Regulus KPC1 BP User manual

1
Solar System with KPC1 BP Collectors
EN
v. 1.6
Installation and Operation Manual

2
CONTENTS
General Installation and Operation Instructions .…....……...…….…................................. 3
1 Supply of Mounting System ..……........……...……..………....……..……............................ 4
2 Sloping Roof Mount ..........................................………………………................................. 5
2.1 Preparation ...………………………………………....………............................................ 6
2.2 Roof anchor installation for sloping roofs ..……………….………................................... 6
2.2.1 Roof anchor installation for sloping roofs ..……………………................................ 6
2.2.2 Installation with roof anchors and rafters ………………………............................... 7
2.2.3 Installation with roof anchors for slate, shingle or metal roofs ............................... 7
2.2.4 Installation with bolts for fixing rails onto a roof .................................................... 7
2.2.5 Installation with universal templates for Cembrit roofs ...................................... 9
2.3 Installing rails onto roof anchors ….........……………………………............................... 9
2.4 Collector mounting …………………………….………………………............................... 9
3 Connection Pipe Passage through a Roof …...…...…................................................... 10
4 Flat Roof Mount …………....……….…………………........................................................ 11
4.1 Overview ………..........…….……………….………………………................................. 11
4.2 Flat roof support mounting ………………….....………….............................................. 12
5 Hydraulic Connection …………………………………………………................................. 15
5.1 Collector connecting .......………………………………………………............................ 15
5.2 Collector interconnecting …………………..…………………………............................. 15
6 Temperature Probe Positioning …………………………………….................................... 16
7 Pump Station ………………………………………..........…………...................................... 17
8 Expansion Vessel Sizing and Working Pressure Calculation ………........................... 18
8.1 Expansion vessel sizing ……………………………...…………..................................… 18
8.2 Calculation of a system working pressure ……………..………................................… 18
8.3 Calculation of an expansion vessel preset pressure …………................................…. 18
8.4 Examples of calculating working pressure and expansion vessel pressure ...........…. 18
8.4.1 Example of calculating system working pressure ………......................…………. 18
8.4.2 Example of calculating expansion vessel pressure …………...................………. 18
9 Installation of Air Release Valves …………………..………….….................................…. 19
10 System Filling, Flushing, Leak Test and Air Bleeding …............................................. 20
10.1 Filling ……………………………………......………………………....................………. 20
10.2 Flushing …………………………………………........………………..................………. 20
10.3 Air bleeding …………………………….................……………….....................………. 20
10.4 Leak test ………………….............................….……………………....................……. 20
11 Commissioning …………..……...............................................................................……. 21
12 Operation, Checks and Maintenance ………........…………………...........................…. 21
13 Servicing and Warranty …………..................………………………….........................…. 21
14 Technical Data .…...…...................................................…...….....................…............… 22
15 Connection dimensions…………………..……...........................................................…. 24
16 Annual Check Description ............................................................................................. 25
Service sheet ......................................................................................................................... 26

3
Collector description
REGULUS KPC1 BP Flat Plate Solar Collectors are
designed for solar domestic hot water heating (DHW),
backup- and pool heating with solar energy. Solar radiati-
on penetrates the glass and is intercepted by an effici-
ent absorption layer applied on an all copper absorber.
The heat is then transferred into heat transfer fluid. The
absorber is sealed in a compact frame with high quality
thermal insulation. The collectors are designed for year
round operation, that’s why they work in a separate pri-
mary circuit filled with antifreeze heat carrier.
The collectors are not intended for direct water
heating. If different heat transfer fluid is used
than specified by the manufacturer, irreversible
damage to the collector may be done.
Transport, handling and storing
Collectors shall be transported in their original packing,
in upright position (standing on their shorter side) or lying
horizontal with glass upwards, stack of max. 10 pieces
on a pallet.
During handling the collector glass shall be always
facing upwards.
Please check the condition of the collector upon recepti-
on from your supplier or forwarder. Later claimed mecha-
nical damage (frame, glass, connection) will be refused.
When stored, the collector shall not be exposed to rain
and its absorber exposed to solar radiation.
Scope of supply
1. KPC1 BP Collector
2. Instruction manual
3. Warranty Certificate
4. Commissioning form - info for the Manufacturer
General instructions for installation
The installation and commissioning must be done by a
trained worker or a specialized company.
During installation and before commissioning, it is
necessary to cover collectors in order to avoid overhea-
ting and possible burn injury to the installer.
Prior to installation, conditions set by the roofing manu-
facturer and the max. permissible roof load shall be
checked.
Mounting method for solar collectors shall always
respect local conditions, i.e. roof inclination and weather
influence on the overall load on the collector. Kindly con-
sult the fixing method with a structural statics expert.
During installation the collectors and accessories shall
be handled carefully. Defects caused by improper hand-
ling or DIY installation are not cover by warranty.
Generally valid rules and standards for occupational
safety shall be respected during installation. This con-
cerns mainly technicians walking on a roof and the secu-
ring the area against objects falling down from a roof.
Only REGULUS fixing elements may be used. Other
fixing elements may be used only with a written approval
from REGULUS company.
Collectors shall not be exposed to solar radiation un-
til commissioned. The absorption surface may get
damaged.
Collectors shall be installed and operated in compliance
with this Manual and with respective generally valid rules
and norms.
Collector placing
The collector must be placed outdoors. The glass
absorption surface should be orientated to South, with
deviations not over 45° (Southwest or Southeast). For a
year round operation the right inclination angle is 40°-
50°, for summer operation smaller inclination is better
(30°). The collector may be placed also vertically (90°
inclination, e.g. on a façade) which is ideal for winter
operation. If placed at an angle of 75°-90°, suitable
measures shall be taken to prevent water entering its air
vents.
Collectors shall be installed with the sheath upwards as
marked.
A collector inclination shall not be less than 20°.
On inclined roofs it is recommended to install
solar collectors as close to the roof ridge as
possible. Should this solution be impossible,
then protections against snow slide shall be installed
above the collectors.
Max. permissible snow and wind load ≤1,8 kN/m2
Max. permissible wind load - negative pressure
≤1,0 kN/m2
GENERAL INSTALLATION AND OPERATION INSTRUCTIONS

4
Mounting kits for fixing and connecting KPC1 BP solar collectors Code
Connection kit for a KPC1, KPA1, KPS11 and KPG1
(G3/4“ M inlet and outlet, 2 plugs, G3/8“F for air vent valve, sheath for solar temperature sensor) 7710
Fixing kit for one KPC 1 collector
*[for 4 anchors or 2 supports+1 strut]] 7720
Fixing and interconnection kit for 2 KPC 1 collectors
*[for 4 anchors or 2 supports+1 strut] 7712
Fixing and interconnection kit for 3 KPC 1 collectors
*[for 6 anchors or 3 supports+1 strut] 7714
Fixing and interconnection kit for 4 KPC 1 collectors
*[for 8 anchors or 4 supports+1 strut] 7716
Fixing and interconnection kit for 5 KPC 1 collectors
*[for 10 anchors or 5 supports+1 strut] 7718
* Roof fixing and interconnecting kits are necessary to create a hydraulically connected collector array fixed to 2
mounting rails. The kits contain interconnecting fittings with insulation, two mounting rails, fastening material for
mounting collectors onto the rails. They do not involve any roof anchors, supports, struts. These shall be selected
from the following chart by the roof type and roofing material.
Supports and strut for flat and sloping roof installation Code
Triangle support for flat roof bracket 6859
Strut incl. screws for triangle supports for flat roof 9563
Triangle bracket, 25° for sloping roofs 8805
Triangle bracket, 45° for sloping roofs 10094
Triangle bracket, 60° for sloping roofs 9631
Anchors for various roofing types Code
Aluminum anchor for slate roofs 6920
Aluminum anchor for pantiles - adjustable height 7013
Anchor for pantiles - hot-dip galvanized steel 7929
Aluminum anchor for pantiles - rafter mounted 6932
Stainless-steel anchor for pantiles 6857
Stainless steel anchor for pantiles - rafter mounted, incl. self tapping screws 10159
Universal Cembrit template, 400x400 mm square, metal* 8726
Universal Cembrit template, 600x300 mm rectangle, metal* 8790
Bolt for fixing rails onto a roof 7320
*Anchors with bolts for rails shall be mounted on templates (assemblies are shown). Templates and anchors are
available in red, black, zinc plated and stainless steel. For each collector array also piping passages through the
roof are needed.
1. DELIVERY OF MOUNTING SYSTEM

5
Pos. Item Code
1 Flat plate collector 7610
2 Roof anchor with M8 bolt/special head for rails
6857 or other,
depending on
roofing type
Triangle brackets for inclination adjustment, suitable for anchors for sloping roofs - 25°,
45° and 60° angle
8805,10094,
9631
Interconnecting pipes
Fixing and interconnection kits No. of collectors (kit code) Item code12345
(7720) (7712) (7714) (7716) (7718)
3 Aluminum rail, 2 pieces 1.08 m 2.14 m 3.205 m 4.28 m 5.35 m 6949
4 M8 nut for the rails 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 6925
5 M8 ×18 bolt with allen head 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 7259
6 Retaining side bracket 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 7725
7Retaining bracket for collector
bottom 2 pcs 4 pcs 6 pcs 8 pcs 10 pcs 7709
8Compression nut and ring for collec-
tor interconnectio - 2 pcs 4 pcs 6 pcs 8 pcs 7629
9Insulation 35 mm diam., 19 mm
thick 0.5 m 0.75 m 1 m 1.5 m 2 m 7188
Insulation tape 0.8 m 1 m 1.5 m 2 m 2.5 m 7227
1
8
3
2
6
7
5
4
9
2. SLOPING ROOF MOUNT
Fig. 1 Collector installation on a sloping roof

6
2.1 Prior to installation
Prior to installation of solar collectors, select a suitable
position respecting the following conditions:
• roof facing South
• roof inclination (25°- 45°)
• unshaded place
• accessible for servicing
• permissible roof load
• shortest possible distance between the collectors and
(accumulation) tank
Further have ready the necessary material, tools and
safety equipment for working on a roof.
Check if the roofing manufacturer offers roof hooks and
if the roof warranty will not be violated.
2.2 Roof anchor installation for sloping roofs
2.2.1 Installation with roof anchors and
auxiliary boards
Prior to installing anchors on auxiliary boards, the fol-
lowing shall be ensured:
• The auxiliary board length shall exceed the length of
the rail by at least 200 mm on each end.
• The auxiliary board width shall be between 100 and
200 mm.
• It shall be 30 mm thick
• The height of the auxiliary board from the counter
batten shall be equal to the batten thickness which
can be reached by underlying the auxiliary board (see
Fig. 3).
Installation
• Remove roofing so that auxiliary boards can be
inserted (approx. distance between boards 1600-1800
mm). For roof tiles, just shifting them upwards in the
length of the auxiliary board is sufficient (see Fig. 4).
40
30
10
30
30
auxiliary board
battens
counter batten
rafter
waterproofing membrane
underlay
No. of collectors Total length No. of anchors
2 2122 mm 4
3 3184 mm 6
4 4246 mm 8
5 5308 mm 10
1062
~500 ~500
~500 ~500
~500 ~500
~500 ~500
1062 1062
1062
10621062
1062 1062 1062 1062
600
600
600
600
room for an auxiliary board
counter batten
rafter
roof battens
Fig. 3: Underlay to match thick battens
Fig. 4: Remove roof tiles to fix the board
Fig. 2: Layout of roof anchors

7
• Fix the auxiliary boards to battens so that the distribu-
tion of anchors resembles the positions in Fig. 2. At
the same time screw the boards so high that the roof
anchor does not hinder placing the roof tile with the
right overlap (see Fig. 8).
• Hang the roof anchors onto the auxiliary board
respecting their distribution shown in Fig. 2.
• Fix the anchors using stainless steel screws.
2.2.2 Installation with roof anchors for rafters
For tiled roofs, rafter anchors can be used. Either a fixed
(not adjustable) stainless-steel hook (Fig.7a) can be
used, or an adjustable aluminum anchor (Fig. 7b) that
enables horizontal shift of the anchor along the fixing
board. For this anchor type also the rail fixing height can
be adjusted.
Installation
• Remove roofing in places where anchors shall be fixed
(Fig. 5). The distance “a” between anchors is defined
in Fig. 2.
• Cut the counter batten used for fixing the waterproo-
fing membrane.
• Prior to the installation itself, use an underlay for
anchors according to the thickness of battens and
counter battens so that the anchors installed do not
hinder proper positioning of the roof tiles.
• Screw the adjustable aluminum anchor to a rafter and
move it in the groove horizontally so that it doesn’t
hinder proper positioning of the roof tile. If a fixed
stainless steel anchor is used, its position shall be
adjusted before fixing.
• Fix all the other roof anchors in the same way.
• When installing roof anchors, maintain a direction
parallel to the roofing (horizontal).
2.2.3 Installation with roof anchors for shin-
gle or metal roofs
• Depending on the number of collectors, measure and
calculate the positions for fixing roof anchors (Fig. 2).
Such places shall be selected for mounting where
anchors can be fixed sufficiently into the roof frame
(rafter or similar).
• Prior to fixing the anchor, apply suitable silicone
putty on the contact surface (adjacent to the roofing)
in order to prevent water leaking, or possibly use a
sealing method recommended by the roofing manu-
facturer.
• Simply lay the anchor onto the roof tiles and fix it with
stainless-steel bolts.
If the roofing is made of e.g. copper or
zinc-plated iron, then the anchor contact surface
shall be isolated using suitable underlay (rubber).
Otherwise there is a risk of contact corrosion.
2.2.4 Installation using bolts for fixing rails
onto a roof
This method of installation is preferably used for roofs of
bitumen corrugated sheets like Gutta or Onduline etc., or
for corrugated eternit or metal sheets.
counter
batten
rafter
roof
battens
waterproofing membrane
a
Installation:
• Depending on the number of collectors, locate the
places for drilling holes and installing bolts into the
roofing (Fig. 6f). Pre-drill 6 mm diam. holes into a
rafter or another massive wooden roof element for the
bolts.
Holes should be always drilled in the crest
of the roofing wave, not in its valley, to avoid
leakage.
• The bolt shall be screwed into a rafter or another mas-
sive wooden roof element (see 2.2.3) using spanner
No. 7.
• After screwing the bolt in, put on the rubber seal (Fig.
6f) and using a washer and nut, seal the drilled hole.
• Then mount the U-shaped bracket (Fig. 9) on the
bolt, between two nuts with a serrated washer.
• Then M8 bolt with floating head (for rails) shall be
mounted into the other end of the bracket. First insert
the floating head into the groove of the rail, and then
tighten the bolt together with the rail to the U-shaped
bracket using a nut and a serrated washer.
Fig. 5: Fixing an auxiliary board and roof anchors
Fig. 6: Opening the space for anchor fixing

8
140−160
290
99
40
79−99
65.5
Ø 6
(138)
70
58
300
100
35
2× Ø6
80
6
150
120
136−156
65.5
40
Ø 9
54
56
180
Ø 6
6
228 78−98
Fig. 7: Basic overview of fixing elements
150
80
125
≈160
35
Ø 10
40
45
150
7
5
RIGHT
10 - 30 mm
Fig. 8: Right anchor position with roof tiles
c) Roof anchor of stainless steel
or zinc-plated steel for pantiles
a) Stainless steel anchor on rafter, for pantiles,
incl. screws b) Aluminum anchor on rafter, for pantiles
d) Aluminum roof anchor for panti-
les, adjustable height e) Aluminum roof anchor for metal
or slate roofing
100
ø 9
80
100
40
40
f) Roofing bolt for rail fixing

9
2.3 Fixing rails on roof anchors
• have ready two rails in the length required for the
number and type of collectors to be installed.
• Align the travelling screw head (Fig. 10) with the hori-
zontal rail and shift the rail onto it, or shift the screws
into the rail first and fix to the anchors. Use serrated
lock washers to fix the nuts.
• Align the rails so that they lie in parallel to roof tiles.
The diagonal between the rails must be of the same
length: D1 = D2 (Fig. 11).
• Then tighten the nuts on fixing bolts.
2.4 Collector mounting
Collectors shall be covered during mounting.
Installation:
• Insert safety retaining brackets (Fig. 12) into the bot-
tom rail, 2 brackets per collector.
• Insert the retaining brackets into the bottom rail about
100 mm from the collector edge.
• Lay the first collector carefully on the rails and align it
in the brackets.
Collectors shall be placed on the rails with
marking upwards. The distance between the
bottom edge of the collector and of the base rail
depends on the design and size of the retaining
brackets. The collector bottom edge is by circa
75 mm lower.
• The distance between the collector edge and the end
of the bottom rail is B = 35 mm (Fig. 13)
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
rozmĈr kolektoru
1000 × 2 000 mm
Installation
of 1 collector
on rectangu-
lar roofing
Installation of 2 collectors on rectangular roofing Installation of 3 collectors on rectangular roofing
Installation
of 1 collector
on square
roofing
Installation of 3 collectors on square roofing
Installation of 2 collectors on square roofing
roof anchor
top / bottom rail
M8 bolt with
travelling head
parallel
D1
D2
Fig. 10: Fixing the rail onto the roof anchors
Fig. 11: Alignment of base rails
2.2.5 Installation with universal templates for Cembrit roofs
Distribute the universal templates on the roof in such a manner that the layout of fixing points corresponds to the Fig. 9.
Fig. 9: Layout of universal templates

10
Fig. 12: Inserting safety retaining brackets
• Insert nuts into both the rails (Fig. 14). Put the reta-
ining side brackets on the rails and fix the collector
using M8x18 bolts.
• Lay the following collector next to the first one, mainta-
ining a sufficient gap. Then put on the threaded fittings
(Fig. 15, pos. 9) and push the collector to the already
mounted one until stop. Hold the fitting with a spanner
to prevent turning and tighten the nuts. More on this in
chapter 5 Hydraulic Connection.
• Continue mounting further collectors in the same way
(see page 15).
Safety retaining bracket
Rails
~100 mm
B
14
~100 mm
~800 mm
6
7
5
24
39
For passing the connection pipes through a roof e.g. ventilation tiles can be used, where the hole is modi-
fied according to the diameter of the pipe with insulation. Anyway standards of the roofing manufacturer
shall be respected for pipe passage through a roof.
3. CONNECTION PIPE PASSAGE THROUGH A ROOF
5 – M8 nut for rail
6 – M8x18 allen head bolt
7 – Retaining bracket
Fig. 14: Fixing the retaining brackets
Fig. 13: Distance between the safety retaining brackets

11
4.1 - Overview
Pos. Item Code
1 Flat plate collector 7610
2 Triangular support
Number of collectors (number of supports needed)
6859
12345
(2) (2) (3) (4) (5)
3 Strut incl. bolts for triangular support 9563
Interconnection pipes
Fixing and interconnecting kits
Number of collectors (kit code) Item
code
12345
(7720) (7712) (7714) (7716) (7718)
4 Aluminum base rail, 2 pieces 1.08 m 2.14 m 3.205 m 4.28 m 5.35 m 6949
5 M8 nut for the base rail 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 6925
6 M8x18 bolt (allen head) 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 7259
7 Retaining side bracket 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 7725
8 Retaining bracket for collector bottom 2 pcs 4 pcs 6 pcs 8 pcs 10 pcs 7709
9 Compression nut and ring for collector interconnection - 2 pcs 4 pcs 6 pcs 8 pcs 7629
10 Insulation 35 mm diam., 19 mm thick 0.5 m 0.75 m 1 m 1.5 m 2 m 7188
Insulation tape 0.8 m 1 m 1.5 m 2 m 2.5 m 7227
3
2
1
89
6
7
5
4
10
4. FLAT ROOF MOUNT
Fig. 15 Collector installation on a flat roof

12
4.2 - Flat roof support mounting
A flat roof support consist of two base rails, triangular
supports and one strut.
The number of triangular supports depends on the num-
ber of collectors. One strut is sufficient for supports for
up to 5 collectors.
Installation:
• Lay two rails in parallel on the mounting surface, their
pitch shall be 1660 mm.
• The diagonals between the rails shall be of the same
length: D1 = D2 (Fig. 16)
• Insert the M8 bolt with a special head (Fig. 18) into the
rail grooves.
cca 500 mm
D2
2
4
4
1660 mm
T strut
base rails
L strut
D1
Fig. 16: Aligning the rails and mounting the first triangular support
• Assemble the triangular supports that come partially
screwed together (Fig. 17). Fix the loose support ends
with a bolt (Fig. 17) and tighten all connections.
• Locate the positions to fix triangular supports. The
distance of the first triangular support from the end of
the rail shall be about 500 mm..
• Fix the L-support of the triangle to the base rail using
screws, serrated lock washers and nuts for rails (Fig.
19) and tighten the connections.
• Install the next triangular support in the same way. Its
distance is the same as that of the roof anchors in
Fig. 2.

13
• Install the strut between the two triangular supports
(Fig. 19). Following Fig. 19, insert special M8 nuts into
the triangle support rail. Then lay the strut onto the
rails and fix it with M8x12 bolts with washers (Fig. 19).
• Continue assembling the remaining triangular sup-
ports with a pitch as shown in Fig. 2. Adjust this
distance so that the pitch of the triangular supports
is similar to that of roof anchors in Fig. 2 and the last
support shall be located about 500 mm from the ends
of both rails.
After fixing the strut and other supports, kip the
entire structure into the position intended for
collector installation. (The strut is upright, T rail
of each triangular support lies on the ground.)
spanner No.13
3
2
c
Fig. 19: Strut installation
Fig. 20: Installation of further supports.
Fig. 18: Assembly using special bolts.
Fig. 17: Assembly using special bolts.
Special nut
for rails
rail
M8x12 bolt with
allen head
L strut

14
Secure the support structure either by screwing it into
the roof, or applying a burden.
In no event the permissible roof load shall be
exceeded. Consulting a statics expert in advan-
ce is necessary. A damaged roof must be re-
insulated by a specialist.
Fix the collectors to the rails in the same man-
ner as if installing on an inclined roof (see point
2.4).
Minimum distance between collector fields see Fig. 22.
Flat roof mount up to 8m high
roof
1 collector 290 kg
2 collectors 580 kg
3 collectors 870 kg
4 collectors 1160 kg
5 collectors 1450 kg
Fig. 21: Static safety (burden)
twice the height winter
sun
solar
collector
height
25°
solar
collector
Fig. 22: Minimum distance between collector fields

15
5.1 - Connecting the collectors
For collector mounting follow the instructions in chapter
5.2. Fasten the first collector and lay the following one
next to the first one, maintaining a sufficient gap. Then
put the threaded fittings on both the upper and lower
outlets and push the collector to the already mounted
one until stop. Hold the fitting with a spanner (Fig. 24)
to prevent turning, and tighten the nuts. Continue in the
same way with further collectors.
Put the insulation on the threaded fittings only
after a successful leak test.
5.2 - Interconnecting the collectors
Hydraulic interconnection of collectors shall be done
according to Fig. 23a. Maximum of 5 collectors may be
connected with threaded fittings in a row. If there are
more than 5 collectors in a row, a compensator shall be
installed in the middle of the array. With a compensator,
max. of 10 collectors in a row may be installed. The con-
necting pipes shall be lead the shortest way. The recom-
mended pipe diameters and flow rates through collector
arrays are shown in Tab. 1.
Collectors may be also connected as shown in Fig.
23b. This kind of connection is permitted when up to 3
collectors are used and the max. flow rate is 1 l/min/
collector. Then the cold liquid inlet is at one side bottom
and the hot liquid outlet is at the same side top. Both the
other ends shall be plugged..
A brass elbow shall be installed at the inlet to the collec-
tor array with a transition to the interconnection piping. At
the outlet from the collector array, a brass adapter shall
be installed that will enable connection to the piping.
The brass elbow and adapter are involved in Regulus
connection kits, code 10413 and 10414.
All solar components must be carefully and safely sea-
led and must be made of material resistant to glycol and
temperatures up to 160 °C. For connection piping we
recommend using KOMBIFLEX stainless-steel flexible
pipes, or copper pipes joined by soldering.
5. HYDRAULIC CONNECTION
Fig. 23a:
The recom-
mended
method of
collector
intercon-
necting
Fig. 23b:
Alternative
one-sided
connection
method
Fig. 24: Col-
lector con-
necting (the
pic. shows
connection
of the upper
fitting; the
lower fitting
shall be
connected
and tighte-
ned in the
same way.)

16
Number
of collec-
tors
Connection type Max.
recomm.
flow rate
Connecting pipe
Copper Kombiflex
array x collector
1 1 × 1 2 l/min Cu 15 × 1 DN 12
2 1 x 2 series 4 l/min Cu 15 × 1 DN 16
3 1 x 3 series 6 l/min Cu 18 × 1 DN 16
4 1 x 4 series 8 l/min Cu 18 × 1 DN 20
5 1 × 5 series 10 l/min Cu 22 × 1 DN 20
6 2 × 3 parallel 12 l/min Cu 22 × 1 DN 25
8 2 × 4 parallel 16 l/min Cu 28 × 1,5 DN 25
9 3 × 3 parallel 18 l/min Cu 28 × 1,5 DN 25
10 2 × 5 parallel 20 l/min Cu 28 × 1,5 DN 25
12 3 × 4 parallel 24 l/min Cu 28 × 1,5 -
Max. 30 m of the inlet and outlet piping together.
Fig. 26: Position of a temperature sensor
In no event plastic tubes can be used for inlet/outlet
piping as they do not meet the operation requirements
for solar systems.
Pipes for collectors can be lead through disused chim-
neys, ventilation shafts or grooves in a wall. In order to
prevent high thermal losses through convection, open
shafts shall be properly sealed. Also thermal dilatation
shall be remembered and pipes fitted with compensators
or other compensation elements.
Piping shall be connected to the house earthing.
Pipes of the solar system must be fitted with
thermal insulation e.g. of AEROFLEX type, so
that thermal dissipation from the pipes does not deteri-
orate a total efficiency of the solar system. The thermal
insulation must be resistant to temperatures up to 160
°C, for outdoor piping also a UV protection is essential
as well as non-deliquescence of the material. For indoor
piping, the thermal insulation should be at least 13 mm
thick, for outdoor piping at least 19 mm.
Place the thermal probe into the pocket of the T- or X-
piece at the outlet from the last collector, see pic. 26.
A twisted wire 2x1 mm2, non-shielded should be used,
separated from power cables.
Its maximum length is 100 m. Minimize the number of
electrical boxes a terminal blocks.
connection length: up to 25 m cross section: 0.25 mm2
connection length: up to 50 m cross section: 0.5 mm2
connection length: up to 100 m cross section: 1.0 mm2
• the thermal and mechanical resistance of the wire
used shall correspond to the environs the wire passes
through.
6. TEMPERATURE SENSOR POSITIONING
Tab. 1: Recommended pipe diameters
AV23 Flow rate regulator with
indicator 2-12 l/min, 3/4“
3/8” air discharge valve and
3/8” ball valve up to 160°C
Fig. 25 Possible collector connections

17
The pump station shall be installed in accordance with
the respective manual.
Regulus pump stations contain the principal components
shown in Fig. 27:
1 - Ball valve on flow line (red frame thermometer, 0-
120 °C dial), with check valve
2 - Ball valve on return line (blue frame thermometer,
0-120 °C dial), with check valve
3 - Safety unit protects the installation from
overpressure. It involves a 6 bar safety valve,
manometer and G ¾” connection to expansion
tank.
7. SOLAR PUMP STATION
4 - Air eliminator
5 - 3-speed circulation pump, manual control
6 - Flow control screw
7 - Filling valve
8 - Flowmeter
9 - Drain valve
10 - Safety valve spillway connection
Safety valves are always included in pump stations.
If no pump station is used in the installation, the solar
system shall be equipped with a 6 bar safety valve,
resistant to high temperatures (usually up to 160 °C).
No shut-off valve shall be installed between a safety
valve and collectors.
Fig. 27: FlowCon B Solar Pump
Station
1
23
4
5
67
8
9
10

18
(Tab. 2 is valid for height up to 20 m only, otherwise the
size shall be calculated.)
8.1 - Expansion vessel sizing
A solar expansion vessel shall be sized for a tempe-
rature difference between the min. winter temperature
and the max. summer temperature. The working range
of expansion vessels is from -10 °C to +130 °C. Further
it shall be able to contain fluid volume of all collectors
in case of stagnation (max. collector temperature at
no flow and high sunshine intensity). In solar systems
with forced circulation such pressure expansion vessels
shall be only used that are fitted with a propylene-glycol
resistant membrane and whose min. working pressure is
6 bar. Installation shall be done in a position with the dia-
phragm flooded. In case the hear carrier starts boiling,
the diaphragm mustn’t get in touch with steam!
The recommended size of an expansion vessel see
Table 2..
Tab. 2: Expansion vessel recommended size. Max. 30 m
of the inlet and outlet piping together.
8.2 - Calculation of a system working pressure
The pressure in the solar system is calculated using the
relation
p = 1.3 + (0.1 h)
p…pressure in a solar system [bar]
h…height from a pressure gauge to the middle of a col-
lector field [m]
Adjust the pressure by discharging solar liquid after the
pressure test is done.
8.3 - Calculation of expansion vessel preset
pressure
Before filling the system, adjust the initial overpressure
in the expansion vessel to a value by 0.5 bar below the
calculated system pressure.
p exp = p - 0.5 [bar]
In order to set the pressure, use a current car-tyre pres-
sure gauge of a suitable pressure range.
The expansion vessel has a current tyre valve under its
lid.
8.4 - Examples of calculating working pres-
sure and expansion vessel pressure
8.4.1 - An example of calculating system working
pressure
The height from a pressure gauge to the middle of a
collector:
h = 10 m
Pressure in the solar system (the solar system is to be
pressurized to this value):
p =1.3 + (0.1 h) = 1.3 + (0.1 . 10) = 2.3 bar
8.4.2 - An example of calculating expansion vessel
pressure
Before filling the system, the preset pressure in the
expansion vessel shall be adjusted to the value of:
p exp = p - 0.5 = 2.3 - 0.5 = 1.8 bar
Number of
collectors Expansion vessel size Max. piping length
3 18 Max. 30 m of
the inlet
and outlet
piping
together
4 25
5 40
6 60
8 60
9 80
10 80
12 100
8. EXPANSION VESSEL SIZING AND WORKING PRESSURE CALCULATION
Fig. 28: Expansion vessel

19
Install the air vent to the highest point of the system.
Should there be more places with a risk of air pockets,
air vents should be installed also there.
It is recommended to amend the air vent with a local
pipe widening that calms down the stream and helps in
good separating bubbles from the fluid (see Fig. 30).
A ball valve shall be always installed under the automatic
air vent valve, so that the automatic air vent can be clo-
sed after the system commissioning. Solar liquid leaks
can be avoided in case of system stagnation.
For an efficient removal of bubbles from the system it is
advisable to fit the pump station with an air eliminator
(see Fig. 29).
9. INSTALLATION OF AIR RELEASE VALVES
Fig. 29: Air eliminator
Fig. 30: Horizontal air eliminator
and an automatic air vent

20
The below listed procedures are valid when a Regulus
pump station is used.
10.1 Filling
• in order to fill the system, use a filling device with a
reservoir for solar liquid and a filling pump (see Fig. 31)
• attach the filling hose to the feed valve and open the
valve completely
• attach the return hose to the bleed valve and open the
valve completely
• close the integrated ball valve in the flowmeter (the
groove in the flowmeter‘s adjusting screw must be
horizontal).
• open the check valve (valves - two for a twin-pipe
solar pump station) above the pump by turning the ball
valve by 45° (intermediate position between open and
closed)
• pour sufficient quantity of solar fluid into the reservoir
of the filling device, turn on the filling pump and fill the
solar system.
10.2 Flushing
• flush the solar system for at least 15 minutes using
the filling device. In order to bleed air and possible
impurities from the system perfectly, open shortly the
integrated ball valve of the flowmeter from time to time
(the groove vertically).
10.3 Air bleeding
• with the filling pump running, close the bleed valve and
increase the pressure up to about 5 bar
• close the feed valve and turn off the filling pump, open
the regulation screw on the flowmeter (groove horizon-
tally), do not disconnect the filling pump hoses!
• set the circulation pump(s) to the highest speed and
repeat switching on and off to air-bleed the system (an
air-free pump works almost noiselessly)
• watch the system pressure and when it starts falling,
increase it by turning on the filling pump and opening
the feed valve to 5 bar
• repeat air bleeding so long until the float in the
flowmeter‘s regulation valve takes a steady position
during pump operation and bubbles stop appearing in
the flowmeter. After that, let the circulation pump run
for at least 5 minutes.
• in case an automatic air vent/s is/are used anywhere in
the solar system, close this valve after air bleeding.
10. SYSTEM FILLING, FLUSHING, LEAK TEST AND AIR BLEEDING
10.4 Leak test
• examine the whole system at 5 bar pressure (all con-
nections, solar collectors, valves etc.), no visible leaks
are allowed. Leave the system under pressure for at
least 2 hours, then examine the system once again
• consider the test result successful if no leaks appear
and/or no noticeable pressure drop appears in the
system
• set the working pressure by point 8.2 Calculation of
system working pressure
• set the pump to a suitable speed and set the flow by
the flowmeter and data in Tab. 1
• disconnect the hoses of the filling device and screw
caps on the feed and bleed valves
• open entirely the ball valve(s) above the pump
• after several days of operation, air-bleed the system
again.
Do not flush the system with water. Since it is impossible
to empty it completely, a risk of frost damage appears.
Fig. 31: Filling a solar system