Regulus KPS11 User manual

www.regulus.cz
KPS11
KPS11
EN
Installation and Operation Instructions
Solar System with KPS11 Collectors

2
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 Installation with roof anchors and auxiliary boards ................................................. 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
2.2 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 .......………………………………………………............................ 14
5.2 Collector interconnecting …………………..…………………………............................. 14
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

3
Collector description
REGULUS KPS11 Flat Plate Solar Collectors are
designed for solar domestic hot water heating (DHW),
backup- and pool heating with solar energy. Solar radi-
ation penetrates the glass and is intercepted by an ef-
cient absorption layer applied on an aluminum 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 pri-
mary 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. KPS11 Collector
2. Instruction manual
3. Warranty Certicate
4. Commissioning form - info for the Manufacturer
General instructions for installation
The installation 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
from 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 a an outer wall) .
Collectors shall be installed 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.
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 installa-
tion 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

4
Mounting kits for xing and connecting KPS11 solar collectors Code
Connection kit for a KPC, KPS, KPG and KPH
(G3/4“ M inlet and outlet, 2 plugs, G3/8“ for air vent valve, sheath for solar temperature sensor) 7710
Fixing kit for one KPS11 collector
*[for 4 anchors or 2 supports+1 strut] 12184
Fixing and interconnection kit for 2 KPS11 collectors
*[for 6 anchors or 3 supports+1 strut] 12185
Fixing and interconnection kit for 3 KPS11 collectors
*[for 8 anchors or 4 supports+1 strut] 12186
Fixing and interconnection kit for 4 KPS11 collectors
*[for 10 anchors or 5 supports+1 strut] 12187
* Roof xing and interconnecting 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 selected
from the following chart by the roof type and roong material.
1. DELIVERY OF MOUNTING SYSTEM
Supports and struts for at and sloping roof installation Code
Triangle support strut 15° 11979
Triangle support strut 25° 10975
Triangle support strut 45° 6859
Strut incl. screws for triangle support 9563
Supports for sloping roof installation Code
Triangle strut 15° for sloping roofs 10748
Triangle strut 25° for sloping roofs 8805
Triangle strut 45° for sloping roofs 10094
Triangle strut 60° for sloping roofs 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

5
Pos. Item Code
1 Flat plate collector 16278
2 Roof anchor with M8 bolt/special head for rails
6857 or other,
depending on
roong type
Triangle brackets 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 code1234
(12184) (12185) (12186) (12187)
3 Aluminum rail, 2 pieces 1.32 m 2.61 m 3.92 m 5.20 m 6949
4 M8 nut for the rails 4 pcs 8 pcs 12 pcs 16 pcs 6925
5 M8 ×20 bolt with allen head 4 pcs 8 pcs 12 pcs 16 pcs 12136
6 Retaining side bracket 4 pcs 8 pcs 12 pcs 16 pcs 12141
7 Retaining bracket for collector bottom 2 pcs 4 pcs 6 pcs 8 pcs 11690
8Compression nut and ring for collector inter-
connection - 2 pcs 4 pcs 6 pcs 7629
9 Insulation 35 mm diam., 19 mm thick 0.5 m 0.75 m 1 m 1.5 m 7188
10 Rail end plug 4 pcs 4 pcs 4 pcs 4 pcs 11773
Insulation tape 0.8 m 1 m 1.5 m 2 m 7227
2. SLOPING ROOF MOUNT
1
8
3
2
6
7
5
4
9
10
Expansion mount and interconnection kits for 1 KPS11+ANT solar collector Code
Expansion mount and interconnection kit for 1 KPS11 solar collector 12188
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 roong manufacturer offers roof hooks and
if the roof warranty will not be violated.
2.1.1 Installation with roof anchors and aux-
iliary boards
Prior to installing anchors on auxiliary boards, the follow-
ing shall be ensured:
• The auxiliary board length shall exceed the length of
the rail by at least 200 mm at 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 insert-
ed (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 re-
specting 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
board. For this anchor type also the rail xing height can
be adjusted.
40
30
10
30
30
auxiliary board
battens
counter batten
rafter
waterproofing membrane
underlay
No. of collectors Total length No. of anchors
2 251 cm 6
3 379 cm 8
4 508 cm 10
90.5
~35
~35
~35 ~35 ~35 ~35
103 103 109.5
109.5109.5
60
60
60
90.5
103 109.5
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

7
Installation
• Remove roong in places where anchors shall be xed
(Fig. 6). The distance “a” between anchors is dened
in Fig. 2.
• Cut the counter batten used for xing the waterproof-
ing 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 par-
allel 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 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 x it with
stainless-steel bolts.
If the roong is made of e.g. copper or zinc-plat-
ed 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. 6d). 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.
• The hanger bolt shall be screwed with its screw end
into a rafter or another massive wooden roof element
using spanner No. 7.
• After screwing the hanger bolt in, put on the rubber
seal (Fig. 6d) and using a washer and nut, seal the
counter
batten
rafter
roof
batten
s
waterproofing membrane
a
drilled hole.
• 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

8
(138)
70
58
300
100
35
2× Ø6
80
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
b) Roof anchor of stainless steel
or zinc-plated steel for pantiles
a) Stainless steel anchor on rafter, for pantiles,
incl. screws
c) Stainless steel roof anchor for
metal or slate roong
70
ø 9
80
130
40
40
9
d) Hanger bolt for rail xing
RIGHT !
70
230
35
2× Ø6
72
6

9
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 bolts
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 diagonals 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 bot-
tom 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
Fig. 11: Fitting safety retaining brackets
Safety retaining bracket
Rails
~100 mm
B
14
~100 mm
~1030 mm
Fig. 12: Distance between the safety retaining brackets

10
• Insert nuts into both the rails (Fig. 13). Put the retain-
ing 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
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
6
7
5
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 15).
Fig. 13b: Pipe passing through ventilation tile

11
4.1 - Overview
Pos. Item Code
1 Flat plate collector 16278
2Triangular support, for 45°, 25° and 15° inclina-
tion
Number of collectors (number of supports needed) 6859,
10975,
11979
1 (2) 2 (3) 3 (4) 4 (5)
3Strut incl. bolts for triangular support 9563
Interconnection pipes
Mount and interconnection kits
Number of collectors (kit code) Item
code
1 (12184) 2 (12185) 3 (12186) 4 (12187)
4 Aluminum base rail, 2 pieces 1.32 m 2.61 m 3.92 m 5.20 m 6949
5 M8 nut for the base rail 4 pcs 8 pcs 12 pcs 16 pcs 6925
6 M8x20 bolt (allen head) 4 pcs 8 pcs 12 pcs 16 pcs 12136
7 Retaining side bracket for KPS11 4 pcs 8 pcs 12 pcs 16 pcs 12141
8 Retaining bracket for collector bottom 2 pcs 4 pcs 6 pcs 8 pcs 11690
9Compression nut and ring for collector interconnection - 2 pcs 4 pcs 6 pcs 7629
10 Insulation 35 mm diam., 19 mm thick 0.5 m 0.75 m 1 m 1.5 m 7188
11 Rail end plug 4 pcs 4 pcs 4 pcs 4 pcs 11773
Insulation tape 0.8 m 1 m 1.5 m 2 m 7227
4. FLAT ROOF MOUNT
Fig. 14 Collector installation on a at roof
3
2
1
89
6
7
5
4
10
11
Expansion mount and interconnection kits for 1 KPS11 solar collector Code
Expansion mount and interconnection kit for 1 KPS11 solar collector 12188

12
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 to support up to 4
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. 15)
• Insert the M8 bolt with a special head (Fig. 17) into the
rail grooves.
cca 350 mm
D2
2
4
4
1660 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). Fix the loose support ends
with a bolt (Fig. 16) and tighten all connections.
• Locate the positions to x triangular supports. The
distance of the rst triangular support from the end of
the rail shall be about 350 mm.
• Fix the L-support of the triangle to the base rail using
screws, serrated lock washers and nuts for rails (Fig.
17) 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. 18). Following Fig. 18, insert special M8 nuts into
the triangle support rail. Then lay the strut onto the
rails and x it with M8x12 bolts with washers (Fig. 18).
• 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.
After xing 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. 18: Strut installation
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

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 arrays 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
twice the height winter
sun
solar
collector
height
25°
solar
collector
Fig. 20: Static safety (burden)
Fig. 21: Minimum distance between collector elds

15
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
outlets and push the collector to the already mounted
one 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. 22a. Maximum of 6 collectors may be
connected with threaded ttings in a row. If there are
more than 6 collectors in a row, a compensator shall be
installed in the middle of the array. With a compensator,
max. of 8 collectors in a row may be installed. The con-
necting pipes shall be lead the shortest way. The recom-
mended pipe diameters and ow rates through collector
arrays are shown in Tab. 1.
Collectors may be also connected as shown in Fig. 22b.
This kind of connection is permitted when only max. 2
collectors are used and the max. ow rate is 1l/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 kit, code 7710.
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 joined by soldering.
5. HYDRAULIC CONNECTION
Fig. 22a:
The recom-
mended
method of
collector
intercon-
necting
Fig. 22b:
Alternative
one-sided
connection
method
Fig. 23: Col-
lector con-
necting (the
pic. shows
connection
of the upper
tting; the
lower tting
shall be
connected
and tighte-
ned in the
same way.)

16
Number
of
collec-
tors
Connection type Max.
recomm.
ow rate
Connecting pipe
Copper Kombiex
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
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
12 3 × 4 parallel 24 l/min Cu 28 × 1.5 -
Max. 30 m of the inlet and outlet piping together.
Fig. 25: Position of a temperature sensor sheath
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 tted with compensators
or other compensation elements.
Piping shall be connected to the house earthing.
Pipes of the solar system must be tted with thermal
insulation e.g. of SOLARFLEX type, so that thermal
dissipation from the pipes does not deteriorate a total
efciency 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. 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.
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. 24: Variants of 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. 26:
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
tank.
7. SOLAR PUMP STATION
4 - Air eliminator
5 - Circulation pump
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 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

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 temper-
ature 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 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 di-
aphragm ooded. In case the heat carrier starts boiling,
the diaphragm mustn’t get in touch with steam!
For 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 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 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 lling the system, the preset pressure in the ex-
pansion 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

19
Install the air vent at 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 uid (see pic. 29).
A ball valve shall be always installed under the auto-
matic air vent valve, so that the automatic air vent can
be closed after the system commissioning. Solar liquid
leaks can be avoided in case of system stagnation.
For an efcient removal of bubbles from the system it is
advisable to t the pump station with an air eliminator
(see Fig. 28).
9. INSTALLATION OF AIR RELEASE VALVES
Fig. 28: Air eliminator
Fig. 29: 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
• for safety reasons, you should only ll the collectors
when there is no direct irradiation from the sun
(or cover the collectors)
• in order to ll the system, use a lling device with a
reservoir for solar liquid and a lling pump (see Fig. 30)
• attach the lling hose to the feed valve and open the
valve completely
• please use antifreeze solar uid Regulus - Solarten
Super to ll the system
• attach the return hose to the bleed valve and open the
valve completely
• close the integrated ball valve in the owmeter (the
groove in the owmeter‘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 sufcient quantity of solar uid into the reservoir
of the lling device, turn on the lling pump and ll the
solar system.
10.2 Flushing
• ush the solar system for at least 15 minutes using
the lling device. In order to bleed air and possible
impurities from the system perfectly, open shortly the
integrated ball valve of the owmeter from time to time
(the groove vertically).
10.3 Air bleeding
• with the lling pump running, close the bleed valve and
increase the pressure up to about 5 bar
• close the feed valve and turn off the lling pump, open
the regulation screw on the owmeter (groove horizon-
tally), do not disconnect the lling 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 lling pump and opening
the feed valve to 5 bar
• repeat air bleeding so long until the oat in the owme-
ter‘s regulation valve takes a steady position during
pump operation and bubbles stop appearing in the
owmeter. After that, let the circulation pump run for at
least 5 minutes.
10. SYSTEM FILLING, FLUSHING, LEAK TEST AND AIR BLEEDING
• in case an automatic air vent/s is/are used anywhere in
the solar system, close this valve after 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 ow by
the owmeter and data in Tab. 1
• disconnect the hoses of the lling 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 ush the system with water. Since it is impossible
to empty it completely, a risk of frost damage appears.
Fig. 30: Filling a solar system