Thermotech FP202 Installation and operating instructions

Manual and installation guide
THERMOTECH SOLAR HEATING SYSTEM
IG1003_1105
Solar collector package
Assembly package DB-0 for Solar Collector FP202
Tile roof installation with roof brackets

Thermotech Solar Heating System
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www.thermotech.eu

Thermotech Solar Heating System
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TABLE OF CONTENTS
Safety information ..........................................................4-5
Installation instructions .....................................................6
Operational information .....................................................7
Handling instructions ..........................................................8
Solar collector information................................................9
Material overview...........................................................10-11
Attachment point recommendations.................... 12-13
Assembly ........................................................................14-22
Flow information/pressure drops ...............................23
Interconnection alternatives..................................24-27
Warranty ...............................................................................28
Notes ......................................................................................29
Page
Solar collector
package DB-0
Tile roof installation with
roof brackets
We reserve the right to change products without notice. Please refer to www.thermotech.eu for the latest versions of products and
installation guides. Any prices shown exclude VAT unless otherwise stated. No liability is accepted for any typographical errors.

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Before any work is begun, fall protection equipment in ac-
cordance with DIN 18338 and DIN 18451 must be procured.
Also read the regulatory directives for working on roofs.
Safety information Solar collector package DB-0
Only use safety equipment (belts, harnesses, attachments, etc.)
that has been tested by a certied testing institute.
If the rules for roof safety are not observed, this can lead to
falls from roofs with life-threatening injuries as a result.
Use of ladders that are not properly secured to the roof or
underlying surface can lead to hazardous falling accidents.
When work is carried out close to overhead electrical lines,
work may only be conducted if:
• If it is absolutely certain that power to the lines has been
disconnected and remains so until work is complete.
• Live sections are covered.
• Prescribed safety distances are maintained.
Distance Voltage
1 m Up to 1,000 V
2 m From 1,000 to 11,000 V
3 m From 11,000 to 22,000 V
4 m From 22,000 to 38,000 V
> 5 m Unknown

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Safety information Solar collector package DB-0
e manufacturer recycles products marked with the ECO
label.
Only approved heat-conducting media intended for solar
heating installations may be used.
Safety devices must be attached above the installer whenever
possible. ese must be secured in suciently strong con-
struction elements.
Never used damaged ladders. Do not repair broken steps on
wooden ladders.
Ensure that ladders are properly secured. Note that the ladder
pitch must be between 68° and 75°. Prevent ladders from glid-
ing, tipping over or sinking down into the underlying surface
by using hooks or attached pads, for example.
Only lean ladders against secure surfaces. Firmly secure lad-
ders in areas with trac.
Use protective goggles when drilling and handling solar col-
lectors.
Always use protective shoes during installation.
Protective gloves must be used when installing solar collectors.
Protective helmets must be used during installation.

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Installation instructions Solar collector package DB-0
123
GENERAL INSTRUCTIONS
e assembly system DB-0 for solar collector FP202 is
only intended for tile roofs. Only prescribed materials
may be used during installation.
Before installation is begun, knowledge of local ordinan-
ces must be obtained to prevent unforeseen complications
from arising.
When the solar collector is to be carried by hand, straps
should be used to prevent damage to the panel. Do not
carry the panel by its connections. Avoid impact with the
solar collector, especially to the glass, rear and connec-
tions.
ROOF LOADS
e solar collectors may only be installed on roofs and
other construction elements that can withstand the static
pressure that occurs. In certain cases it can be necessary
to contact a consultant or other tradesman to determine
if the construction is suitable for installation of solar col-
lectors.
Special consideration must be taken to the quality of the
bearing wooden joists that constitute attachment points
for the solar collectors.
e customer's inspection of the entire solar collector
installation according to DIN 1055, sections 4 and 5 (as
well as the applicable local and regional ordinances) is
especially important in areas with substantial amounts of
snow or high winds (1 m3of loose snow weighs about 60
kg and 1 m3of wet snow weighs about 200 kg).
Maximum snow and wind loads may not be exceeded.
As a rule, rows of solar collectors must be installed so that
no accumulations of snow can reach the solar collectors.
is is accomplished using snow guards or other type of
protection. e distance to the roof edge must be at least
1 meter.
NB: Installation of the solar collectors requires alteration
to the existing roof. It may be that additional covering
materials are required, such as tile, bre board or other
type of covering to prevent leakage due to wind and snow
loads. is especially applies to roofs with little pitch.
LIGHTNING PROTECTION
When installing on the roof of an existing building, the
solar collectors should be connected to the lightning pro-
tection system if one exists. If the installation concerns
new construction, a risk assessment must be conducted
for the building to determine whether or not a lightning
protection system should be installed.
CONNECTIONS
Connect the solar collectors to one another using the
clamping ring connectors. If exible lines will not be used
when running the tubing, special consideration must be
taken to linear expansion to protect the lines. is can be
achieved with for example, expansion bends or exible
tubing in the system.
Larger solar collector systems must have expansion bends
or exible tubing between the solar collectors. When the
clamping ring connectors are secured, a holding-up tool
must always be used in the form of a spanner or pipe
tongs so as to prevent damage to the panel's connections.
PITCH
Solar collectors must be installed at an angle of 15–
75°, facing to the south as much possible, to achieve good
results. e solar collector's connections and ventilation
channels must be protected against both the entry of
water as well as dirt and dust.

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Operational information Solar collector package DB-0
122
FILLING
Due to safety considerations, the system must be lled
when there is no direct sunlight or with the solar collec-
tors covered.
In areas where freezing temperatures may occur, anti-
freezing solution must be used. Concentrated anti-freez-
ing solutions must be mixed with water prior to lling the
system.
Recommended anti-freezing solution for at solar collec-
tors is Tyfocor.
• 40% Tyfocor-L mixed with 60% water produces a freez-
ing point of -22ºC. Solidication point -26ºC
• 50% Tyfocor-L mixed with 50% water produces a freez-
ing point of -22ºC. Solidication point -44ºC
One can never be completely sure that a solar collector
system can be entirely drained of liquid, which is one
reason why solar collector systems in areas subject to frost
must always be lled with anti-freezing solution, even
during pressure and function testing.
To protect the system against high temperature and pres-
sure loads, the system should be put in service as soon
as possible aer lling, and absolutely within 4 weeks. If
this does not occur, the at seals must be replaced prior to
putting the system in service so as to prevent leakage.
FITTING OF TEMPERATURE SENSOR
e temperature sensor for the solar collectors must be
placed in the immersion tube on the panel that termi-
nates the solar collector group and from which the heat is
further transported.
To attain optimal contact between the sensor and the sur-
rounding material in the solar collector, heat-conducting
compound should be used in the immersion tube.
All materials used during installation of sensors must be
able to withstand temperatures of up to 250ºC.
OPERATING PRESSURE
e maximum operating pressure is 10 bar.
BLEEDING THE SYSTEM
e solar heating system must be bled:
• When the system is lled
• 4 weeks aer being put in operation
• When it is necessary, such as in the event of opera-
tional problems
Warning! When the system is bled, there is risk for scald-
ing when hot vapours are released.
Only bleed the system when the temperature of the heat-
conducting medium is < 60ºC. When the system is bled,
the solar collectors may not be warm. Cover the solar
collectors or bleed in the morning.
CHECKING HEAT-CONDUCTING MEDIUM
e heat-conducting medium must be checked every
second year with regard to anti-freezing properties and
pH value:
• Check the anti-freezing solution's properties with a
tester and replace or add medium as necessary.
• Check the pH value with a pH indicator. If the pH
value is lower than 7, the medium must be replaced.
MAINTENANCE OF SOLAR COLLECTOR
e solar collectors must be checked once yearly for the
occurrence of leakage and to determine whether dirt or
other foreign matter has fastened on the solar collectors.

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Handling instructions Solar collector package DB-0
123
D EN IT FR ES
DB-0
Transporthinweis
Transport note
Indicazioni per il Trasporto
Indications pour le transport
Indicaciones para el Transporte
20

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Solar collector information Solar collector package DB-0
122
TECHNICAL DATA
Gross area: 2.02 m2Maximum operating pressure: bar
Reference area: 1.84 m2Stagnation temperature: 234ºC
Weight: 35 kg Recommended flow: 0.25-0.5 l/min* m2
Volume: 1.56 litres
D EN IT FR ES
DB-0
Angaben zum Kollektor
Information about the collector
Informazioni sul Collettore
Indications portant sur le capteur
Datos del colector
21
Technische Daten - Technical data - Dati tecnici - Données techniques - Datos técnicos
Bruttofläche
Overall area
Superficie lorda
Surface hors tout
Área total
2,02 m²
Inhalt
Contents
Capacità
Contenance
Capacidad
1,56 l
Aperturfläche
Aperture area
Superfi cie di apertura
Surface d’entrée
Área de apertura
1,84 m²
Max. Betriebsdruck
Max. operating pressure
Pressione di esercizio max.
Pression max. de fonctionnement
Presión máxima de servicio
10 bar
Nettofläche
Absorber area
Superfi cie netta
Surface d’absorption
Área de absorbedor
1,84 m²
Stillstandstemperatur
Stagnation temperature
Temperatura di stagnazione
Température d’arrêt
Stillstandstemperatur
234 °C
Gewicht leer
Weight empty
Peso a vuoto
Poids à vide
Gewicht leer
35 kg
empfohlener Durchsatz
Recommended flow rate
Portata consigliata
Débit recommandé
Flujo recomendado
15 - 30 l / (h*m²)
1130,6
1215
1730
1170
1690,6
70 117
81

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Material overview Solar collector package DB-0
123
D EN IT FR ES
DB-0
Materialübersicht
Overview of materials
Panoramica dei materiali
Vue d’ensemble du matériel
Vista general de los materiales
22
1.4 1.5
1.6
M8x25
2.1
1.7 1.8
1.2
1.1
1.9 1.10
2.3 2.4 4.1
M8
Ø16
M8
5.1 5.3
6.2 6.3
M8x25 6x60
6.1
6.4

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Material overview Solar collector package DB-0
122
D EN IT FR ES
DB-0
Materialübersicht
Overview of materials
Panoramica dei materiali
Vue d’ensemble du matériel
Vista general de los materiales
23
6.8
6.6
6.5
Handbuch
Manual
Manuale
Manuel
Manual
7.1
6.6

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Attachment point recommendations DB-0
e attachment points must be as evenly distributed as
possible along the tracks.
NB: Be sure to t the solar collectors with the immersion
tube for the temperature sensor upwards!
VERTICAL INSTALLATION
Total solar collectors: Total track length: Connection points:
2246 cm 6
3 367 cm 8
4 490 cm 10
5615 cm 12
6 736 cm 14

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Attachment point recommendations DB-0
e attachment points must be as evenly distributed as
possible along the tracks.
NB: Be sure to t the solar collectors with the immersion
tube for the temperature sensor upwards!
HORIZONTAL INSTALLATION
Total solar collectors: Total track length: Connection points:
1 179 cm 4
2 358 cm 8
3537 cm 12
4716 cm 16
5 895 cm 20
61,074 cm 24

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Assembly Solar collector package DB-0
Drill Risk for scalding!
See page...
Right angle
Hand tighten
Use spanner
NB:
Electrician required!
Parallel
Materials that must be ob-
tained
NECESSARY TOOLS
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
26
DE
GB
IT
FR
ES
DE
GB
IT
FR
ES
Verbrühungsgefahr!
Danger of scalding!
Pericolo di ustione!
Danger d’échaudures!
Peligro de quemaduras!
DE
GB
IT
FR
ES
Parallel
Parallel
Parallelo
Parallèlement
En paralelo
DE
GB
IT
FR
ES
Befugte Elektrofachkraft
Qualified electrician
Tecnico elettrico autorizzato
Électricien spécialisé agréé
Técnico eléctrico autorizado
DE
GB
IT
FR
ES
Wichtiger Hinweis
Important note
Note importante
Remarque importante
Nota importante
...
DE
GB
IT
FR
ES
Fest anziehen
Tighten firmly
Serraggio con utensile
Resserrer fermement
Apretar fuertemente
DE
GB
IT
FR
ES
Handfest
Hand-tight
Serraggio manuale
Réglege manuel
Apretar a mano
DE
GB
IT
FR
ES
Siehe Seite
See page
Vedi pag.
Consulter la page
Ver la página
DE
GB
IT
FR
ES
Bohren/Vorbohren
Drill/pre-drill
forare/fissare
Perçage/pré-perçage
taladrar/taladrar previamente
DE
GB
IT
FR
ES
Bauseits zu stellendes Material
Materials to be provided by others
Materiale a cura del committente
Matériels à fournir pour la mise en œuvre
Material a suministrar en obra
DE
GB
IT
FR
ES
Erforderliches Werkzeug
Tools required
Attrezzi necessari
Outtillages nécessaires
Herramientas necesarias
rechter Winkel
right angle
angolo retto
angle droit
ángulo recto
13/19
30/32
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
26
DE
GB
IT
FR
ES
DE
GB
IT
FR
ES
Verbrühungsgefahr!
Danger of scalding!
Pericolo di ustione!
Danger d’échaudures!
Peligro de quemaduras!
DE
GB
IT
FR
ES
Parallel
Parallel
Parallelo
Parallèlement
En paralelo
DE
GB
IT
FR
ES
Befugte Elektrofachkraft
Qualified electrician
Tecnico elettrico autorizzato
Électricien spécialisé agréé
Técnico eléctrico autorizado
DE
GB
IT
FR
ES
Wichtiger Hinweis
Important note
Note importante
Remarque importante
Nota importante
...
DE
GB
IT
FR
ES
Fest anziehen
Tighten firmly
Serraggio con utensile
Resserrer fermement
Apretar fuertemente
DE
GB
IT
FR
ES
Handfest
Hand-tight
Serraggio manuale
Réglege manuel
Apretar a mano
DE
GB
IT
FR
ES
Siehe Seite
See page
Vedi pag.
Consulter la page
Ver la página
DE
GB
IT
FR
ES
Bohren/Vorbohren
Drill/pre-drill
forare/fissare
Perçage/pré-perçage
taladrar/taladrar previamente
DE
GB
IT
FR
ES
Bauseits zu stellendes Material
Materials to be provided by others
Materiale a cura del committente
Matériels à fournir pour la mise en œuvre
Material a suministrar en obra
DE
GB
IT
FR
ES
Erforderliches Werkzeug
Tools required
Attrezzi necessari
Outtillages nécessaires
Herramientas necesarias
rechter Winkel
right angle
angolo retto
angle droit
ángulo recto
13/19
30/32
GUIDE SYMBOLS

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Assembly Solar collector package DB-0
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
27
24
2
1.9
1.10
2.3
5.3
24
1
24
1a
25 Nm
12
12
12

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Assembly Solar collector package DB-0
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
28
3
2.4
3a
3b

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Assembly Solar collector package DB-0
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
29
4a
4a
4
4b
5a
5b
1.1
1.2
2.1
4.1
5.1
1.9
4b
90°

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Assembly Solar collector package DB-0
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
30
5e
5c
5d
5d
5c
5a
5b
5a
5b
5
25 Nm
5.1
1.6
1.4
4.1

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Assembly Solar collector package DB-0
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
31
6
25 Nm
7
24
7c
7b
7a
N1
7d
48
7a
7b
4.1
5.1
1.8
7d
1.7
7c
N1
6.1
12

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Assembly Solar collector package DB-0
D EN IT FR ES
DB-0
Montage
Mounting
Montaggio
Montage
Montaje
32
8
25 Nm
8b 8a 8c
90°
4.1
5.1
1.5
8c
8b
8b*
90°
8b*
N2
8a