Consolar EURO L20 User manual

MA401EN_IP_EUROL20AR_2019_11_29_il 1
EURO L20 In-roof Mounting System
for Plain Tile Roofing
●For roof pitch > 25°
●Weather proof integration with durable aluminium
cladding panels and aluminium skirting
●Pipe connections protected under upper cladding
sheets
The shown installation is for plain tile roofings with round-
ed tiles. Installation with classic slates generally is carried
out in the same way.
Fig. 1 Partial view of EURO roof integration with plain tile roofing.
Content
1. General Safety Notes . . . . . . . . . . . . . 2
1.1 Symbols . . . . . . . . . . . . . . . . . . . 2
1.2 Norms and Regulations . . . . . . . . . . . . 2
1.3 Qualification of the Installer . . . . . . . . . . 2
1.4 Intended Use and Application . . . . . . . . . 2
1.5 Notes on Proper Collocter Storage . . . . . . . 2
1.6 Pre-Installation Notes . . . . . . . . . . . . . 2
1.7 Recycling Note . . . . . . . . . . . . . . . . 3
2. Scope of Delivery . . . . . . . . . . . . . . . 2
2.1 Basic Set. . . . . . . . . . . . . . . . . . . 4
2.2 Extension Set. . . . . . . . . . . . . . . . . 5
3. Installation Dimensions . . . . . . . . . . . . 6
4. Installation . . . . . . . . . . . . . . . . . . 8
INSTALLATION INSTRUCTIONS

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1 General Safety Notes
1.1 Symbol
The following symbols are used throughout these instruc-
tions and must be adhered to
DANGER of possibly serious personal injury
WARNING against material damage
NOTE as additional information
1.2 Norms and Regulations
The standards and regulations applicable at the installa-
tion location must be adhered to.
●Make sure to observe country and territory regulations
related to roof works and roof sealing standards as well
as professional codes for plumbing work. The installa-
tion process must reflect the on-site conditions as well
as applicable rules, regulations and accident preven-
tion procedures. Appropriate work safety measures
must be observed (ropes, hooks, lines, scaffolding,
protection nets).
●Safety barriers to protect pedestrians against falling
parts must be set up.
●The dimensioning of the mounting system (number of
roof brackets etc.) should be specifically carried out for
each individual project, following the specified struc-
tural engineering standards and regulations.
●Prerequisite for the proper application always is a solid
mounting base that can accommodate the occurring
forces (weight, wind and snow loads).
●Especially the pipes in the lower parts of the building
must be connected electrically conductive, conforming
to standards. The collector installation must be profes-
sionally integrated with an existing or new lightning
protection system.
1.3 Qualification of the Installer
Setup, installation and proper commissioning of the solar
installation must be carried out by authorized profession-
als. Non-compliance renders the warranty void.
1.4 Intended Use and Application
Scope and Limitations of Application
The collector is intended for the application in solar ther-
mal installations for hot water preparation and space
heating support. As operating mediums water (attention
– risk of freezing!) or an appropriate water-glycol mixture
can be used in a closed circuit. Operational conditions
underrunning the dew point within the collector for pro-
longed periods are not permitted! This can occur for ex-
ample, when collectors are integrated in the brine circuit
of a heat pump.
Maintenance
For maintenance notes and additional information about
setup and operation of the collector field, please refer to
the technical information “Solar Thermal Systems”.
1.5 Notes on Proper Collector Storage
1.5.1 Proper Outdoor Storage of Collectors
●Remove protective film and lay down collectors with
glass pane up. Avoid direct ground contact (e.g. un-
derlay square timber). Avoid scratches on glass panes
by using spacers between collectors (e.g. wooden bat-
tens).
●When leaning collectors against walls or similar, use a
minimum inclination of 15° and apply spacers. Do not
use cardboard as under liner. If incorrectly stored, hu-
midity can enter the collectors through the air vents.
●Storing collectors in foil package may damage the
glass surface (see figure 2).
1.6 Pre-Installation Notes
Ensure technically correct roof structure
For roof integrated installation the space behind the col-
lector field has to be protected against uprising and ac-
cumulating humidity. Ensure that the roof is sufficiently
ventilated in the area of the in-roof collector field (see
“Installation Field” on page 6)
●Danger of open injuries when working with sharp
edged metal sheets and components!
●Risk of burns at collector connections as soon as uncov-
ered collector is exposed to the sun.
●Remove glass protection PE-LD film before commenc-
ing installation work!
●Do not subject the coollector connections to mechani-
cal loads or use as transportation handles. Specially de-
signed collector handles are available for this purpose.
●Keep a minimum distance between collectors and roof
structures such as chimneys, air vents, sky lights that
may release moist air. Otherwise there is a n increased
risk of excess humidity entering through the air vents
of the collector encasing.
Overheat Protection
For roof heating centrals and when 4 or more EURO col-
lectors with anti reflective glass are installed vertically, the
“Technical Information Solar Thermal Systems – Setup,
Commissioning and Maintenance” must be followed to
avoid damage to the solar circuit.
Ensure technically correct roof structure
For roof integrated installation the space behind the col-
lector field has to be protected against uprising and ac-
cumulating humidity. Ensure that the roof is sufficiently
ventilated in the area of the in-roof collector field (see
“Installation Field” on page 6)

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Fig. 2 Do not expose collector covered with protective film to rain.
Preventing frost Damage
After pressure testing and flushing, collectors cannot be
completely emptied. Make sure that no pure water re-
mains in collector during risk of frost!
1.7 Recycling Note
At the end of the long operational lifetime, the valuable
materials of the installation should be recycled in an envi-
ronmentally sound manner.
Fig. 3 WARNING! Collector connections heat up during solar irradia-
tion.
Fig. 4 Remove glass protection film before installing collector!

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2. Scope of Delivery
2.1 Basic Kit
Tab. 1 Scope of supply, basic set 192 001 57
Pos. Component Qty. Part no..
1 Flashing, top left 1 819 721 62
2 Flashing, top rights 1 819 721 64
3 Wooden support 2 819 920 46
4 Coll. connection hose 2 192 041 14
5 Collector interconnection hose 1 192 040 91
6 Foam rubber tape 3 819 450 20
7 Cellular rubber sealing tape 2 110 101 23
8 Collector fixing clip, top 4 190 102 15
9 Side panels (slate / plain tile) 28 819 720 99
10 Silicone T-profile 1819 450 10
11 Corner wedge, bottom left
(2parts) 1819 720 95 819 721 06
12 Corner wedge, bottom right
(2parts) 1819 720 98 819 721 07
13 Flashing, bottom left 1 819 720 96
14 Flashing, bottom right 1 819 720 97
15 Collector fixing clip, bottom 4 819 721 03
16 Metal clip, bottom 4 819 721 02
Table 1 continued
Felt nail (for no. 12) 35 188 53
Self tapping screws 4 x 35
(for no.’s 3 and 8) 26 819 501 86
Self tapping screws 5 x 120
(for no.. 3) 4819 501 88
Sheet metal screws 4.5 x 25
(for no.. 3) 4819 501 87
Silicone sealant 1 120 100 20
Fig. 5 Components basic kit

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2.2 Extension Set
Fig. 6 Components extension kit
Scope of supply, extension set 192 001 58
Pos. Component Quantity Part no.
1 Flashing sheet, top 1 819 721 63
2 Wooden support 1 819 920 46
3 Collector connection hose 1 192 040 91
4 Foam rubber tape 1 819 450 20
5 Cellular rubber tape 2 110 101 23
6 Collector fixing clip top 2 190 102 15
7Silicone T-profile 1 819 450 10
8 Flashing sheet, bottom 1 819 720 96
9 Collector fixing clip bottom 1 819 721 03
10 Metal clip bottom 1 819 721 02
Roof felt nails 10 188 53
Self tapping screws 4 x 35
mm (for no.’s 2 and 6) 12 819 501 86
Self tapping screws 5 x 120
mm (for no. 2) 2 819 501 88
Sheet metal screw 2 819 501 87
Sheet metal screw 4.5 x 25
(for no. 2 2

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3 Installation Field
To properly assure a durable installation, various prereq-
uisites must be fulfilled:
●For plain tile and similar roofings on roof battens a wa-
ter proof and diffusion resistant sarking (no vapor bar-
rier!) is required, with at least 24 mm strong counter
battens to assure proper backside venting (Fig. 8). If
the proper backside ventilation is not assured through
ridge or eaves, ventilations tiles have to be installed
horizontally above and below the collector field with a
spacing of approx. 90 cm.
●For classic slate roofings on wood boarding an undam-
aged water proof and diffusion resistant sarking has to
be laid. Below and above the collector field a roof vent
should be provided for approx. every 90 cm.
●Keep a minimum distance of one meter between col-
lector fields and roof structures that emit moist air, such
as chimneys, skylights, kitchen and air condition vents.
Otherwise there is a risk that additional moisture enters
the collectors through the ventilation openings in their
frames.
●At least three rows of roof tiles should be kept above
and below the collector field.
●The roof tile rows above the collector have to project
for at least 150 mm over the upper flashing sheet.
Procedure: For plain tile or similar roofing use the existing
roof battens as support construction. Affix the required
additional battens according to the dimensions in Fig. 7.
and Fig. 8.
For slate roofing without underlying roof battens install
the collector fixing clips and all other components directly
onto the base.
Ideally determine the installation field so that on one side
there will be a distance of approx. 35 mm between collec-
tors and roofing slates. On the other side cut tiles/slates to
size. For large roofing areas it is recommended to average
out the collector field.
Table 3Dimensions for Installation (mm)
No. of
collectors Collector field width Installation field width A
1 collector 1215 1285
2 collectors 2435 2505
3 collectors 3655 3725
4 collectors 4875 4945
Fig. 7 Dimensions of installation field and positions of installation battens in mm. Choose batten thickness based upon existing battens.
Additionally required battens are coloured grey (5 pieces); batten length ≥ A (width of installation field).

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Fig. 8 In-roof installation cross section (above) and transverse section (below).
1Roof batten, 2Counter battens, 3Sub membrane (lower delta sarking), 4Rafters, 5Vapor proof sarking, 6Backside ventilation space
Fig. 9 Serial connection of horizontally installation (max. 6 collectors).
Connection of more than 6 units by combining parallel and serial connection.
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1
2
3
4
5
Solar sensorSolar sensor

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4. Installation
Fig. 10 Installation tools: folding rule, drilling machine, Phillips-Bit PZ
2 and 3, open spanner sizes 16, 19, 24, hammer, cutter knife, silicone
gun (where required angle grinder with stone cutter)
Fig. 11 Align 2 lower collector fixing clips per collector with batten, fix
with self tapping screws 4 x 35 (max. 100 mm from collector edge and
300 mm from rafter) (1). Insert collectors with approx. 8 mm spacing (2).
Fig. 12 Insert silicone T-profile between collectors. Alternately push-
ing and pulling eases work. Then push collectors together until flush.
Fig. 13 Screw on upper collector fixing clip on both collector edges
with 2 self tapping screws 4 x 35 each, max 100 mm from collector
corner and max. 200 mm from the next rafter.
Fig. 14 Apply thin layer of silicone seal between wings of T-profile
and collector frame.
Fig. 15 Connect collectors. Slide collector connection hoses onto the
collector connections until they lock-in. Check proper fit by pulling
on the hose!

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Fig. 16 Connect collectors to solar circuit. Later check for leak tight-
ness! ATTENTION: Danger of burns at connections during solar irra-
diation!
Fig. 17 Pipe lead with sarking membrane: make a T-shape cut into
the sarking, lead through the connection hose and close cuts with ap-
propriate tape. Inside the roof connect the collector connection hose
(stainless steel, 18 mm) to the solar circuit, for example via double
socket or compression ring coupling.
Fig. 18 Slip rubber seal over cable, insert solar sensor into sensor
sleeve; close opening with rubber seal and lead cable through roof.
Fig. 19 Position wooden support along collector and fasten with
4x35 and 5 x 120 self tapping screws.
Fig. 20 Adjust roof tiles/slates below collectors; fix with self tapping
screws.
Fig. 21 Fix metal clips for lower flashing sheet (1) and fold onto tile
or slate (2).

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Fig. 24 Cut off sheeting above the batten (1) and then afix each side
panel with roofing felt nails on roof battens (2).
Fig. 25 Along the side sheetings roof tiles may have to be cut to size.
If necessary holes have to be drilled through the tiles to afix them on
the battens.
Fig. 26 Position the following tiles as in Fig. 22 and Fig. 23, align at
upper edge of following batten, afix with nail.
Fig. 27 Cover each panel properly with a tile or slate. Repeat the same
procedure from bottom to top.
Fig. 23 Fold standing up sheet flat onto roofing.Fig. 22 Insert the two pieces of the corner wedge into deeper groove
at the collector (1 + 2) and slide together (3)

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Fig. 28 Insert lower flashing sheets. Fig. 29 Fix lower flashings with metal sheet clips.
Fig. 30 Affix cellular rubber strip onto upper edge of collector frame. Fig. 31 Interlock upper flashing sheets into one another at the
crimped edges; use rear ear for fixing sheets against sliding (details
above).
Fig. 32 Lay upper flashing sheet in place and push sheet groove over
collector lip.
Fig. 33 Push upper flashing sheets to collector corners (1) nail to
battens (2) and adjust standing up sheet at the corners as described
before.

Subject to modifications, errors excepted · ©Consolar Solare Energiesysteme GmbH · www consolar de
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Fig. 35 Secure each flashing sheet with two central sheet metal
screws.
Abb. 36 Readily installed EURO roof integration on plain tile roof.
Fig. 34 Affix black foam rubber strip along the upper edge.