Regulus KPG1H-ALC User manual

www.regulus.eu
KPG1H-ALC
KPG1H-ALC
EN
Installation and Operation Manual
Solar Thermal System with KPG1H-ALC Collectors

2
CONTENTS
General Installation and Operation Instructions .…....……...…….…................................. 3
1 Supply of Mounting System ..……........……...……..………....……..……............................ 4
2 Sloping Roof Mount ..........................................………………………................................. 5
2.1 Preparation ...………………………………………....………............................................ 7
2.1.1 Roof anchor installation for sloping roofs ..……………………................................ 7
2.1.2 Installation with roof anchors and rafters ………………………............................... 7
2.1.3 Installation with roof anchors for slate, shingle or metal roofs ............................... 8
2.1.4 Installation with bolts for tting rails onto a roof .................................................... 8
2.2 Installing rails onto roof anchors ….........……………………………............................... 10
2.3 Collector mounting …………………………….………………………............................... 10
3 Connection Pipe Passage through a Roof …...…...…................................................... 11
4 Flat Roof Mount …………....……….…………………........................................................ 12
4.1 Overview ………..........…….……………….………………………................................. 12
4.2 Flat roof support mounting ………………….....………….............................................. 14
5 Hydraulic Connection …………………………………………………................................. 16
5.1 Collector connecting .......………………………………………………............................ 16
5.2 Collector interconnecting …………………..…………………………............................. 16
6 Temperature Probe Positioning …………………………………….................................... 18
7 Pump Station ………………………………………..........…………...................................... 19
8 Expansion Vessel Sizing and Working Pressure Calculation ………........................... 20
8.1 Expansion vessel sizing ……………………………...…………..................................… 20
8.2 Calculation of a system working pressure ……………..………................................… 20
8.3 Calculation of an expansion vessel preset pressure …………................................…. 20
8.4 Examples of calculating working pressure and expansion vessel pressure ...........…. 20
8.4.1 Example of calculating system working pressure ………......................…………. 20
8.4.2 Example of calculating expansion vessel pressure …………...................………. 20
9 Installation of Air Release Valves …………………..………….….................................…. 21
10 System Filling, Flushing, Leak Test and Air Bleeding …............................................. 22
10.1 Filling ……………………………………......………………………....................………. 22
10.2 Flushing …………………………………………........………………..................………. 22
10.3 Air bleeding …………………………….................……………….....................………. 22
10.4 Leak test ………………….............................….……………………....................……. 22
11 Commissioning …………..……...............................................................................……. 23
12 Operation, Checks and Maintenance ………........…………………...........................…. 23
13 Servicing and Warranty …………..................………………………….........................…. 23
14 Technical Data .…...…...................................................…...….....................…............… 24
15 Connection dimensions…………………..……...........................................................…. 26
16 Annual Check Description ............................................................................................. 27
Service sheet ......................................................................................................................... 28

3
Collector description
REGULUS Flat Solar Collectors are designed for solar
domestic hot water heating (DHW), backup- and pool
heating with solar energy. Solar radiation penetrates the
glass and is intercepted by an efcient absorption layer
applied on an all aluminum absorber. The heat is then
transferred into heat transfer uid. The absorber is sea-
led in a compact frame with high quality thermal insulati-
on. The collectors are designed for year round operation,
that’s why they work in a separate primary circuit lled
with antifreeze heat carrier.
The collectors are not intended for direct wa-
ter heating. If different heat transfer uid is used
than specied 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. 14 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. KPG1H-ALC collector
2. Instruction manual
3. Warrant Certicate
General instructions for installation
The installation 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 roong manu-
facturer and the max. permissible roof load shall be
checked.
Mounting method for solar collectors shall always re-
spect local conditions, i.e. roof inclination and weather
inuence on the overall load on the collector. Kindly con-
sult the fastening 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 mount elements may be used. Other
fastening 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°).
Collectors are installed according to marking.
The collectors shall be installed at an angle
between 15° and 75°.
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 collec-
tors.
The numbers of roof anchors shown in the Mount Kits
for Fitting and Connecting Regulus Solar Collectors are
designed for the following load:
Max. permissible snow and wind load ≤ 1,8 kN/m2
Max. permissible wind load - negative pressure ≤ 1,0 kN/m2
The customer/user shall be informed about this fact
prior to starting installation of a solar thermal system. If
a higher load than shown above is expected in the area
in question, a statics expert shall be consulted and more
roof anchors designed, or other measures taken that
would ensure safe collector tting. Regulus refuses any
responsibility for damage caused by wrong design of
collector fastening.
GENERAL INSTALLATION AND OPERATION INSTRUCTIONS

4
Mounting kits for tting and connecting KPG1H-ALC solar collectors Code
Connection kit for collector array
(3/4“ M inlet and 3/4“ M outlet with a sheath for solar temperature sensor) 14618
Mount kit for installation of 2 collectors 10700
Mount and interconnection kit for 2 collector 14517
Extension kit for xing and connecting 1 collector 14518
* Roof mount and interconnecting kits are necessary to create a hydraulically connected collector array
tted to 2 mounting rails. The kits contain interconnecting ttings 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 roong material.
Anchors for various roong types Code
Stainless-steel anchor for slate roofs 11574
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
Bolt for tting rails onto a roof 7320
1. DELIVERY OF MOUNTING SYSTEM
Supports and support strut for landscape installation on at roof Code
Triangle support strut 25° 10907
Triangle support strut 45° 10921
Support strut incl. bolts for triangle supports, for landscape installation on at roof 10908
Supports for landscape installation on sloping roof Code
Triangle strut 15° for landscape installation on sloping roof 11070
Triangle strut 25° for landscape installation on sloping roof 11071
Triangle strut 45° for landscape installation on sloping roof 11072
Wall Bracket for landscape installation Code
Wall Bracket for landscape installation, pitch 15° 14792
Wall Bracket for landscape installation, pitch 25° 14793
Wall Bracket for landscape installation, pitch 45° 14794

5
2. SLOPING ROOF MOUNT
Fig. 1 Collector installation on sloping roof
2
1
78
5
6
4
3
9
10
11
Pos. Item Code
1 Flat plate collector 11427
2 Roof anchor with M8 bolt/special head for rails
6857 or other,
depending on
roong type
Triangle struts for inclination adjustment, suitable for anchors for sloping roofs - 15°, 25°
and 45° angle
11070, 11071,
11072
Interconnecting pipes

6
Mount and interconnection kits for landscape installation, landscape connection kit
No. of collectors (kit code)
Item code1 2 Connection kit
(10700) (14517) (14618)
3 Aluminum rail, 2 pieces 2.20 m 4.40 m - 6949
4 M8 nut for the rails 4 pcs 6 pcs - 6925
5 M8 ×16 bolt with allen head 4 pcs 4 pcs - 6926
6 Retaining side bracket 4 pcs 4 pcs - 10522
7 Retaining bracket for collector bottom 2 pcs 4 pcs - 13057
9 Insulation 35 mm diam., 19 mm thick 0.5 m 0.4 m - 7188
10 Retaining bracket between 2 collectors - 2 pcs - 10673
11 H-rail end plug 4 pcs 4 pcs - 11773
Insulation tape 0.8 m 0.8 m - 7227
822 mm nipple - 1 pcs - 7629
Nipple 3/4“ M/M, thick wall - - 1 pcs 6970
Elbow 3/4“ M , brass - - 1 pcs 13496
Pipe cross 3/4“ F Cu 22mm pipes, brass - - 1 pcs 7632
Single sheath, 7x8 x 200 mm, 1 sensor, 1/2“ - - 1 pcs 7217
Capillary spring, small, 1/2“, stainless steel - - 1 pcs 10845
Extension mount and interconnection kits for 1 KPG1H solar collector Code
Extension mount and interconnection kit for 1 solar collector 14518
Počet kolektorů Celková délka Počet podpěr
1 220 cm 2
2440 c
m3
185 185 35 35
cca 38
150
35 35
cca 38
Fig. 2: Roof anchor fastening for landscape collectors
No of collectors Overall length No of anchors

7
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
thermal store / stoage water heater
Further have ready the necessary material, tools and
safety equipment for working on a roof.
Check if the roong manufacturer offers roof hooks and
if the roof warranty will not be violated.
2.1.1 Installation with roof anchors and au-
xiliary boards
Prior to installing anchors on auxiliary boards, the fo-
llowing 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 roong so that auxiliary boards can be
inserted (approx. distance between boards 800-900
mm). For roof tiles, just shifting them upwards in the
length of the auxiliary board is sufcient (see Fig. 4).
• Fit 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.
• Fit the anchors using stainless steel screws.
2.1.2 Installation with roof anchors for rafters
For tiled roofs, rafter anchors can be used. Either a xed
(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 fastening
40
30
10
30
30
auxiliary board
battens
counter batten
rafter
waterproofing membrane
underlay
room for an auxiliary board
counter batten
rafter
roof battens
Fig. 3: Underlay to match thick battens
Fig. 4: Remove roof tiles to t the board
auxiliary board width is
100 - 200 mm

8
board. For this anchor type also the rail tting height can
be adjusted.
Installation
• Remove roong in places where anchors shall be tted
(Fig. 5). The distance “a” between anchors is dened
in Fig. 2.
• Cut the counter batten used for fastening the waterpro-
ong 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 xed
stainless steel anchor is used, its position shall be
adjusted before faastening.
• Fit all the other roof anchors in the same way.
• When installing roof anchors, maintain a direction
parallel to the roong (horizontal).
2.1.3 Installation with roof anchors for shin-
gle or metal roofs
• Depending on the number of collectors, measure and
calculate the positions for ting roof anchors (Fig. 2).
Such places shall be selected for mounting where an-
chors can be fastened sufciently into the roof frame
(rafter or similar).
• Prior to tting the anchor, apply suitable silicone putty
on the contact surface (adjacent to the roong) in or-
der to prevent water leaking, or possibly use a sealing
method recommended by the roong manufacturer.
• Simply lay the anchor onto the roof tiles and fasten it
with stainless-steel bolts.
If the roong is made of e.g. copper or zinc-pla-
ted iron, then the anchor contact surface shall be
isolated using suitable underlay (rubber). Other-
wise there is a risk of contact corrosion.
2.1.4 Installation using bolts for tting 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.
Installation:
• Depending on the number of collectors, locate the
places for drilling holes and installing bolts into the ro-
ong (Fig. 7e). 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 roong wave, not in its valley, to avoid
leakage.
counter
batten
rafter
roof
batten
s
waterproofing membrane
a
• The bolt shall be screwed into a rafter or another
massive wooden roof element using spanner No. 7.
• After screwing the bolt in, put on the rubber seal and
using a washer and nut, seal the drilled hole.
• Then mount the U-shaped bracket on the bolt, be-
tween two nuts with a serrated washer.
• Then M8 bolt with oating head (for rails) shall be
mounted into the other end of the bracket. First insert
the oating 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: Fitting an auxiliary board and roof anchors
Fig. 6: A place for mounting a roof anchor on a
rafter - detail

9
70
ø 9
80
130
40
40
9
(138)
70
58
300
100
35
2× Ø6
80
6
150
120
136−156
65.5
40
Ø 9
54
56
180
Fig.7: Basic overview of fastening elements
150
80
125
≈160
35
Ø 10
40
45
150
7
5
e) Roong bolt for rail fastening
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) Stainless steel roof anchor for metal
or slate roong
RIGHT !
70
230
35
2× Ø6
72
6

10
2.2 Fitting 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. 9) with the hori-
zontal rail and shift the rail onto it, or shift the screws
into the rail rst and fasten to the anchors. Use serra-
ted lock washers to t 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. 10).
• Then tighten the nuts on fastening bolts.
2.3 Collector mounting
Collectors shall be covered during mounting.
Installation:
• Insert safety retaining brackets (Fig. 11) into the
bottom rail, 2 brackets per collector.
• Insert the retaining brackets into the bottom rail about
100 mm from the collector edge.
• Lay the rst collector carefully on the rails and align it
in the brackets.
Collectors shall be placed on the rails with
the connection piping 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. 12).
roof anchor
top / bottom rail
M8 bolt with
travelling head
parallel
D1
D2
Fig. 9: Fitting the rail onto the roof anchors
Fig. 10: Alignment of base rails
Fig. 11: Inserting safety retaining brackets
Safety retaining bracket
Rails
~100 mm
B
~100 mm
Fig. 12: Distance between the safety retaining brackets

11
• Insert nuts into both the rails (Fig. 13). Put the retai-
ning side brackets on the rails and fasten the collector
using M8x16 bolts.
• Lay the following collector next to the rst one, mainta-
ining a sufcient gap. Then put on the threaded ttings
(Fig. 14, pos. 9) and push the collector to the already
mounted one until stop. Hold the tting 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 14).
48
6
7
5
For passing the connection pipes through a roof
e.g. ventilation tiles can be used, where the hole
is modied according to the diameter of the pipe
with insulation. Anyway standards of the roong
manufacturer shall be respected for pipe passage
through a roof.
3. CONNECTION PIPE PASSAGE THROUGH A ROOF
5 – M8 nut for rail
6 – M8x16 allen head bolt
7 – Retaining bracket
Fig. 13: Fitting the retaining brackets
Fig. 13b: Pipe passing through ventilation tile

12
4.1 - Overview
4. FLAT ROOF MOUNT
Fig. 14 Collector installation on a at roof
Pos. Item Code
1 Flat plate collector 11427
2Triangle support for horizontal installation on at roof
Number of collectors (No. of
supports needed) 10907,
10921,
127861 2
(2) (3)
3Support strut incl. bolts for triangle supports, for horizontal installation on at roof 10908
Horizontal collector installation
3
2
1
89
6
7
5
4
10
11
12

13
Mount and interconnection kits for landscape installation, landscape connection kit
Number of collectors (kit
code)
Item code
1 2 Connec-
tion kit
10700 14517 14618
4 Aluminum base rail, 2 pieces 2.20 m 4.40 m - 6949
5 M8 nut for the base rail 4 pcs 6 pcs - 6925
6 M8x16 stainless-steel bolt (allen head) 4 pcs 4 pcs - 6926
7 Retaining side bracket 4 pcs 4 pcs - 10522
8 Retaining bracket for collector bottom 2 pcs 4 pcs - 13057
10 Insulation 35 mm diam., 19 mm thick 0.5 m 0.4 m - 7188
11 Retaining bracket between 2 collectors - 2 pcs - 10673
12 H-rail end plug 4 pcs 4 pcs - 11773
Insulation tape 0.8 m 0.6 m - 7227
9Threaded ttings 22 mm - 1 pcs - 7629
Nipple 3/4“ M/M, thick wall - - 1 pcs 6970
3/4” M/M Brass Elbow - - 1 pcs 13694
Pipe cross 3/4“ F Cu 22mm pipes, brass - - 1 pcs 7632
Single sheath, 7x8 x 200 mm, 1 sensor, 1/2“ - - 1 pcs 7217
Capillary spring, small, 1/2“, stainless steel - - 1 pcs 10845
Extension mount and interconnection kits for 1 KPG1H solar collector Code
Extension mount and interconnection kit for 1 solar collector 14518
Počet kolektorů Celková délka Počet podpěr
1 220 cm 2
2440 c
m3
185 185 35 35
cca 38
150
35 35
cca 38
No of collectors Overall length No of supports

14
4.2 - Flat roof support mounting
A at 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 sufcient for supports for
up to 5 collectors.
Installation:
• Lay two rails in parallel on the mounting surface, their
pitch shall be 885 mm.
• The diagonals between the rails shall be of the same
length: D1 = D2 (Fig. 15)
• Insert the M8 bolt with a special head (Fig. 17) into the
rail grooves.
cca 350 mm
D2
2
4
4
885 mm
T strut
base rails
L strut
D1
Fig.. 15: Aligning the rails and mounting the rst triangular support
• Assemble the triangular supports that come partially
screwed together (Fig. 16). Join the loose support
ends with a bolt (Fig. 16) and tighten all connections.
• Locate the positions to t triangular supports. The
distance of the rst triangular support from the end of
the rail shall be about 350 mm.
• Fit the L-support of the triangle to the base rail using
screws, serrated lock washers and nuts for rails 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.

15
• Install the strut between the two triangular supports
(Fig. 18). Following Fig. 18, insert special M8 nuts into
the triangle support rail. Then lay the strut onto the
rails and fasten it with M8x12 bolts with washers.
• Continue assembling the remaining triangular supp-
orts with a pitch as shown in Fig. 2. Adjust this distan-
ce 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 350 mm from the ends of both
rails.
After tting 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
strut
2
c
Fig. 19: Installation of further supports
Fig. 17: Assembly using special bolts.
Fig. 16: Assembly using special bolts.
Special nut
for rails
rail
M8x12 bolt with
allen head
L strut
Fig. 18: Strut installation

16
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 ad-
vance is necessary. A damaged roof must be
re-insulated by a specialist.
Fit the collectors to the rails in the same man-
ner as if installing on an inclined roof (see point
2.3).
Minimum distance between collector elds see Fig. 21.
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
twice the height winter
sun
solar
collector
height
25°
solar
collector
5.1 - Collector connecting
For collector mounting follow the instructions in chapter
5.2. Fasten the rst collector and lay the following one
next to the rst one, maintaining a sufcient gap. Then
put the threaded ttings on both the upper and lower out-
lets and push the collector to the already mounted until
stop. Hold the tting with a spanner (Fig. 23) to prevent
turning, and tighten the nuts. Continue in the same way
with further collectors.
Put the insulation on the threaded ttings only
after a successful leak test.
5.2 - Collector interconnecting
Hydraulic interconnection of collectors shall be done
according to Fig. 22. Maximum of 3 collectors may be
connected with threaded ttings in a row. The connecting
pipes shall be lead the shortest way. The recommended
pipe diameters and ow rates through collector arrays
are shown in Tab. 1.
5. HYDRAULIC CONNECTION
Fig. 20: Static safety (burden)
Fig. 21: Minimum distance between collector elds

17
VSTUP VÝSTUP Fig. 22:
The rec-
ommended
method of
collector
intercon-
necting
Fig. 23: Col-
lector con-
necting (the
pic. shows
connection
of the upper
tting; the
lower tting
shall be
connected
and tight-
ened in the
same way.)
Then the cold liquid inlet is at one side and the hot liquid
outlet is at the second side.
At the inlet into a collector array, a brass elbow shall be
installed to the connecting pipe.
A brass pipe cross shall be installed at the outlet from
the collector array that will enable connection to the
piping, sheath installation for the collector temperature
probe and eventual installation of a ball valve and an
automatic air discharge valve. The brass elbow and
pipe cross are involved in Regulus connection kit, code
14618.
All solar components must be carefully and safely sealed
and must be made of material resistant to glycol and
temperatures up to 160 °C. For connection piping we
recommend using KOMBIFLEX stainless-steel exible
pipes, or copper pipes connected by soldering.
In no event plastic tubes can be used for inlet/outlet pi-
ping as they do not meet the operation requirements for
solar thermal 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 tted with compensators
or other compensation elements.
Piping shall be connected to the house earthing.
Pipes of the solar thermal system must be tted with
thermal insulation, so that thermal dissipation from the
pipes does not deteriorate a total efciency of the solar
thermal 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.
OUTLET
INLET

18
Number of
collectors
Connection type Max.recomm.
ow rate
Connecting pipe
array x collector Copper Kombiex
1 1 × 1 2 l/min Cu 15 × 1 DN 12
2 1 x 2 in series 4 l/min Cu 15 × 1 DN 16
3 1 x 3 in series 6 l/min Cu 18 × 1 DN 16
4 2 x 2 in parallel 8 l/min Cu 18 × 1 DN 20
6 2 × 3 in parallel 12 l/min Cu 22 × 1 DN 25
9 3 × 3 in parallel 18 l/min Cu 28 × 1.5 DN 25
Max. 30 m of the inlet and outlet piping together.
Fig. 25: Position of a temperature sensor
6. TEMPERATURE SENSOR POSITIONING
Tab. 1: Recommended pipe diameters
Fig. 24: Variants of non-typical connections
Place the temperature sensor into the pocket of the
X-piece at the outlet from the last collector, see pic. 25.
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.
Regulátor průtoku AV23
s ukazatelem 2-12 l/min, 3/4“
Odvzdušňovací ventil 3/8“ a
kulový kohout 3/8“ do 160 °C
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

19
The pump station shall be installed in accordance with
the respective manual.
Regulus pump stations contain the principal components
shown in Fig. 26:
7. SOLAR PUMP STATION
Safety valves are always included in pump stations.
If no pump station is used in the installation, the solar
thermal system shall be equipped with a 6 bar safety
valve, resistant to temperatures up to 160 °C.
No shut-off valve shall be installed between a safety
valve and collectors.
Fig. 26: Solar Pump Station
1
2
3
4
5
6
7
8
9
10
1 - Ball valve on ow 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
vessel.
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

20
(Tab. 2 is valid for elevation 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 temperatu-
re 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 uid volume of all collectors in
case of stagnation (max. collector temperature at no ow
and high sunshine intensity). In solar thermal systems
with forced circulation such pressure expansion vessels
shall be only used that are tted 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 ooded. 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 thermal system is calculated
using the relation
p = 1.3 + (0.1 h)
p…pressure in a solar thermal system [bar]
h…height from a pressure gauge to the middle of a col-
lector eld [m]
Adjust the pressure by discharging solar liquid after the
pressure test is done.
8.3 - Calculation of expansion vessel preset
pressure
Before lling 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 thermal system (the 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 lling 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. 27: Expansion vessel