10.3 Install intermediate reflector (accessories) ............24
10.4 Installing the end cap and intermediate panel ......25
10.5 Insulating the connection lines and pipework .......25
10.6 Removing the collector film .................................25
11 Cleaning the collectors .......................... 26
12 Environmental protection and disposal.. 26
13 Maintenance/inspection........................ 26

3
Key to symbols and safety instructions
1 Key to symbols and safety
instructions
1.1 Key to symbols
1.1.1 Warnings
Warnings in this document are identified by a
warning triangle printed against a grey back-
ground.
Keywords at the start of a warning indicate the
type and seriousness of the ensuing risk if mea-
sures to prevent the risk are not taken.
The following keywords are defined and can be used in this
document:
• NOTICE indicates a situation that could result in dama-
ge to property or equipment.
• CAUTION indicates a situation that could result in
minor to medium injury.
• WARNING indicates a situation that could result in
severe injury or death.
• DANGER indicates a situation that will result in severe
injury or death.
1.1.2 Important information
This symbol indicates important information
where there is no risk to people or property.
1.2 General safety instructions
These installation instructions are intended for gas fitters
and plumbers.
> Read the installation instructions (collector, solar pump
station, solar controller, etc.) before installation.
> Observe safety instructions and warnings.
> Observe national and regional regulations, technical
rules and guidelines.
> Keep a record of any work carried out.
Determined use
The collectors are designed to produce heat in solar thermal
systems. The installation set is exclusively designed for the
safe installation of collectors.
> Only operate collectors in fail-safe sealed unvented
solar systems (exclusion of oxygen).
> Only operate collectors with suitable solar controllers.
> Do not place objects on top of the collector.
Collector storage
The collectors and the installation material may cause burns
when exposed to solar radiation.
> Protect the collectors and installation material from solar
exposure.
> Store the collectors in dry conditions; if stored outside,
use a rain cover.
> Do not stand on the collectors.
Work on the roof
There is a danger of falling when working on the roof if
measures are not taken to prevent accidents.
> If there is not any independent anti-fall safety device,
wear personal protective equipment or safety equip-
ment.
> Observe accident prevention regulations.
Load bearing capacity of the roof
> Only install collectors on roofs with sufficient load
bearing capacity.
> If in doubt, consult a structural engineer and/or roofer.
Handover to the user
When handing over the solar system, explain the operating
conditions to the user.
> Explain the operation—with particular emphasis on all
safety-related actions.
> Explain that conversions and repairs must only be car-
ried 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
to the user for safekeeping. This involves:
- Keeping the instructions in a visible place, protected
from heat, water and dust.
- Passing them on to subsequent owners/users.
2 Information about the collec-
tor and its accessories
The vacuum tube collectors TUBO II C (with CPC-reflector)
and T (without CPC-reflector) are referred to as „collectors“
for short in these instructions. Pantiles, Roman tiles, stone
tiles etc. will all be referred to as roof tiles.
2.1 Roof connection
The graphics in these instructions use the example of a roof
covered with roof tiles and the roof connection for this type
of roof. If the installation varies for other types of roofs, this
is indicated in the text.

Key to symbols and safety instructions
4
Type of roof Roof connection
Roman tiles
Sheet metal, corrugated sheets
Slate/shingle/plain tile
Tab. 1 Roof connection
2.2 Collector
The vacuum tube collector has six twin-wall glass tubes with
vacuuminsulated interiors. A temperature sensor is installed
on each collector which is accessible after the cover [6] is
removed.
TUBO C (with
reflector)
TUBO T (without
reflector)
Collector angle greater than 24° less than 25°
Tab. 2 Recommended use
6720816962-03.1ST
4
5
6
23
1
Fig. 1 TUBO II C
[1] CPC (not in TUBO II T); [2] Pipe register; [3]Vacuum tube;
[4] Collector connection, flow (hot, red transport protection);
[5] Collector connection, return (cold, blue transport protec-
tion); [6] Access to the collector temperature sensor
6720816962-06.1ST
2
3
5
4
1
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

5
Key to symbols and safety instructions
Technical data
TUBO C TUBO T
Certificates
(CE marking, Solar Keymark)
Length 1947mm
Width 624mm
Height 85mm
Collector connection (nominal
diameter) DN15
Absorber capacity (VFl) 0,851
Total collector area (gross area,
AGr)1,22m2
Absorber area (net area, AAb) 1,07m20,39m2
Maximum heat output (Pmax) at
1000W/m2650W1) 362W
Aperture area (area on which
the usable sunlight falls, AAp)0,98m2 2) 0,46 m2
Net weight excluding pa-
ckaging (m) 18kg
permissible collector operating
pressure (pmax)10bar
permissible collector angle 25-90° 0-90°
Tab. 3 Technische Daten
1) Additional 66 W per intermediate reflector
2) Additional 0.1 m2between two collectors (accessory: intermedi-
ate reflector)
85
624
1947
6 720 818 573-03.1T
Fig. 3 Collector dimension
mbar
V [l/h] 6720816963-40.1 ST
0
50
100
150
200
250
300
350
400
010203040506
07
0
Fig. 4 Collector pressure drop (measured with heat transfer medium
LS at 50 °C)
Product data for energy consumption
The following product data satisfy the requirements of
the EU Regulations No. 811/2013 and No. 812/2013,
813/2013 and 814/ 2013 supplementing Directive
2010/30/EU.
Product data Symbol Unit TUBO C TUBO T
Collector
aperture area Asol m20,98 0,46
Collector
efficiency
(∆T=40K)
col %61 64
Zero-loss
efficiency 01) 0,663 0,787
First-order
coefficient a11) W/ (m2K) 0,782 2,99
Second-order
coefficient a21) W/ (m2K2)0,012 0,015
Incidence
Angle Mo-
difier
IAM 1,00 1,27
Tab. 4 Performance data
1) Reference: Aperture area
2.3 Determined use
The installation set is exclusively designed for the safe
mounting of collectors.
> Never modify components.
Collector protection
> To protect the collectors against damage through frost
and corrosion, operate them with LS solar heat transfer
medium.

Key to symbols and safety instructions
6
> Only remove the protective film from the collector after
commissioning.
> Commission the thermal solar system within four weeks
after installation at least.
Permissible types of roof
These instructions describe the collector installation on
pitched roofs with roof tiles, plain tiles, slate/shingle, sheet
metal and corrugated sheets.
> Only use the installation set on such roofs.
Permissible roof slopes (see Tab. 2, page4)
Only install the installation set on the following roofs:
- Roof hook: Permissible roof slope 25° to 65°
- Double ended screws: Permissible roof slope 5° to 65°
> For installation on roofs with a slope of less than 25°,
have a roofer ensure that the roof is watertight.
Installation above walkways
Should the glass tubes be shattered, there is a risk of injury
through glass splinters if persons are below the collector
array.
> Avoid installation above walkways.
Permissible loads
> Only install collectors in locations with lower values than
those shown in the following. If needed, seek the advice
of a structural engineer.
The installation set is suitable for the following maximum
loads:
• maximum snow load on the floor after DIN EN 1991-1-
3: 2.0 kN/m²
• maximum wind speed to corresponding to DIN EN
1991-1 -4 of up to 129 km/h (corresponding to a
backpressure of 0.8 kN/m2)
> To determine the maximum wind speed, take into ac-
count the following factors:
- Location of the thermal solar system
- Geographical height of the terrain
- Topography (terrain/buildings)
- Height of building
The maximum snow load is calculated using regional zones
(snow load zones) and the ground level elevation.
> Find out the local snow load (see relevant local data).
Prevent an accumulation of snow above the collector:
> Install a snow guard above the collector (maintain a
clearance of no more than 1 m between the collector
and the snow guard).
-or-
> Regularly clear snow build-up.
Other applicable instructions and important information
The installation and maintenance instructions for the solar
pump station include vital information regarding the use of
vacuum tube collectors in a solar thermal system. Observe
particularly the information on the following subjects:
• Never braze pipework near the collectors.
• If the system is used for central heating backup or
covers more than 60 % of the DHW demand, install an
intermediate vessel upstream of the expansion vessel.
• Install the expansion vessel (EV) with a tee 20-30 cm
above the solar pump station in the return.
• Flush and fill the system with LS solar heat transfer me-
dium under pressure (never use water, as the collectors
cannot be drained). Consequently, there is no need for
an air vent valve above the roof.
• Adjust the following values according to the installation
and maintenance instructions of the solar pump station:
- Pre-charge pressure for the expansion vessel.
- Operating pressure
- Flow rate.
• The clearance between the solar pump station (expan-
sion vessel connection) and the bottom edge of the
collector array must be at least 2 m.
• The minimum pipe length (single length) between the
solar pump station (expansion vessel connection) and
the collector array must be at least 10 m.
2.4 Accessories
The technical and specification brochure includes a concur-
rent, comprehensive overview.
2.5 EU Declaration of Conformity
The design and operation of the collectors conform to the
European Directives and supplementary national require-
ments. Compliance is demonstrated by the CE marking.
The Declaration of Conformity can be requested from the
manufacturer (see the back cover for the address).
Components and technical documentation
A thermal solar system is designed to heat domestic hot
water (DHW) and can also provide central heating backup
where required. It is made up of various components which
also include installation instructions. Further instructions
may be found with the accessories.

7
Key to symbols and safety instructions
6720816962-05.1ST
4
3
1
2
Fig. 5 Components of a solar system
[1] Collectors; [2] Solar pump station with expansion vessel,
temperature and safety equipment; [3] Solar cylinder; [4] Solar
controller
2.6 Scope of delivery
> Check that the delivered material is complete and
undamaged.
2.6.1 Collector installation set
6720816962-04.1ST
7
1
3
2 4
5
6
8
Fig. 6 Installation set for 4 collectors (gray: Installation set, expansion for 2 collectors)

Key to symbols and safety instructions
8
No. Component Installation set, standard version1) for Installation set, expansion
for
Roof connection installation
set for
1 collector 2 collectors 3 collectors 2 collectors 3 collectors 2 collectors2) 3 collectors
1Single-side collec-
tor clamp 4 4 4 - - - -
2 M8 × 25 screw 8 8 12 8 12 - -
3Double-sided
collector clamp - 2 4 4 6 - -
4Horizontal profile
rail3) 2 2 2 2 2 - -
5Vertical profile rail
1704 mm 2 2 3 2 3 - -
6 Roof hook4) - - - - - 4 6
7 Profile rail joiner - - - 2 2 - -
8 Anti-slip protector 2 4 6 4 6 - -
Tab. 5 Number of components per set
1) Per collector row
2) And for 1 collector
3) Für 1 collector: 626mm lang, für 2 Kollektoren: 1254mm lang, für 3 Kollektoren: 1874 mm lang
4) Installation sets for other types of roof are described in chapter 6, page13.
2.6.2 Connection set
6720816962-02.1ST
1
9
10
2
3
56
7
4
8
11
Fig. 7 1 on-roof connection set and 2 interconnection sets

9
Regulations
No. Connection set for 1 row of collectors Qty
1 Connector pipe (insulation not shown) 2
2 Hydraulic plug-in connector 2
3 Clamp 4
4Installation and maintenance instruc-
tions 1
5 Cap 2
6 Cover (1 x left, 1 x right) 2
7 Cable tie 5
8 5 mm Allen key 1
Tab. 6 Connection set
2.6.3 Collector with interconnection set
6720816962-01.1ST
910
11
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. 7 Individual parts in the collector packaging
3 Regulations
3.1 Validity of regulations
> Observe updated regulations or supplements. These
regulations also apply at the time of installation.
3.2 Standards, regulations, directives
Observe all standards and guidelines applicable to the
installation and operation of the system in your country and
region.
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 Part 1-4: Effects on structures
• Connection of thermal solar systems:
- EN 12976: Thermal solar systems and components
(pre-assembled systems)
- EN 12977: Thermal solar systems and components
(custom built systems)
- DIN 1988: Technical Regulations for Drinking Water
Installations (TRWI)
• Electrical connection:
- DIN EN 62305 Part 3 / VDE 0185-305-3: Protection
against lightning, injury and structural damage
1) VOB: German Construction Contract Procedures, Part C: General
technical specifications in construction contracts (ATV)
4 Transport
DANGER: Risk of life by falling from
roof!
> Never use a ladder to move components to
the roof because the installation material
and collectors are heavy and difficult to
handle.
> Whilst working on the roof, take all necessa-
ry precautions against a possible fall.
> If there are no general anti-fall safety
devices available, wear personal protective
equipment.

Before installation
10
WARNING: Risk of injury through
falling parts!
> During transport, secure the collectors and
installation materials to prevent them falling.
WARNING: Risk of injury through
glass splinters.
> When handling collectors, always wear
safety gloves and goggles.
The collector transport protection contains im-
portant components (see Fig. 8, page9).
> Only remove the transport packaging after the collector
has been installed.
> Dispose of shipping packaging by environmentally
responsible means.
6720816962-43.1ST
Fig. 9 Use two people to carry the collector
NOTICE: Collector damage from im-
proper transport.
> Do not connect any straps, belts, etc. to the
collector connections.
> To make it easier to transport the collectors and the in-
stallation materials, the following assembly aids, which
have sufficient loadbearing capacity, can be used:
- Lifting belt
- Roofing ladder or equipment for sweeping chimneys
- Lean-to lift
- Scaffolding
5 Before installation
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.
> Protect the collector and installation material
from solar exposure.
We recommend that you engage the services of
a roofing contractor, as they are experienced in
working on roofs and will be aware of the risk
of falling.
> Obtain information about on-site conditions and local
regulations.
> Arrange collectors in the optimal position on the roof.
For this, pay particular attention to the following:
- Take the space required on the roof into account (see
chapter 5.3).
- Align the collector array facing as close to south as
possible (see Fig. 10).
- Align the collector array so that it is in line with win-
dows, doors etc. (see Fig. 10).
- Avoid potential shading (see Fig. 11).
- Observe the hydraulic connection to the pipework (see
chapter 5.2).
N
S
W
6720816962-08.1ST
Fig. 10 Aligning collector array
> Prevent shading of the collector array through adjacent
buildings, trees etc.

11
Before installation
6720816962.07-1.ST
Fig. 11 Avoid shading
5.2 Collector layout
Refer to the technical guide for stores and controller for
detailed information on designing the system hydraulics
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.
6720816962-09.1ST
3
1
2
Fig. 12 Permissible layout and orientation
[1] Collector temperature sensor always in the collector to
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)
6720816962-10.1ST
Fig. 13 Maximum of 14 collectors, connection on the same side, right
or left (1 row)
6720816962-27.1ST
Fig. 14 Maximum of 14 collectors, connection on alternate sides
(1row)
6720816962-11.1ST
Fig. 15 Maximum of 14 collectors, connection on the same side, right
or left (2 rows)
6720816962-12.1ST
Fig. 16 Maximum of 14 collectors, connection on the same side, right
or left (2 rows)

Before installation
12
6720816962-13.1ST
1
Fig. 17 Maximum of 14 collectors per row (connected in parallel
according to Tichelmann)
[1] Shut-off valve for pressure (separate for each collector row)
6720816962-28.1ST
1
Fig. 18 Maximum of 14 collectors per row (connected in parallel)
[1] Control valve for hydraulic balancing (separate for each
collector row) and shut-off valve for pressure filling
6720816962-29.1ST
1
Fig. 19 Maximum of 14 collectors per individual field (connected in
parallel)
[1] Control valve for hydraulic balancing (separate for each
field) and shut-off valve for pressure filling
5.3 Space required on roof
DANGER: Risk to life through collec-
tors that cannot withstand high winds
and peak suction forces!
> Maintain the minimum clearance to the edge
of the roof (dim. a).
aa = b
10
a =
10
b
h
h
a
a
6720816962.15-1.ST
E
a
C
Fig. 20 Dimension a in accordance with DIN EN 1991-1-4
• Dim. a: Either formula can be used. The lower value
can be applied.
• Dim. A: see Tab. 8
• Dim. B: 2 m
• Dim. C: At least two rows of tiles to ridge or chimney.
• Dim. D: At least 0.5 m for the flow on the right or left
of the collector array.
• Dim. E: Equals 1.81 m and is the minimum clearance
from the upper edge of the collector to the lower profile
rail, which is installed first.
No. of collectors Dim. A No. of collectors Dim. A
1 0,73m 8 5,13m
2 1,36m 9 5,76m
3 1,99m 10 6,39m
4 2,62m 11 7,02m
5 3,25m 12 7,65m
6 3,87m 13 8,28m
7 4,50m 14 8,91m
Tab. 8 Necessary room
5.4 Lightning protection
> Check regional regulations as to whether a lightning
protection system is required.
Lightning protection is frequently required for buildings
higher than 20 m, for example.

13
Before installation
> Have a qualified electrician install the lightning protec-
tion.
> If a lightning protection system is installed, check whe-
ther the thermal solar system is included in this system.
5.5 Required tools and materials
• 27 and 30 mm open-ended spanner for connecting the
pipework
• 19 mm open-ended spanner for double ended screws
• Screwdriver with Torx bit T10
• Ø 6 mm wood drill bit Ø and 13 mm metal drill bit for
double ended screws
• Angle grinder for plain tiled roofs
• Level
• Plumb line
• Ventilation tile or aerial outlets
• Material for pipe insulation
5.6 Installation sequence
> Determine the clearances for roof connections.
> Fit the roof connections.
> Install the profile rails vertical or horizontal.
> Fitting anti-slip protectors.
> Fitting the collector clamp.
> Install the collectors and prepare the collector tempera-
ture sensor.
> Connect the pipework to the collectors.
> Install the intermediate panel.
6 Installing the roof connection
DANGER: Risk to life by falling from
roof!
> Whilst working on the roof, take all necessa-
ry precautions against a possible fall.
> If there are no general anti-fall safety
devices available, wear personal protective
equipment.
Subject to the type of roof, the roof connection is made with
different roof hooks or with double ended screws.
> Use a roofing ladder to provide a better footing on
roofs and/or to slide up individual roof tiles.
> Remove and replace broken roof tiles, shingles, roofing
sheets etc.
6.1 Determining clearances
NOTICE: Damage to the roof from
overloaded roof tiles.
> At least one unloaded roof tile must be
between two roof hooks.
On roofs with roof tiles, the tile valleys, and on
roofs with corrugated sheets, the corrugation
peaks, determine the actual clearance between
the roof hooks/double ended screws.
> For the indicated dimension ranges, always use the
greatest possible clearance for the roof connec-
tion.
> Determine the roof hook positions and transfer them to
the roof (see Fig. 22).
6720816962-34.1ST
Fig. 21 At least one unloaded roof tile between two sequential roof
hooks

Before installation
14
6720816962-14.1ST
W
300-569 686-1197
G1 G2 G3
62-572
G2 E2 (E3)
593-968 593-968
G3
593-968 593-968
E2 (E3)
686-1197 686-1197 686-1197
[mm]
W
1140-1520
1097-1597
1137-1557
62-572
1260 1880
(E3: 593-968) (E3: 593-968) (E3: 593-968) (E3: 593-968)
Fig. 22 Clearances between roof connections (roof hook, special roof hooks or double ended screw)
G1 Standard version for 1 collector; G2 Standard version for 2 collectors; G3 Standard version for 3 collectors; E2 Expansion
for 2 collectors; E3 Expansion for 3 collectors
6.2 Mounting roof hook as rafter anchor
Fig. 23 Roof hook
> The roof hooks can be transferred to three heights and
must then be tightened with the screw. [1.]
> Determine the roof hook positions in vertical direction.
Set horizontal clearances according to Fig. 22 in regu-
lar intervals.
6720813331-02.1ST
16 Nm
16 Nm
1.
2. 1.
2.
Fig. 24 Moving the roof hook

15
Before installation
1947
6720813331-08.1ST
114 0 -
1520
[mm]TUBO II C
W
W
Fig. 25 Vertical alignment of the roof hooks
> If required, attach sufficiently viable boards/planks
(minimum thickness: 30 mm) to the rafter. If necessary,
remove counter batten in this area.
> Fit the bracket in the valley of the tile so that when
loaded it doesn‘t contact the tile.
6720813331-01.1ST
> 5 mm
a
270 280 290 300 310 320 330 340 350 360 370 380 390260
a [mm]
Fig. 26 Fasten roof hooks
> With rafters larger than 60 x 100 mm, the roof hook
can be mounted directly onto the rafter. Pre-drill rafter
using 5 mm drill. (See Fig. 27)
Fig. 27
6720813331-07.1ST
5 mm
8x90 DIN EN 14592
> 60x100 mm
Fastening of the roof hook with 8 x 90 DIN EN 14592
> If this is not possible, a board with a thickness of min.
5 cm can be screwed onto two rafters as indicated in
Fig. 28. Hereby the roof hook can be moved to the left
or right side of the rafter. In this case the rafters must be
capable of bearing a load. Consult a structural engineer
in case of doubt.
Fig. 28
6720813331-09.1ST
> 5 cm
3 mm
5x50 DIN EN 14592
Fastening of the roof hook with 5 x 50 DIN EN 14592
6.3 Fitting the roof hooks with roof tiles
WARNING: System damage through
subsequent loosening of the long nuts
on the roof hooks.
When the nut is tightened, a lock is activated.
> If the long nut is undone more than once,
secure it on site (such as with suitable adhe-
sive).

Before installation
16
WARNING: System damage through
breaking roof hooks.
> Relocate the bottom part of the roof hook to
the top hole.
NOTICE: Unprofessional work may
lead to the roof leaking.
> Consult a roofer for advice and assistance.
> Relocate the bottom part of roof hook [1] with a screw
in the top hole [2]. Do not yet tighten the nut.
6720640298-01.1ST
1
3
2
< 35
Fig. 29 Preparing roof hook
[1] Bottom part of roof hook; [2] Use the top hole; [3] Trim if
required
> Where required, secure boards/planks with adequate
load-bearing capacity to the rafters [3]. Where requi-
red, remove counter battens from this area.
NOTICE: Roof leaks through incorrect-
ly positioned roof hooks.
> Position the roof hook centrally on the roof
tile. The bottom part then lies on the rafter
(boards/planks).
> Tighten nut [1] when the serrated washer [2] grips the
teeth of the bottom part of the roof hook.
> Secure the lower part of the roof hook with three suitab-
le on-site screws.
6720640298-32.1ST
2
1
3
> 3 mm
Fig. 30 Fit the roof hooks
> Trim adjacent plain tiles (dotted line [1]).
1
6720640298-30.1ST
Fig. 31 Cutting plain tiles to size
6.4 Fitting special roof hooks for slate/shingles
NOTICE: Fitting special roof hooks for
slate/shingles.
> Have a qualified roofer carry out the
installation on slate/shingle roofs.
> To ensure a watertight installation, insert a plate on site
[3] underneath the special roof hook.
> Fit the special roof hook at the front with gaskets [2]
and screw [1].
> Adequately secure the special roof hook at the back on
the roof substrate.

17
Before installation
3
41
2
6720640298.20-2.ST
Fig. 32 Example sealing technique
[1] Screw; [2] Gaskets (on-site); [3] Plate (on-site); [4] Fitted
special roof hook
6.5 Fitting double ended screws on sheet metal roofs
NOTICE: Unprofessional work may
lead to the roof leaking.
> Have a qualified roofer carry out the instal-
lation on sheet metal roofs.
> On site, solder sleeves to the sheet metal roofing materi-
al for the double ended screws.
This ensures that the roof is watertight.
The double ended screws are fitted in a similar
way to the installation described for corrugated
roofs (see chapter 6.6, page17).
6720816962.39-1.ST
1
2
3
4
5
6
< 105 mm
Fig. 33 Fit the post screws
[1] Support block; [2] M12 nut; [3] Sealing washer; [4] M12
double ended screw; [5] Sleeve (on-site); [6] Washer
6.6 Fitting double ended screws on corrugated roofs
DANGER: Risk to life through brea-
thing in fibres containing asbestos!
> Observe local regulations on handling of
asbestos.
> Wear personal protective equipment (e.g.
breathing apparatus).
NOTICE: System damage through a
substructure with inadequate load
bearing capacity.
> The double ended screws require support
timbers of at least 40 × 40 mm.
We recommend making a drilling template to
ensure accurate vertical drilling.
63043965.23-1.SD
Fig. 34 Creating a drilling template
> With a Ø 13 mm metal drill bit, drill through the peaks
of the corrugations. However, do not drill into the timber
below.
> With a Ø 6 mm wood bit, drill absolutely vertically
through the drilling template [1] and substructure.
6720640298.10-1.ST
6 mm
13 mm
1.
2.
90°
1
Fig. 35 Pre-drilling

Before installation
18
> Turn the pre-assembled double ended screw 19 mm
with an openended spanner until dimension Z (Tab. 9)
is reached (see Fig. 36).
NOTICE: Leaky roof from damaged
washer.
> Only screw the nut over the washer hand-
tight onto the washer.
> Tighten nut [2] until the washer [4] makes full contact
with the corrugated sheet.
Y
Z
0 mm
6720816962.40-1.ST
19
1
2
3
5
4
Fig. 36 Fitted double ended screw with retaining block
[1] Support block; [2] M12 nut; [3] Washer; [4] Sealing
washer; [5] M12 double ended screw
Corrugation height, dim. Y dim. Z
35mm 70mm
40mm 65mm
45mm 60mm
50mm 55mm
55mm 50mm
60mm 45mm
Tab. 9 Dimensions
7 Fitting the profile rails
The profile rails must be installed at one height.
> If necessary, adjust the height between the roof hooks
and profile rails.
6720816962-44.1ST
Fig. 37 Check the uniform height of the roof hooks
7.1 Install the profile rails vertically
> Select appropriate slots, and connect the profile rail
with a sliding nut to the roof hook.
> Tighten the screw after aligning the profile rail.
6720816962-16.1ST
Fig. 38 Fastening profile rails to the roof hook
6720816962-41.1ST
Fig. 39 With a support block: Fastening the profile rail with 2 screws

19
Before installation
6720816962-30.1ST
Fig. 40 Precisely align the profile rails
7.2 Fit horizontal profile rails
If there are more than 3 collectors, you need to connect the
profile rails.
> Push the profile rails as far as they will go into the plug-
in connector.
> To lock, tighten both fitted threaded pins in the plug-in
connector using a SW 5 spanner.
6720816962-19.1ST
Fig. 41 Connecting profile rails
It is important for the subsequent collector
installation that the profile rails are accurate-
ly aligned. Tighten the screws only following
alignment.
> Screw the horizontal profile rails with a 5 mm Allen key
and screw M8 onto the vertical profile rails.
6720816962-17.1ST
Fig. 42 Connecting profile rails with screw and rivet net
> Align sides of the upper and lower profile rails with
each other.
> 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.
6720816962-31.1ST
90°
90°
Fig. 43 Aligning the profile rails
7.3 Fitting the anti-slip protectors
Only use the slots marked with the arrows to fit the anti-slip
protectors.
> Push the anti-slip protector over the profile rail and let it
click into slot.
6720816962-33.1ST
clic k
Fig. 44 Fitting anti-slip protectors (white triangles = alternative
positions)

Installing the collectors
20
8 Installing the collectors
DANGER: Risk to life by falling from
roof!
> The installation on the roof must be perfor-
med 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
handling and installation.
> After completing installation, check that the
installation set and collectors are securely
positioned.
NOTICE: Lack of seal from damaged
O-rings!
> Do not use mineral oil-containing lubricants
(such as thread sealing compound). The coll-
ector connections are sufficiently lubricated
at the plant.
8.1 Collector installation
NOTICE: Collector damage from ex-
cessive load.
Do not stand on the collector.
> Use a roofing ladder to provide a better
footing on roofs and/or to slide up individu-
al roof tiles.
6720816962-46.1ST
Fig. 45 Do not stand on the collector!
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11
concerning the collector layout.
8.1.1 Fit one-sided collector clamps on the left
Fit the single sided collector clamp on the oppo-
site side only after the final collector has been
installed.
> Push the collector clamp into the profile rail and let it
click into the slot.
6720816962-18.1
click
click
Fig. 46 Fitting the collector clamp
8.1.2 Placing the first collector on the profile rails
WARNING: Risk of injury through
falling collectors.
> Ensure that the collector profile engages in
the antislip protectors.
> Remove the top and bottom packaging cover.
> Remove the interconnection set.
6720816962-45.1ST
Fig. 47 Remove the packaging cover
> Place the collector onto the profile rails and allow it to
slide into the anti-slip protectors.