Regulus Ashburn KPI1 User manual

EN
ver. 1.1
Installation and Operation Manual
KPI1 Inroof Solar Collector
6904180

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No liability is accepted for incorrect use, unauthorized changes to the assembly components, or the resulting consequences.
Figures and illustrations used. Due to the possibility of setting and printing errors, and to the need for continuous technical
change, please understand that we cannot accept liability for the correctness of the data.
General Information

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Contents
3
General Information ........................................................................................................................................................... 2
Safety information ............................................................................................................................................................ 4
Transport note ................................................................................................................................................................... 5
Assembly instructions - Collector ...................................................................................................................................... 6
Overview of tools ............................................................................................................................................................... 7
Overview of materials......................................................................................................................................................... 8
Inroof-mounting ................................................................................................................................................................10
Sugenstion for attachment points .................................................................................................................................... 21
Technical data - Collector.................................................................................................................................................. 23
Connection diagram .......................................................................................................................................................... 24
Operating tips - Solar power system ................................................................................................................................ 25

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Safety information
Safety precautions: Before commencing mounting work on roofs, it must
be ensured in all cases that the non-personal fall protection and fall-arrest
systems required by DIN 18338 (Roof Covering and Roof Sealing Works)
and DIN 18451 (Scaffolding Works) are in place. Other country-specific
regulations must be observed!
If non-personal fall protection or fall-arrest systems cannot be installed for
technical reasons, all personnel must be secured by means of suitable
safety harnesses!
Only use safety harnesses (safety belts, lanyards and straps, shock
absorbers, fall arresters) that were tested and certified by authorized
testing bodies.
If non-personal fall protection or fall-arrest systems are not provided,
orking without the use of suitable safety harnesses may lead to falls from
heights and therefore cause serious or lethal injuries!
Ladders not properly secured against sinking in, sliding or falling over may
lead to dangerous falls!
Whenever you are near live overhead electric cables where contact is
possible, only work if:
- it is ensured that they are voltage-free and this is secured for the
duration of work.
- the live parts are secured by covering them or cordoning them off.
- the prescribed safety distances are maintained.
Voltage radius:
3 m......................1000 - 11000 V
4 m......................11000V - 22000 V
5 m..................... 22000 V - 38000 V
> 5m in case of unknown voltages
The manufacturer hereby guarantees to take back products identified with
an eco-label and to recycle the materials used.Only the heat transfer medi-
um specified may be used!
Safety harnesses should be fixed above the users whenever possible.
Safety harnesses should only be fastened to sufficiently load-bearing
structures or fixing points!
Never use damaged ladders (e.g., wooden ladders with split runners
or rungs, or bent or buckled metal ladders). Never try to repair broken
runners, rungs or steps on wooden ladders!
Ensure that ladders are put up safely. Observe the correct leaning angle
(68° - 75°). Prevent ladders from sliding, falling over or sinking into
the ground (e.g. using wider feet, feet suited to the ground or hooking
devices).
Only lean ladders against secure points. Secure ladders in traffic areas by
suitable cordoning.
Contact with live electric overhead cables can be lethal.
Wear protective goggles when drilling and handling evacuated tube collec-
tors (danger of implosion)!
Wear safety shoes when carrying out installation work!
Wear cut-proof safety gloves when mounting collectors and handling
evacuated tube collectors (danger of implosion)!
Wear a helmet when carrying out installation work!
1m......................Voltages up to 1000 V

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Transport note
ATTENTION:
Do not lift collectors by the connections or the screw threads!

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Assembly instructions
General and transport instructions
The mounting system is suitable for tiled roofs only. Installation must only be carried out by qualified personnel. The entire
information in these instructions is intended exclusively for such qualified personnel. Only the supplied material should be
used for the installation. Prior to starting installation and operation of the solar collector system, please inform yourself about
the applicable local standards and regulations. The use of a carrying strap is recommended for transporting the collector.
The collector must not be lifted at the connections or on the threading. Avoid impacts and mechanical influences on the
collector, in particular on the solar glass, the rear panel and pipe connections.
Statics - tiled roofs
The collectors may only be mounted on sufficiently load-bearing roof surfaces and substructures. It is imperative that the static
load bearing capacity of the roof or substructure is checked in terms of local and regional conditions prior to installation of the
collectors by the customer, if necessary through the involvement of a structural engineer. Particular attention should be paid to
the quality of the (timber) substructure in terms of the stability of the screw connections necessary for fastening the collectors.
The checking of the entire collector structure by the customer as per DIN 1055 part 4 and 5 or as per the applicable country-
specific regulations is particularly important in areas with heavy snowfall (note: 1 m³ powder snow ~ 60 kg / 1 m³ wet snow ~
200 kg) or in areas exposed to high wind speeds. The assessment should also take into account any particular circumstances
at the place of installation (foehn wind, air jets or eddy formation etc.) which can lead to increased loads. When selecting the
installation site it should be ensured that the maximum load is not exceeded either by snow or wind forces. As a rule, collector
arrays must be installed such that any possible collection of snow is prevented from reaching the collectors by snow barriers
(or through special forms of installation). The distance to roof ridges/edges must be at least 1 m. Max. wind speed 150 km/h
and max. snow load 1.4 kN/m2
Note: Installing a collector array signifies an intervention into an (existing) roof. Roof coverings, e.g. tiles, shingle and slate, especially in
the case of converted and inhabited loft spaces or roofs with less than the minimum slope (with regards to the covering) require additional
measures by the customer, e.g. sarking membranes, as security against water penetration caused by wind pressure and driving snow.
Lightning protection / Equipotential bonding of the building
For installations of solar collectors, the standard for lightning protection EN 62305 Part 1-4 shall be respected.
Connections
Depending on the design, the collectors must be connected with one another and/or the connection pipes using screw fit-
tings (G1“ internal/external thread) with flat-face sealing. Ensure correct placement of the flat gaskets. If flexible pipes are
not used as connectors, precautions must be taken to protect the connection pipes against temperature fluctuations caused
by heat expansion, e.g. expansion bends and flexible piping (see Connecting the collectors to one another/Operational
recommendations). Larger collector arrays must be assembled with expansion bends or flexible members inserted in the
links. (IMPORTANT: check the pump design). When tightening the union nuts, always balance (counter) the torque with a
pipe wrench or another spanner to prevent damage to the absorber.
Collector inclination / General notes
The collector is suitable for angles between 20° (minimum) and 65° (maximum). The collector must be installed so that rear
ventilation for preventing the diffusion of moisture in the collector is guaranteed. The collector connections and the ventila-
tion openings must be protected against the penetration of water as well as contamination such as dust etc.
Cleaning
Clean the water courses of the sheet metal edging at least once per year (or more often if required).
Legal guarantee
Legal guarantee claims can only be made if the supplier‘s own antifreeze has been used and maintenance has been carried
out correctly. Installation by qualified personnel with absolute adherence to the instructions is a prerequisite for the justifi-
cation of claims.

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Overview of tools
Measuring tape
Drill
Cross bit (Pz-2), Torx bit (TX-15)
Hex spanner Water pump pliers Angle grinder
Hammer

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Overview of materials
Installation batten 30x40x2450 Attachment bracket Self-trapping screws 5x60 / 5x40
Connecting bend Flat gasket Front corner section right/left or middle
Side piece right/left Side tin cover strip Sealed plumping screw 4,5*35
Middle cover strip Sealed plumping screw 3,9x13 Wooden wedge

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Overview of materials
Self-tapping screws 6x120 Side piece connector right/left Middle cover right/left or middle
Rear corner section right/left or middle Self-tapping screws 4x25 Metal retainer, roofingnail
Foam rubber wedge

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Inroof-mounting
1: Uncover the roof according to the collector surface area
Width: approx. 1.25m per collector + 1.5m
Height: approx. 3.0m for single row installation
Height: approx. 5.0 - 6.0m for double row installation.
2a: Attach the installation batten below, screws 5x60
2b: Measurement A = 80mm for tile sheet metal edging
Measurement A = 50mm for shingle and crown tile sheet metal edging
2c: Measurement B = 200mm or tile width + 50mm
1
2a
2c
2b

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Inroof-mounting
6: Secure the collectors to the upper attachment bracket, 1 bracket in the
centre of each collector glass, screws 5x40. If necessary, install upper
installation batten, screws 5x60
3: Fasten the attachment bracket on the installation batten as shown on
the attachment diagram (page 25), screws 5x40
4: Set and align collectors on the roof
5: Fasten the collectors to the (bottom) attachment bracket, screws 5x40
3
5
6
4

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Inroof-mounting
7: Hydraulically connect the collectors using short connecting bends
8: Connect the roof-integrated connection set (8a/8b). Alternative: Create
a Cu connection using a soldered connection. Install the sensor with
the sensor tube extension at the forward flow.
9: Install the installation batten for the second collector row, screws 5x60.
Distance between the lower and upper collector = 200 mm.
7
8a
8b
9a

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Inroof-mounting
10: Fasten the attachment bracket on the installation batten as shown on
the attachment diagram (page 25), screws 5x40
11: Set and align the second row of collectors (11a), secure them using
the lower (11b) or upper attachment bracket, screws 5x40. If necessa-
ry, install upper installation batten, screws 5x60.
Hydraulically connect the second row of collectors as shown in point
7 and 8.
9b
10
11a
11b

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Inroof-mounting
Warning: The collector array must be checked for leaks before installing the
metal casing!
12: Slide the lower corner section to the left into the required nut of the
glass lower bar.
Note: Before installing the underside of the metal casing, remove the
collectors’ lower protection piece!
13: Slide the lower section into the middle
14: Slide the lower corner section from the right
15: Secure the lower section on the required positions (stampings) using
sealed plumbing screws 4.5x35
12
13
14
15

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Inroof-mounting
18: Place the wooden wedge in the middle between the collector rows and
tighten it on the roof structure using screws 6x120. Install the side
piece connector on the right and left.
Repeat steps 16, 17, 19, 20, 21 and 22 for the second collector
row accordingly!
16: Install the side pieces on the right and left. Upper edge of the sheet
metal flush with the upper edge of the collector.
17: Secure the side pieces to the roof batten using metal retainers and
roofing nails
18
17
16

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Inroof-mounting
19: Attach the lateral cover strip on the right and left
20: Attach the side tin cover strip to the lower corner section on the right
and left at the collector using sealed plumbing screws 4.5x35
21: Push the middle cover strip (between adjacent collectors) from the
bottom as far as it can go
22: Tighten the middle cover strips using two sealed plumbing screws and
the lateral tin cover strip using one sealed plumbing screw 3.9x13
19
20
21
22

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Inroof-mounting
26: Tighten the left and right middle cover to the side tin cover strip and
the collector on the required position using a sealed plumbing screw
4.5x35
23: Slide in the middle cover on the left
24: Slide in the middle cover to the centre
25: Slide in the middle cover on the right
23
24
25
26

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Inroof-mounting
27: Place the wooden wedge in the middle above the collector and tighten
it on the roof structure, screws 5x120. Hang the left upper corner secti-
on (27b) in the collector.
28: Tighten the left upper corner section outside of the reinforcing seam
on the wooden wedge, screws 4x25
29: Hang the middle upper section in the collector and connect the upper
left corner section. Tighten the sheet metal outside of the reinforcing
seam using a screw 4x25.
27a
27b
29
28

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Inroof-mounting
33: Glue the foam rubber wedge on the side and the top (applies to sheet
metal edgings for tile roofs only!).
30: Hang the right upper section in the collector and connect it to the mid-
dle upper section
31: Tighten the upper section on the left and right side to the cover strip
and the collector using a sealed plumbing screw 4.5x35
32: Laterally secure the right and left upper corner section to the roof
batten using metal retainers and roofing nails
30
32
33a
31

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Inroof-mounting
34: Cover the collector field. If necessary, the tile must be cut to the appro-
priate size using an angle grinder. The top projecting end of the tile
must be 80 and 140mm over the metal edge
35: Finally, adjust the lead skirting (for sheet metal edging with tile roofs
only) to the contour of the tile
36: Note: When installing the side sections of the plain-tile metal casing,
the tiles and metal parts must always be alternately covered!
33b
35
36
34