Regulus KPS1 User manual

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www.regulus.cz
KPS1
KPS1
EN
Installation and Operation Instructions
Solar System with KPS1 Collectors

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CONTENTS
General Installation and Operation Instructions .…....……...…….…................................. 3
1 Supply of Mounting System ..……........……...……..………....……..……............................ 4
2 Sloping Roof Mount ..........................................………………………................................. 5
2.1 Preparation ...………………………………………....………............................................ 6
2.1.1 Roof anchor installation for sloping roofs ..……………………................................ 6
2.1.2 Installation with roof anchors and rafters ………………………............................... 6
2.1.3 Installation with roof anchors for slate, shingle or metal roofs ............................... 7
2.1.4 Installation with bolts for xing rails onto a roof .................................................... 7
2.1.5 Installation with universal templates for Cembrit roofs ...................................... 9
2.2 Installing rails onto roof anchors ….........……………………………............................... 9
2.3 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
17 Service sheet ..................................................................................................................... 26

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Collector description
REGULUS KPS1 Flat Solar Collectors are designed for
solar domestic hot water heating (DHW), support- and
pool heating with solar energy. Solar radiation pene-
trates the glass and is intercepted by an efcient absorp-
tion layer applied on an aluminium absorber. The heat
is then transferred into heat transfer uid. 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 primary
circuit lled with antifreeze heat carrier.
The collectors are not intended for direct water
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. 10 pieces
on a pallet.
During handling the collector glass shall be always fac-
ing upwards.
Please check the condition of the collector upon re-
ception from your supplier or forwarder. Later claimed
mechanical 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. KPS1 Collector
2. Instruction manual
3. Warranty Certicate
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 nec-
essary to cover collectors in order to avoid overheating
and possible burn injury to the installer.
Prior to installation, conditions set by the roong man-
ufacturer and the max. permissible roof load shall be
checked.
Mounting method for solar collectors shall always
respect local conditions, i.e. roof inclination and weath-
er inuence on the overall load on the collector. Kindly
consult the xing method with a structural statics expert.
During installation the collectors and accessories shall
be handled carefully. Defects caused by improper han-
dling 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 se-
curing the area against objects falling down from a roof.
Only REGULUS xing elements may be used. Other
xing elements may be used only with a written approval
by REGULUS company.
Collectors shall not be exposed to solar radiation until
commissioned. The absorption surface may get dam-
aged.
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 an outer wall) which is ideal for winter
operation.
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 protec-
tions against snow slide shall be installed above
the collectors.
The numbers of roof anchors shown in the Mounting Kits
for Fixing 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 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 xing. Regulus refuses any responsibility
for damage caused by wrong design of collector xing.
Lightning protection
Lightning protection is obligatory for solar systems.
When installed on a roof, collectors must be wired
to lightning protection equipment. Czech norm ČSN EN
62 305 shall be observed.For other countries check with
local authorities.
GENERAL INSTALLATION AND OPERATION INSTRUCTIONS

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Mounting kits for xing and connecting KPS1 solar collectors Code
Connection kit for a KPS1
(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 KPS1 collector
*[for 4 anchors or 2 supports+1 strut]] 12178
Fixing and interconnection kit for 2 KPS1 collectors
*[for 6 anchors or 3 supports+1 strut] 12179
Fixing and interconnection kit for 3 KPS1 collectors
*[for 8 anchors or 4 supports+1 strut] 12180
Fixing and interconnection kit for 4 KPS1 collectors
*[for 10 anchors or 5 supports+1 strut] 12181
Fixing and interconnection kit for 5 KPS1 collectors
*[for 10 anchors or 5 supports+1 strut] 12182
* Roof xing and interconnection kits are necessary to create a hydraulically connected collector array xed 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 select-
ed from the following chart by the roof type and roong material.
Supports and strut for at and sloping roof installation Code
Triangle support 15° 11979
Triangle support 25° 10975
Triangle support 45° 6859
Strut incl. screws for triangle supports for at roofs 9563
Supports for sloping roof installation Code
Triangle support 15° 10748
Triangle support 25° 8805
Triangle support 45° 10094
Triangle support 60° 9631
Anchors for various roong types Code
Stainless steel anchor for slate roofs 11574
Anchor for pantiles - hot-dip galvanized steel 7929
Stainless-steel anchor for pantiles 6857
Stainless steel anchor for pantiles - rafter mounted, incl. self tapping screws 10159
Bolt for xing rails onto a roof 7320
1. DELIVERY OF MOUNTING SYSTEM

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Pos. Item Code
1 Flat plate collector 16277
2 Roof anchor with M8 bolt with special head for rails
6857 or other,
depending on
roong type
Triangle supports for inclination adjustment, suitable for anchors for sloping roofs - 15°, 25°,
45° and 60° angle
11748, 8805,
10094, 9631
Interconnecting pipes
Fixing and interconnection kits
No. of collectors (kit code)
Item code1 2 3 4 5
(12178) (12179) (12180) (12181) (12182)
3 Aluminum rail, 2 pieces 1.12 m 2.21 m 3.32 m 4.42 m 5.52 m 6949
4 M8 nut for the rails 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 6925
5 M8×20 bolt with allen head 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 12136
6 Retaining side bracket for KPS 4 pcs 8 pcs 12 pcs 16 pcs 20 pcs 12141
7 Retaining bracket for collector bottom 2 pcs 4 pcs 6 pcs 8 pcs 10 pcs 11690
8Compression nut and ring for collector inter-
connection - 2 pcs 4 pcs 6 pcs 8 pcs 7629
9 Insulation 35 mm diam., 19 mm thick 0.5 m 0.75 m 1 m 1.5 m 2 m 7188
10 Base rail emd plug 4 pcs 4 pcs 4 pcs 4 pcs 4 pcs 11773
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
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2. SLOPING ROOF MOUNT
Fig. 1 Collector installation on a sloping roof
Expansion mount and interconnection kits for 1 KPS1+ANT solar collector Code
Expansion mount and interconnection kit for 1 KPS1+ and KPC1+ solar collector 12183

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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 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 1600-1800
mm). For roof tiles, just shifting them upwards in the
length of the auxiliary board is sufcient (see Fig. 4).
• 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.
2.1.2 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 xing
40
30
10
30
30
auxiliary board
battens
counter batten
rafter
waterproofing membrane
underlay
No. of collectors Total length No. of anchors
2 211 cm 6
3 319 cm 8
4 428 cm 10
5 536 cm 10
70.5
~35 ~35
~35 ~35
~35 ~35
~65 ~65
83 83
89.5
89.589.5
93 93 93
60
60
60
60
70.5
83
89.5
93
room for an auxiliary board
counter batten
rafter
roof battens
Fig. 3: Underlay to match thick battens
Fig. 4: Remove roof tiles to x the board
Fig. 2: Layout of roof anchors
auxiliary board width is
100 - 200 mm

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board. For this anchor type also the rail xing height can
be adjusted.
Installation
• Remove roong in places where anchors shall be xed
(Fig. 6). The distance between anchors is dened in
Fig. 2.
• Cut the counter batten used for xing the waterproo-
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.
• Fix 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 xing roof anchors (Fig. 2).
Such places shall be selected for mounting where
anchors can be xed sufciently into the roof frame
(rafter or similar).
• Prior to xing the anchor, apply suitable silicone
putty on the contact surface (adjacent to the roong)
in order to prevent water leaking, or possibly use a
sealing method recommended by the roong manu-
facturer.
• Simply lay the anchor onto the roof tiles and x 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 xing 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
roong (Fig. 7d). Pre-drill 6 mm 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.
• 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 (Fig.
7d) and using a washer and nut, seal the drilled hole.
counter
batten
rafter
roof
batten
s
waterproofing membrane
a
• Then mount the U-shaped bracket (Fig. 9) on the
bolt, between two nuts with a 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: Fixing an auxiliary board and roof anchors
Fig. 6: Opening the space for anchor xing

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(138)
70
58
300
100
35
2× Ø6
80
6
70
230
35
2× Ø6
72
6
Fig. 7: Basic overview of xing 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) Stainless steel roof anchor for metal or slate roong
steel for pantiles
a) Stainless steel anchor on rafter, for pantiles,
incl. screws
b) Roof anchor of stainless steel or zinc-plated
steel for pantiles
70
ø 9
80
130
40
40
9
d) Roong bolt for rail xing
RIGHT !

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2.2 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. 9) with the hori-
zontal rail and shift the rail onto it, or shift the screws
into the rail rst and x to the anchors. Use serrated
lock washers to x 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 xing 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
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. 12)
roof anchor
top / bottom rail
M8 bolt with
travelling head
parallel
D1
D2
Fig. 9: Fixing the rail onto the roof anchors
Fig. 10: Alignment of base rails
• Insert nuts into both the rails (Fig. 13). Put the retai-
ning side brackets on the rails and x the collector
using M8x20 bolts.
• Lay the following collector next to the rst one, main-
taining a sufcient gap. Then put on the threaded
ttings (Fig. 15, 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 15).
Fig. 11: Inserting safety retaining brackets
Safety retaining bracket
Rails
~100 mm
B
14
~100 mm
~800 mm
Fig. 12: Distance between the safety retaining brackets

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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 – M8x20 allen head bolt
7 – Retaining bracket
Fig. 13: Fixing the retaining brackets
Fig. 14: Pipe passing through ventilation tile