Grant Solar Thermal Assembly Instructions

Solar Thermal
Grant Solar Thermal Systems
On-Roof, Flat Roof and In-Roof Systems
Installation & User Instructions
Part No. DOC 73. Rev. 02 June 2010
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2
System Options
System Options
On-Roof In-RoofFlat Roof
Portrait (side by side)
Portrait (side by side) Landscape (one above other)
Portrait (one above other)
Landscape (side by side)
Grant Aurora
with high quality Silver finish
anodized frame, this
contemporary look is a stylish
feature to accentuate the
property and looks great on
dark roof coverings such as
slate.
Grant solar collectors are slender in appearance and are extremely durable with an extruded Aluminium frame and 4mm thick
low iron glass.
Grant Sahara
with a Bronze anodized frame,
this blends with most
domestic roof types, providing
an aesthetically pleasing
appearance.
Landscape (one above other)
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3
Contents
Contents
Installation Instructions
1General 4
1.1 Product description 4
1.2 Package contents 4
1.3 Organisation of the installation instructions 4
1.4 Safety instructions and symbols 4
1.5 Safekeeping of installation instructions 4
1.6 Installation 4
1.7 Equipment and materials to be provided 5
1.8 Tools required 5
1.9 Standards and guidelines 6
2Package Contents 7
2.1 Standard installation kits and roof fixings
(Roof-mounted system only) 7
3Dimensions & Fixing Intervals 8
3.1 On-Roof system 8
3.2 Flat Roof system 9
3.3 In-Roof systems 10
4On-Roof System Installation 12
4.1 Installation summary 13
4.2 Profile tile 14
4.3 Flat tile 15
4.4 Slate tile 16
4.5 Alignment and fixing of mounting rails 17
4.6 Joining mounting rails 17
5Flat Roof System Installation 18
5.1 Installation summary 19
5.2 Flat Roof system installation 20
5.3 Joining mounting rails 20
6In-Roof System Installation 23
6.1 Installation summary 24
6.2 Substructure 26
6.3 Installation of In-Roof kit 28
6.4 Installation of collectors 33
6.5 Fitting top cover flashing 35
6.6 Closing the roof 35
7Installation of Solar Collectors 36
7.1 Installation sequence of solar collectors 36
7.2 Installation of solar collectors -
On-Roof and Flat Roof 37
8Hydraulic Connections 39
8.1 Compression connection, straight 39
8.2 Compression connection, landscape
systems only 40
9Roof Penetrations 41
9.1 Roof penetrations 41
10 Differential Controller 43
10.1 General information 43
10.2 Technical data 43
10.3 Operation 44
10.4 Sensors 44
11 Electrical Installation 45
11.1 Electrical connection 45
12 User Guide 46
12.1 Operation 46
12.2 Starting up 47
12.3 Explanatory information 47
13 Solar Pump Station 51
13.1 Solar pump station 51
13.2 Installation and operation 52
14 Commissioning the System 56
14.1 Heat transporting fluid 56
14.2 Instructing the operator 56
14.3 Filling and flushing the system 57
15 Commissioning 59
Commissioning check list 59
16 Maintenance 61
17 De-commissioning 62
18 Warranty 63
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4
1General
General
The following information is a step-
by-step guide to the installation and
operation of the Grant Solar
Thermal system.
1.1 Product Description
The Grant Solar Thermal system uses
flat plate solar collectors that can be
fitted in either a ‘portrait’ or ‘landscape’
configuration and offers three different
mounting methods – ‘On-roof’, ‘In-roof’
and ‘Flat-roof’.
The ‘On-roof’ and ‘In-roof’ mounting
kits are designed for use on roof slopes
of between 20° and 65° and must be
installed in accordance with these
instructions.
The ‘Flat-roof’ mounting kit can be
used on any flat surface capable of
carrying the weight of the collectors
and any dead weighting used.
In-Roof Systems only:
A waterproof membrane must be used
on all roofs. On older roofs the sarking
felt is acceptable but if this is not
present, then a breathable waterproof
membrane must be fitted and it should
end at the eaves (roof guttering).
Short term damp can occur beneath
the roof covering (tiles or slates) on roof
slopes of less than 20° or greater than
65°, or where there are long rafters or
joined roofs, as a result of extreme
weather conditions (e.g. driving rain,
snow covering or ice formation). This
can be avoided by using additional
wedge section sealing strips. However,
adequate ventilation of the roof must
still be provided.
Installation kits for ‘On-roof’ installations
are supplied with roof anchors to suit
the type of roof covering concerned –
i.e. profile tiles, flat tiles or slates. This
must be specified when the kit is
ordered. Before commencing
installation check that the roof anchors
supplied are correct for the roof type. If
the height of profile tiles is particularly
high a special adjustable height roof
anchor is available. Contact Grant for
details.
If necessary, the installation can be
modified to suit the site conditions.
However, any changes must be
approved by Grant and must meet
Building Regulations, codes of practice,
and any relevant local bylaws and
regulations in force at the time. Failure
to comply with this will invalidate the
product warranty.
1.2 Package Contents
Solar collectors, fixing components and
other system accessories must be
handled with care during storage and
transport. If the packaging is damaged
during transit this must be immediately
reported to the supplier/delivery driver.
Before starting installation check the kit
supplied contains all the required
components. Refer to Section 2.1.
All packing materials must be disposed
of appropriately after installation.
1.3 Format of installation
instructions
These instructions describe the
installation of collectors in both the
‘portrait’ and ‘landscape’ format using
all three mounting types – ‘On-roof’,
‘Flat roof’ and ‘In-roof’. This is covered
in Sections 4, 5 and 6 respectively.
The actual fitting of the collectors and
the connection to the hydraulic solar
circuit is identical for all the above
mentioned mounting options, and is
covered in Sections 7 and 8
respectively.
1.4 Safety Instructions and
Symbols
When installing the system, take note of
the safety instructions in this document.
The symbols used in the text are
explained below:
Caution:
This symbol draws attention
to a potential hazard!
Note:
This symbol indicates useful
information or a general note.
1.5 Safekeeping of the
Installation Instructions
These Installation & User Instructions
must be handed over to the
householder on completion of the
installation. They should be kept for
future reference as necessary.
1.6 Installation
Installation must be carried out by a
competent installer in compliance with
all current local planning requirements,
Building Regulations, codes of practice,
Health and safety legislation, and any
relevant local bylaws and regulations in
force at the time.
All electrical installation work must be
carried out by a qualified electrician. All
wiring and earth bonding must comply
with current IEE wiring regulations.
In-roof and On-roof installations only:
When installed, both the In-roof and
On-roof systems can experience uplift
due to the wind. When installing either
system ensure that the collectors are
installed no less that THREE tiles from
any roof edge.
Important:
All system pipe connections must
use compression fittings with
brass olives. Soft soldered joints
must NOT be used on the solar
primary circuit.
Plastic pipe must NOT be used
for any part of the solar primary
circuit.
All internal solar primary system
pipework should be insulated
using suitable high temperature
resistant pipe insulation.
!
!
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General
5
1.7 Equipment and Materials
to be provided
General:
• Heat conducting paste - for
temperature sensors (optional)
On-roof Installation:
• 2 ‘Grant’ lead flashings or 2
‘Solardek’ flashings or 2 vent tiles
(see Section 9)
• Fixing screws for fixing battens/roof
anchors
Flat roof installation:
If the supporting frame is secured by
weights rather than being screwed
down, the weights must conform to the
following specifications for a wind
pressure zone up to 8 m building height
and a snow load zone up to 0.75
kN/m2(Table 1).
Table 1: Dead Weight Requirements
Flat Roof installation Up to 8m
1 solar collector 290 kg
2 solar collectors 580 kg
3 solar collectors 870 kg
4 solar collectors 1160 kg
5 solar collectors 1450 kg
As weights, lawn edge stones can be
used, for example.
Permissible roof load must not be
exceeded under any circumstances, and
if necessary a structural engineer must
be consulted beforehand. If the
substructure has been penetrated, it
must be carefully re-sealed in
accordance with technical standards.
In-roof Installation:
• Fixing screws for mounting battens
1.8 Tools Required
On-roof and Flat roof installations:
• Screwdriver (6mm hexagon socket)
• Pencil
• Tape measure or folding rule
• 17/19mm open-jaw spanners (x2)
• 13mm open-jaw spanner
• Screwdrivers (standard and
cross-head)
• Electric screwdriver/drill
In-roof installation:
• Pencil
• Tape measure or folding rule
• 2 open-jaw spanners 17/19mm
• 1 open-jaw spanner 13/14mm
• Screwdrivers (standard and
cross-head, sizes 2 and 3)
• Socket wrench with T-handle, size 6
• Electric screwdriver with socket bit
for sealing screw (8mm hexagon)
• Hammer
• Solar collector carrying handles
• Torx T25 screwdriver
Commissioning:
• Filling station
• Pressure gauge
• Screwdriver (flat bladed)
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6
1General
General
1.9 Standards and Approvals
Grant flat plate solar collectors conform
to the requirements of BS EN 12975
Thermal solar systems and components
– Solar collectors, and have the ‘Solar
Keymark’ approval.
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7
2Package Contents
Package Contents
2.1 Standard Installation Kits
For ‘On-roof and ‘Flat roof’ Installations (in portrait format)
Table 1: Installation Kit Contents
Standard 1 Standard 2 Standard 3 Standard 4 Standard 5
Article Collector Kit Collector Kit Collector Kit Collector Kit Collector Kit
Mounting rail extension kit only 2 2 (plus extension kit) 4 4 (plus extension kit)
Mounting hook 246810
Cylinder bolt 4 8 12 16 20
Fixing bracket 4 8 12 16 20
Anchor block 4 8 12 16 20
Collector flow/return pipe c/w insulation 22222
Collector to collector connector c/w insulation 01234
Installation and operating instructions 11111
On-Roof installation
Roof anchor* 4 6 8 10 12
Flat Roof installation
Flatroofangleframe 23345
Securingcruciformkit 11111
* Roof anchor - to suit type of roof covering (see pages 14 to 17) - Slate - Flat tile - Profile tile
For ‘In-roof’ Installations (in portrait format)
Table 2: Installation Kit Contents
Standard 1 Standard 2 Standard 3 Standard 4 Standard 5
Article Collector Kit Collector Kit Collector Kit Collector Kit Collector Kit
Mounting bracket 4 8 12 16 20
Anchor block 4 8 12 16 20
Collector flow/return pipe c/w insulation 22222
Collector to collector connector c/w insulation 01234
Cylinder bolt 4 8 12 16 20
Side gutter LH 11111
Side gutter RH 11111
Basetray–lowersection** 12345
Basetray–uppersection** 12345
Cover strip 23456
Bottom apron flashing 1-piece*** 10000
Bottom apron flashing LH*** 01111
Bottom apron flashing RH*** 01111
Bottom apron flashing Intermediate*** 00123
Bottom flashing 1-piece**** 10000
Bottom flashing LH**** 01111
Bottom flashing RH**** 01111
Bottom flashing Intermediate**** 00123
Top cover flashing 1-piece 10000
Top cover flashing LH 01111
Top cover flashing RH 01111
Top cover flashing Intermediate 00123
Closurestrip 01234
Fixingscrew 1428446076
Clip c/w nail 12 12 12 12 12
Foam draught seal wedge 66666
Foam draught seal block 23456
Masticbead(roll) 11111
Torx screwdriver bit (T25) 11111
Installation and operating instructions 11111
** Maybe supplied as one tray *** Bottom apron flashing used for tiles only **** Bottom flashing used for slates only
Table 3: Timber Battens (to be supplied by the installer) – minimum lengths (mm)
Bottom batten (30 x 50) 1460 2645 3835 5025 6215
Lower middle batten (30 x 90) 1460 2645 3835 5025 6215
Upper middle batten (30 x 90) 1460 2645 3835 5025 6215
Top batten (30 x 50) 1460 2645 3835 5025 6215
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3Dimensions & Fixing Intervals
8
Dimensions &
Fixing Intervals
3.1 On-roof Installation
Position of Roof Anchors and Mounting Rails
1187mm
3561mm
5935mm
4205mm
4748mm
2374mm
~800mm ~700mm
~1300mm
~1700mm
~1100mm ~1100mm ~1100mm
~1700mm ~1700mm
~1300mm ~1300mm ~1300mm~1300mm
~700mm~200mm max.
500mm
max.
500mm
max.
500mm
max.
500mm
max.
500mm
max.
500mm
max.
500mm
max.
500mm
max.
500mm
max.
500mm
~200mm
~1800mm~1800mm~1800mm
~1800mm
60mm60mm60mm~900mm60mm
60mm
~1800mm60mm
2042mm
2042mm
2042mm
2042mm
2042mm
Figure 1: 1 collector (portrait) Figure 2: 2 collectors (portrait)
Figure 3: 3 collectors (portrait)
Figure 5: 5 collectors (portrait)
Figure 6: 2 collectors (landscape)
Figure 4: 4 collectors (portrait)
1142mm
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Dimensions &
Fixing Intervals
9
3.2 Flat-roof Installation
Position of Roof Anchors and Mounting Rails
60mm
1187mm
3561mm
5935mm
4748mm
2374mm
700mm* ~700mm
~1300mm
~1300mm ~1300mm ~1300mm =1200*
~1300mm ~1300mm =1200mm*=1200mm*
=700mm*
~500mm
~500mm
~500mm
~500mm
~500mm~500mm
~500mm~500mm~250mm~250mm
1770mm1770mm1770mm
1770mm
60
1770mm
2042mm
2042mm
2042mm
2042mm
1320mm 54mm
1318mm
1316mm
1334mm
2042mm
Figure 7: 1 collector (portrait) Figure 8: 2 collectors (portrait)
Figure 9: 3 collectors (portrait)
Figure 11: 5 collectors (portrait)
Figure 10: 4 collectors (portrait)
60mm
60mm
60mm
* This is a fixed dimension and must be as shown above
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3Dimensions & Fixing Intervals
10
Dimensions &
Fixing Intervals
3.3 In-Roof System Installation
Position of Mounting Rails
1-5 Solar Collectors, Vertical, Side by Side
3835mm
6215mm
5025mm
2645mm
2450mm
1460mm
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
2450mm
2450mm
2450mm
2450mm
Figure 13: 2 collectors (portrait)
Figure 14: 3 collectors (portrait)
Figure 16: 5 collectors (portrait)
Figure 15: 4 collectors (portrait)
Note: Dimensions include cover frame
Figure 12: 1 collector (portrait)
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Dimensions &
Fixing Intervals
11
3.3 In-Roof System Installation
Position of Mounting Rails
1-5 Solar Collectors, Horizontal, Side by Side
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
50
100
100
340
190
50
160 160
6525mm
8615mm
10700mm
1550mm 1550mm 1550mm 1550mm
2355mm 4440mm
Figure 17: 1 collector (landscape) Figure 18: 2 collectors (landscape)
Note: Dimensions include cover frame
Figure 20: 4 collectors (landscape)
Figure 19: 3 collectors (landscape)
Figure 21: 5 collectors (landscape)
1550mm
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4On-Roof System Installation
12
On-Roof System
Installation
See Section 9 for details of roof
penetrations.
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Roof Anchor Options
07-A
12
06
13
11
04
03-A
08
09
05
04
10
03-B Flat tile
03-C Slate
03-A Profile tile
14
02
01
On-Roof System
Installation
13
4.1 Installation Summary
The standard installation kit allows solar
collectors to be fitted vertically onto
horizontal mounting rails.
Mounting rails are fixed to the roof
structure using the appropriate type of
roof anchors for the roof covering - e.g.
slates, flat tiles or profile tiles.
Item Description
01 Collector
02 Mounting rail set
03 Roof Anchors -A profile tile
B flat tile
C slate roof
04 Rail profile
05 Anchor block
06 Collector connection kit
07 Collector to Collector
connection kit
08 Cylinder anchor bolt
09 Fixing Bracket
10 Interlocking bolt
11 Hydraulic connection
12 Insulation
13 Temperature sensor
14 Mounting hooks
Figure 22: Installation Summary,
Vertical Solar Collector Layout
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4On-Roof System Installation
14
On-Roof System
Installation
4.2 Profile Tile
Roof Anchors fixed to Rafters
1. For profile concrete tiles, these roof
anchors are attached directly to the
roof rafters (rafter-mounted
installation).
Caution:
Never attach safety harness to the
installation system!
2. Expose the installation area above
the rafters. For roof anchor
intervals, see Page 8, 3.1 On-Roof
System installation.
Note:
As a rule, pushing up the roof tiles
is sufficient. Horizontal positioning
of roof anchors is dependent on the
rafters and the tile valleys.
3. Place roof anchor (03-A) in line with
the top edge of the roof tile in the
tile valley. Fix the base plate of the
roof anchor to the rafter with
screws (16).
4. Fix all further roof anchors in the
same way. For roof anchor intervals,
see Page 8, 3.1 On-Roof System
installation.
Note:
Roof anchors must be horizontally
and vertically aligned (follow roof tile
valleys).
65mm
70mm
40mm
150mm
120mm
60mm
Figure 23: Dimensions of Roof Anchor A
16
03
Figure 24: Horizontal and Vertical Alignment
Horizontal-Distance
Horizontal-alignment
Vertical-alignment
Vertical-Distance
Figure 25: Installation of Roof Anchors A
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On-Roof System
Installation
15
Horizontal-Distance
Horizontal-alignment
Vertical-alignment
Vertical-Distance
4.3 Flat Tile
Roof Anchors fixed to Rafters
1. For flat concrete tiles, these roof
anchors are attached directly to the
roof rafters (rafter-mounted
installation).
Caution:
Never attach safety harness to the
installation system!
2. Expose the area above the rafters.
For roof anchor intervals, see page
8, 3.1 On-Roof System.
Note:
As a rule, pushing up the roof tiles
is sufficient. Horizontal positioning
of roof anchors is dependent on the
rafters and the tile valleys.
3. Place roof anchor (03-B) in line with
the top edge of the roof tile. Fix the
roof anchor to the rafter with screws
(16).
4. Fix all further roof anchors in the same
way. For roof anchor intervals, see
Page 8, 3.1 On-Roof System
installation.
Note:
Roof anchors must be horizontally
and vertically aligned (follow roof tile
valleys).
65mm
100mm
200mm
30mm
125mm
40mm 75mm
Figure 27: Horizontal and Vertical Alignment
Figure 28: Fixing Mounting Battens and Roof Anchors
Figure 26: Dimensions of Roof Anchor B
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4On-Roof System Installation
16
On-Roof System
Installation
4.4 Slate Tile
Roof Anchors fixed to Rafters
1. On slate roofs, additional mounting
battens are fixed to the roof
substructure. Roof anchors ‘C’ are
fixed through the slate tiles to the
mounting batten (batten-mounted
installation).
Caution:
Never attach safety harness to the
installation system!
2. Expose the area required for
installation (length of mounting
batten). For roof anchor intervals,
see Page 8, 3.1 On-Roof System
installation.
Note:
As a rule, pushing up the roof slates
is sufficient. Horizontal positioning
of roof anchors is dependent
on the rafters and the tile valleys.
3. Mounting battens (18) are fixed with
screws to the rafters at a distance of
185mm from the roof batten below.
Note:
The distance of 185mm is
dependent on the roof anchor and
type of roofing and must be modified
if necessary.
4. Place the roof anchor (17) on to the
slate tile and mounting battens and
fix with screws (16).
5. Fix all further roof anchors in the same
way. For roof anchor intervals, see
Page 8, 3.1 On-Roof System
installation.
Note:
Roof anchors must be horizontally
and vertically aligned.
65mm
250mm
30mm
50mm
Horizontal-Distance
Horizontal-alignment
Vertical-alignment
Vertical-Distance
Figure 30: Horizontal and Vertical Alignment
Figure 29: Horizontal and Vertical Alignment
16
17
18
16
17
Figure 31: Fixing Mounting Battens
and Roof Anchors
Figure 32: Fixing Mounting Battens
and Roof Anchors through Sarking
Note:
If roof is fully sarked (timber boards)
then mounting anchors should be
screwed through sarking into the
rafters below.
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4.5 Alignment and Fixing of
Mounting Rails
1. Close the roof covering at the top
and bottom.
2. Fix top mounting rail (04) to the roof
anchor (03).
Position the heads of interlocking
bolts (10) parallel to the mounting
rail (04) and place them on the
mounting rail, push the interlocking
bolts to the top in the roof anchor
(03) and secure with a 90° turn.
Tighten the nuts of the interlocking
bolts (hand tight). Use serrated
washers to secure the nuts.
Install all further mounting rails in
the same way.
3. Align the mounting rails horizontally
and vertically so that the rails and
the roof tiles are parallel. Diagonal
dimensions between mounting rails
must be equal:
D1 = D2
Tighten the nuts on the interlocking
bolts.
Installation of solar collectors:
See pages 33 to 35.
4.6 Joining Mounting Rails
1. On some installations it may be
necessary to join two or more
sections of mounting rail to create a
longer length of rail.
2. Join the sections of rail using the
screws and fishplates (supplied in
the fixing kit provided), as follows:
Fit the fishplate into the rectangular
opening at the end of the one
section of mounting rail. Refer to
Figure 36.
Align the threaded hole in the
fishplate with the hole in the rail
(50mm from the rail end), fit the
cylinder bolt provided and tighten to
secure. Refer to Figure 37.
Fit the exposed end of the fishplate
into the rectangular opening of the
second mounting rail. As before,
align the threaded hole of the fish
plate with the hole in the rail, fit the
cylinder bolt and tighten to secure
the second rail section to the first.
Refer to Figure 38.
Repeat this process for all other
connections between mounting rail
sections.
Figure 33: Roof Covering with Roof Anchors
10
04
03
Figure 34: Fixing the Mounting Rail
Figure 35: Aligning the Mounting Rail
Figure 36: Installing the
Fishplate
Figure 37: Fixing the
Fishplate
Figure 38: Joining
Mounting Rails
Now go to Section 7.
D1
D2
On-Roof System
Installation
17
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5Flat Roof System Installation
18
Flat Roof System
Installation
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5.1 Installation Summary
The standard installation kit allows solar
collectors to be fitted vertically onto
horizontal mounting rails.
Item Description
01 Collector
02 Mounting rail set
03 Roof Anchors -C to flat roof
anchors
04 Rail profile
05 Anchor block
06 Collector connection kit
07 Collector to collector
connection kit
08 Cylinder anchor bolt
09 Fixing Bracket
11 Hydraulic connection
12 Insulation
13 Temperature sensor
14 Mounting hooks
15 Cruciform
07-A
12
06
13
11
01
04
03-C
08
09
05
04
14
02
Figure 39: Installation Summary,
Vertical Solar Collector Layout
Flat Roof System
Installation
19
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5Flat Roof System Installation
20
Flat Roof System
Installation
a
b
5.2 Flat Roof System
Installation
1. Lay mounting rails on the installation
surface with the wide groove
uppermost. Mounting rail interval
= 1770mm.
Diagonal dimensions between
mounting rails must be equal:
D1 = D2
2. Open out a prefabricated flat roof
mounting bracket and place the
long L-profile on the mounting rail
so that the T-profile points
backwards. For interval a, see Page
9, 3.2 Flat roof installation.
3. Fix the flat roof mounting bracket to
the mounting rail using the
interlocking bolts, serrated washers
and nuts provided.
Note:
Interlocking bolts must be secured
to the mounting rail using a 90°
turn.
4. Place the next flat roof mounting
bracket on the mounting rail and fix
using the interlocking bolts. Do not
tighten the bolts too tightly, as final
adjustment may be required. For
interval b, see Page 9, 3.2 Flat roof
installation.
D1
D2
a
04
04
1770
SW 13
Figure 40: Installation of the First Flat
Roof Mounting Bracket
Figure 42: Installation of the Second
Flat Roof Mounting Bracket
Figure 41: Fixing Using Interlocking Bolt
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