Solarbayer PremiumPlan User guide

Solarbayer GmbH 1
P
r
o
f
e
s
s
i
o
n
a
l
s
o
l
a
r
s
y
s
t
e
m
s
!

2Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Table of contents
You are in store for sunny times 3
Safety regulations 4
Installation measures 5
Mounting kit: on-roof 6
Installing the standard roof hooks (standard tiles) 7
Special solution: installing the plain tile hooks 8
Special solution: installing the hanger bolts 9
Special solution: mounting with a stand-kit 10
Special solution: mounting with a flat roof stand-kit 11
Installation of horizontal collector rails 12
Installation of the rail connectors 13
Installation of the collector hooks 14
Mounting of the collectors 15
Connecting the collectors 16
Technical information 17
Filling with heat transfer fluid 18
Standards/regulations/instructions 20
Problems and troubleshooting 21
Connection diagrams 22

Solarbayer GmbH 3
MOUNTING INSTRUCTION High capcity collector PremiumPlan
We are glad that you have selected one of our products.
Your Premium-high capacity flat plate collector
is one of the most powerful collectors currently
on the market. Due to its special absorber
properties you will yield maximum heat for
free because you will not receive a bill from
the sun.
The SOLARBAYER solar systems with
their high capacity collectors and aligned
system components save on the annual
average 50% to 60% of the energy
consumption for heating up drinking water.
In summer months there is even enough
solar power to completely cover the requirements on heating up drinking water. This re-
duces the cost of oil and gas considerably and makes you half-way independent of fossil
fuels.
Solar collectors are not only suitable for heating up drinking water but also for the use in
heating systems, which means that you can also use the SOLARBAYER solar system to
back-up heating systems. This additionally reduces the consumption of oil and gas.
Even in matters of environmental compatibility you are on the sunny side with our solar
systems. On the average, in case of a one-family house, the production of carbon di-
oxide(CO2) is reduced by annually approximately one ton.
Future safety, operating reliability and a long service life characterise all our SOLAR-
BAYER solar systems.
The SOLARBAYER high capacity collectors are made of anti-corrosive and UV-resistant
materials. This is impressively attested by the quality test in accordance with DIN EN
12975. In addition, it confirms the constantly high thermal performance.
You are in store for sunny times

4Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Safety regulations
Carefully read the safety instructions before commencing the installation. It’s for your own safety.
Please follow the structural instructions if the installation location of the solar system is above 600m sea
level and possibly exposed to large amounts of snow (higher than zone 4).
The protections of the manifolds have to be removed before the solar collectors are exposed to the sun
and heat themselves.
Working on the roof
Appropriate safety measures have to be arranged. The following aspects have to be respected to
achieve a secure installation of the solar system:
• always use fall protection while working on a roof
• respect safety regulations when using a ladder
• while working on roof coverings with corrugated sheets the risk of breaking through exists
• secure workplaces on steep roofs
• safety clearances have to be met if an aerial pipeline leads across the roof
• always wear safety goggles and gloves while working with an angle grinder
• Flat plate collectors can achieve a stationary temperature of over 200°C due to incident light. The risk
of burns exists at the connections of flow and return. Always cover the collectors on sunny days during
the installation
• Even regular daylight might cause the fluid in the collector to vaporise. The vapour leaks from the col-
lector connections. Possible risk of scalding.
Familiarise yourself with the general regulations of accident prevention for construction work of your pro-
fessional association or let yourself be instructed by an appropriate person.
Attention: glass
• Don’t extent mechanical pressure on the glass covering. glass splinters might evoke cuts.
• Wear safety goggles and gloves while installing the solar system to avoid injuries due to possible
damages..
Caution:
The solar system has to be filled with a mixture of water and antifreeze before its initiation.
This is also necessary in summer. During the night a temperature fluctuation to minus degrees
might arise due to the high-quality selective coating of the collector and that might lead to a
destruction of the solar system!

Solarbayer GmbH 5
MOUNTING INSTRUCTION High capcity collector PremiumPlan
B
A
rail connectors
Installation measures
add-on mounting kit
basic mounting
kit for 2 collec-
tors
intervals between roof hooks
(standard hooks and plain tile hooks)
PremiumPlan
2.03
PremiumPlan
2.85
collector height mm 1787 2242
collector width mm 1137 1273
A interval (min. – max.) mm 700 – 1100 700 – 1240
B interval (min. – max.) mm 1200 – 1300 1700 – 1800
A
B
groove
(rear of collector)
standard hook

6Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Mounting kit: on-roof
standard hooks
coach bolts (M 8),
washer, snap ring, nut
for fixing the t-profile rails
wood screws (6x50 mm)
for fixing the standard hooks on the rafter
rail connector
coach bolts (M 10),
washer, nut
aluminium connection plate for the extension
of the aluminium profile rail
collector carrier rail
for the perfect support of the collectors

Solarbayer GmbH 7
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Installing the standard roof hooks (standard tiles)
These parts are
necessary:
1st step:
Pre-mount the roof hook onto the
base plate. Unroof the rafters
and mount the base plate onto
the rafter using the coach bolts.
Always make sure that the roof
hook is seated in the tile’s bulge.
2nd step:
The base plate has necessarily
to be screwed onto the roofs’
laths.
There happen to be tiles that ask
for a log of wood as distance
piece
3rd step:
Make sure that the stainless
steel hook has approx. 2-3mm
too much play to the roof. Now
screw the roof hook solidly onto
the base plate with a 13mm flat
wrench.
4th step:
grind as much material from the
tile away as needed, with the
help of the angle grinder, so that
the roof hook perfectly fits under-
neath the tile. Afterwards retile
the roof.
wood screws 6x50 mm
base plate
with standard hook
!
The pictures illustrate
the mounting on the
roof battens. You proba-
bly need longer roof
bolts, depending on the
constructional circum-
stances of your roof, to
guarantee a stable con-
nection between rafter
and hook.
Before initiation you
have to check the ade-
quate bearing capa-
city of your roof!
No grind works on the roof
(risk of falling).

8Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Special solution: installing the plain tile hooks
Demount the rafter and screw
the base plate with the roof hook
onto the rafter.
This kit can generally be used for
most types of tiles that are sea-
ted solidly.
These parts are
necessary:
roof hook for plain tiles
(special equipment)

Solarbayer GmbH 9
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Special solution: installing the hanger bolts
These parts are
necessary:
1st step:
Define the intervals of the drill
holes according to the dimensi-
ons of the collector. Drill them in
a straight row using a plumb-line
or something comparable.
Drill only on stable structure.
Pre-drill with 10mm, afterwards
use 16mm for these tiles.
hanger bolts
(special equipment)
clamp for support
rail
nut M12
washer
sealing
2nd step:
Apply sealing
3rd step:
Screw the hanger bolt through
the tiles onto the pre-drilled rafter
as deep as instructed. Fix the
sealing, washer and nut. Adjust
the clamp’s interval by means of
the nut.
4th step:
Shift the support rail with the
groove onto the clamp, adjust
and fix it.

10 Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Special solution: mounting with a stand-kit
Stand-kit for mounting on standard hooks.
The illustrations show the ready installed base frame on the
standard hooks (without collector rails).
The stand-kit is appropriate to all types of collectors.

Solarbayer GmbH 11
MOUNTING INSTRUCTION High capcity collector PremiumPlan
tighten the collector carrier rail to
the base rail with M 8x60 screws
Fasten the telescope rail to the
base rail with M 8x60 screws
telescope rail connection with
M 8x60 screws
flat roof stand-kit for 2 collectors flat roof stand-kit for 3 collectors
inclination αmin. 40° 45° max. 58°
collector height a2,24m 2,24m 2,24m
overall height b1,44m 1,58m 1,90m
basic length c1,72m 1,58m 1,19m
distance between rows d4,71m 5,18m 6,21m
weight against wind load (kg/m² collector surface area)
according to DIN 1055-4
Gebäudehöhe Ohne Bodenfreiheit Mit Bodenfreiheit >30cm
0 bis 8 m 80 kg/m²* 60 kg/m²*
8 bis 20 m 130 kg/m²* 100 kg/m²*
* in effect for locations under 600 m sea level and wind speeds between 100km/h and 130km/h
Check static of the substructure before mounting
collector arrangement:Calculating the clouding:
vertical angle of the sun 17° on 21.12.
Special solution: mounting with a flat roof stand-kit
collector collector collector
collector
collector
collector
carrier rails collector
carrier rails
base frame base frame

12 Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Installation of horizontal collector rails
1st step:
Shift the coach bolt into the rail’s
groove, afterwards put the rail
onto the roof hook as illustrated
on the picture.
These parts are
necessary:
coach bolts
M 10
2nd step:
Adjust the rail and fix the coach
bolt with washer, snap ring and
nut.
Use the enclosed rail connectors
for the rails’ extension.
collector carrier rail

Solarbayer GmbH 13
MOUNTING INSTRUCTION High capcity collector PremiumPlan
rail connectors
Installation of the rail connectors
1st step:
Pre-mount the rail connector with
coach bolts, snap rings and nuts.
These parts are ne-
cessary for the rails’
extension:
rail connectors
(if necessary)
coach bolts
M 10
2nd step:
Shift the heads of the coach
bolts into the rail’s groove
3rd step:
Coalesce both rails and tighten
the screws

14 Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Installation of the collector hooks
These parts are
necessary:
1st step:
Insert the coach bolts into the
upper and lower groove of the
collector.
coach bolt M 8
2nd step:
Adjust the lower hook (without a
nib) together with washer, snap
ring and nut to the lower part of
the collector, bring it to dimen-
sion and tighten the screws.
This dimension has to be exactly
adjusted because it cannot be
changed after the installation.
This applies to all collectors.
3rd step:
Shift the upper hook (with a nib)
to the uppermost part of the col-
lector and tighten it hand-tight.
After the collector is hooked up
and after its connection to the
other collectors, slide the hook
downwards into the aluminium
profile.
hook with a nib for the upper
mounting of the collector
hook without a nib for the
lower mounting of the col-
lector
This hook has to be pre-
mounted

Solarbayer GmbH 15
MOUNTING INSTRUCTION High capcity collector PremiumPlan
3rd step:
Shift the upper, hand-tightened
hook downwards until the nib of
the hook clicks into the rail’s
groove. The hook is now fixed
with a 13 mm flat wrench.
The carrying construction is now
solidly fixed.
2nd step:
Telescope the collectors and
tighten with the connection. Do
neither cant nor damage the
sealing.
Caution:
Do not tighten by force!
Risk of turning the connecting
pipes.
Oberer
Haltebügel
Unterer
Haltebügel
Obere
Alu-Profilschiene
Kollektor
Untere
Alu-Profilschiene
Mounting of the collectors
1st step:
Check the intervals of the rails once again and adjust them according
to the rails installation measures before hooking in the collectors.
Now hook the collector into the lower rail.
collector
lower aluminium
profile rail
upper aluminium
profile rail
lower hook
upper hook

16 Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Connecting the collectors
Connect the collector’s flow and
return with the provided connec-
ting kit.
Neither cant the threads nor da-
mage the sealing surface.
ready installed T-joint ready installed elbow jointsensor connection
(1st collector, flow)
right collector connection:
pay attention to the correct
placement of the O-ring
Left collector connection:
with swivel nut

Solarbayer GmbH 17
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Technical information
collector surface in m2copper pipe mm
up to 10 15
up to 14 18
up to 22 22
up to 23 28
Flow and return line
recommendations:
Pipeline connections:
• hard soldering (flux free hard solder according
to DIN 8513)
• pressing
Thermal insulation of the
pipelines
The pipeline insulations have to have the follo-
wing characteristics
• short time temperature resistance >150 °C
(e.g. fibreglass, rubber)
• outdoor parts should be UV resistant and
weatherproof (e.g. sheet metal jackets)
• insulation thickness = pipeline diameter (at
least)
(based on a k-value of 0,04W/mK)
Maintenance
An inspection in regular intervals is recom-
mended
Attention: determine bigger dimensions if the pipe-
lines are longer than 10m
0 102030405060 7080 90100
100
90
80
70
60
50
40
30
20
10 tm- ta=
Δ Τ
KELVIN
test results: Fraunhofer Institut and ITW
Swimming pool Heating
Domestic hot
water
Industrial heating
Thermal cooling
Solarbayer-tube collector CPC
Solarbayer-PremiumPro-collector
standard tube collector
standard flat plate collector
Example: You need a collector temperature of approx. 60°C (tm) to achieve a required heating/hot water
temperature of 50°C. An outdoor temperature (ta) of 10°C therefore leads to a Δ Τ of 50 K (60°C–10°C 
Δ Τ 50 K).
The comparison of the efficiency characteristic line illustrates that the collectors of the Solarbayer Pre-
mium series have an excellent efficiency factor
If you are in need of process heat we recommend our tube collectors.

18 Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Filling with heat transfer fluid
Flush
The solar system has to be flushed
with the ready mixed heat transfer
fluid
Course of action:
- check if all screwed connections
are tightened
- check the primary pressure of the
solar expansion vessel at zero
pressure, if necessary adjust to
2,5 bar
- switch the solar station’s ball val-
ves of flow and return to 45° - that
will open the gravity brakes
- close hex key of flow regulator
- connect the hoses of the filling
station with the corresponding
valves
- open any other valve (if existing)
- adjust the inversion valve (if exis-
ting) to “manual”; convert the exits
one after the other during the
flushing
- the solar system can now be flus-
hed in both directions; keep an
eye on the manometer
- don’t flush/fill the solar system
when it is under direct exposure
to light
- the flushing has been successful
when the fluid returns clean and
without air bubbles into the con-
tainer
- operating pressure has to be at
least 3 bar
- close the filling and draining val-
ves and completely open the flow
regulator
- open the ball valves and put the
switching valves (if existing)
- the solar system is now ready for
operation
filling
and
draining
valve
connect the filling station here to fill
and flush the system
Due to their construction the collectors can afterwards never be fully emptied again(vapours and
freezing might lead to damages). It is therefore necessary to rinse the collectors with a glycol
mixture. Our collectors are only to be used with Tyfocor L/LS
Mixing of the heat transfer fluid
You have a protection against frost up to a -24°C when mixing ratio
is 60/40 (60 parts water and 40 parts propylene glycol). A further
decrease of temperature leads to a formation of ice without any ex-
plosive effect. In locations with a risk of frost under -30°C a mixing
ratio of 50/50 is recommended.
You definitely have to mix the fluid in a separate container be-
fore filling the system
CAUTION: The collectors have to be filled with heat-transfer
fluid even if the outdoor temperature is over the freezing
point.
Characteristic data of Tyfocor L
boiling point: 187°C
pour point: <-60°C
flaming point: ~368°C
pH (conc.).: 7,7-8,7 (1:1 – H²O/glykol)

Solarbayer GmbH 19
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Filling the solar system
The pressure of the solar system should be 0,5 bar above the primary pressure of the expansion vessel
(as indicated on the type plate). We recommend a pressure of 3 bar for the system.
For the filling and bleeding of the solar system the use of a SOLARBAYER filling station is recommended.
Adjusting the pump
Adjust the pump at the solar controller to manual. Turn the hex key at the regulation valve as far as possi-
ble to the left, it is now completely open. Adjust pump to power stage II and meter the flow rate at the flow
meter. If necessary boost the power stage until the calculated flow rate is achieved (cf. adjusting the flow
rate).
Hint: always reduce the power stage before throttling the flow rate for electricity saving reasons! The regu-
lator valve stays completely open.
Adjusting the flow rate
recommended minimum flow rate:
Solarbayer-flat plate collectors: 25 l/m²h
Example: 6m² X 25l/m²h=150l:60 min. = 2,5 l/min.
Flow meter with integrated regulation valve (indication in l/min). Adjust
the calculated flow rate with a hex wrench while the pump is working
(clockwise rotation limits the flow).
Electric connections
Electric installations have to be accomplished by a licensed tradesman subject to the German regulations
VDE 0100 and to those of the local power company.
propylene glycol water density at
20°C(g/cm³)
frost protection
(°C)
viscosity
(20°C, mm²/s)
25% 75% 1.023 -10 2,7
30% 70% 1.028 -15 3,9
35% 65% 1.031 -18 4,1
40% 60% 1.038 -24 4,6
45% 55% 1.041 -29 7,0
60% 40% 1.043 -35 7,4
concentrate 1.046 -60 8,1
table of Tyfocor L mixing ratio:
meter-reading
at lower bottom floating body
hex key

20 Solarbayer GmbH
MOUNTING INSTRUCTION High capcity collector PremiumPlan
Standards/regulations/instructions
DIN 4757, part 1
solar heating systems with water and water mix-
tures as heat transfer medium; demands to safety
realisation
DIN 4757, part 2
solar heating systems with organic heat transfer
medium; demands to safety realisation
DIN 4757, part 3
solar heating systems; solar collectors; mea-
nings; safety regulations; testing of stationary
temperature
DIN 4757, part 4
solar thermal systems; solar collectors; determi-
nation of efficiency, heat capacity and pressure
loss
In addition to that European standards are wor-
ked out
PrEN 12975-1
thermal solar systems and their components; col-
lectors, part 1: general demands
PrEN 12975-2
Thermal solar systems and their components;
collectors, part 2. test process
PrEN 12976-1
thermal solar systems and their components; pre-
fabricated systems, part 1: general demands
PrEN 12976-2
thermal solar systems and their components; pre-
fabricated systems, part 2: test process
PrEN 12977-1
thermal solar systems and their components;
customer-designed manufactured systems,
part 1: general demands
PrEN 12977-2
thermal solar systems and their components;
customer-designed manufactured systems, part
2: test process
PrEN 12977-3
thermal solar systems and their components;
customer-designed manufactured systems,
part 3: performance test of warm water stores
DIN 1055, part 4
load assumptions for buildings; traffic loads; wind
loads, wind loads of buildings that are non-
susceptible to vibrations
DIN 1055, Teil 5
load assumption for buildings; traffic loads; snow
loads and ice loads
This list makes no claim to be complete and it is only for information use