SunMaxx TitanPower-AL2 Flush Mounting Instructions

8/6/2019 SunMaxx TitanPower-AL2 Flush Mounting Instructions

1/16

SunMaxxSolar Thermal Systems

Silicon Solar IncInnovative Solar Solutions

TM

Instructions - Flush Mounting Installation System

SunMaxx-M2 Flat Plate Collector


2/16

SunMaxx M2 Flush Mounting Installation System 2

EXPLOSION DRAWING


3/16


PARTS LIST

No. DesignationQuantity

basic kit

Quantity

extension kit

1 Collector2 Rail, 1,155 mm3 Rail, 1,172 mm

020

002

4 Collector fixing kit4.1 4x M8 x 14 hexagonal bolt4.2 4x mounting profile (Z-hooks)4.3 4x 8.4 mm washer4.4 1x installation aid4.5 2x M8 x 10 hexagon socket head cap screw

1 1

5 Rafter anchor for pantiles (variation A) 4 2

6 Rafter anchor kit

6.1 4x 10 wood screw6.2 2x M10 hexagonal bolt6.3 6x 10.5 mm washer6.4 2x M10 hexagonal nut6.5 2x slot nut6.6 4x wooden equalisation board (2 x 5 mm, 2 x 10 mm thick)

2 1

7 Rail connection kit7.1 2x rail connector7.2 4x M8 x 50 hexagonal bolt7.3 8x 8.4 mm washer7.4 4x M8 hexagonal nut7.5 2x 20 mm self-adhesive spacer

0 1

8

Rail end set8.1 4x rail connector8.2 4x end piece8.3 4x M8 x 50 hexagonal bolt8.4 8x 8.4 mm washer8.5 4x M8 hexagonal nut

1 0

9 Corrugated pipe, 800 mm9.1 1x 800 mm corrugated pipe with 12 mm compression fitting and

insulation tube9.2 1 x 12 mm support sleeve9.3 2 x seal

2 0

10 Corrugated pipe, 250 mm10.1 1x 250 mm corrugated pipe with 12 mm compression fittings and

insulation tube10.2 2 x 12 mm support sleeve

0 1

11 Rafter anchor for plain tiles (variation B) 4* 2*

12 Corrugated slab fastening (variation C)12.1 1x hanger bolt12.2 3x M10 hexagonal nut12.3 1x seal12.4 1x rail holder

4* 2*

* optional


4/16


GENERAL

The on-roof installation kit is for installing the K4-EM2S type collectors vertically or horizontally on

a roof. It can be used on roofs with slopes of 20 and above.The rafter anchors are available in variations for the following roof coverings: pan tiles and similar

roof tiles, and plain tiles. Fastening elements are also available for corrugated slabs (e.g.

corrugated sheeting, corrugated fibre cement). Alternatively, standing seam clamps for standing

seam roofs or fastenings for other types of roofs can be combined with the system. These must

be procured by the contractor from the local roofing supplier.

Extra materials such as ventilation tiles for the roof opening for the collector array connections

(available from specialist suppliers) and tin/lead sheets for sealing the rafter anchors on a plain

tile covering may be required.

In some cases it is necessary to plan a means of transporting the collectors onto the roof. Werecommend considering roof access near to the collectors so that checking and maintenance

work can be carried out more easily.

When connected hydraulically, up to 3 K4-EM2S collectors can be connected in series. If more

than 3 collectors are connected, this must be done using a combination of series and parallel

connection.

We recommend declaring the solar energy system to your insurer as added value to the building,

and taking out insurance against lightning and possibly glass breakage.

SAFETY INSTRUCTIONS

The installation and safety instructions must be observed and adhered to. The accident

prevention regulations of the trade associations must be adhered to, particularly when working

on the roof. Where there is a danger of falling, precautions must absolutely be taken.

The entire solar energy system must be installed and operated in accordance with the recognised

technical regulations.

Due to snow and wind loads, extreme forces can be at work on the collector fixings. Attention

should therefore be paid to carrying out the installation carefully. The roof construction (rafters)

must be capable of withstanding the additional load. Furthermore, care must be taken that the

snow and wind loads are discharged into the roof construction at certain points. It may be

necessary to consult a structural engineer.

In case of snow loads of zone 3 and above, and installation locations more than 600 m above sea

level, we ask that you enquire with us about the static test.

When installing the collectors towards the edges of the roof, a minimum gap of 1.5 m from the

eave and of 1.2 m from the ridge must be observed. If this minimum gap cannot be observed, a

structural engineer must be consulted.


5/16


TECHNICAL INSTRUCTIONS

Anti-freeze protection

The solar energy system may only be filled with antifreeze mixture. As it is not possible to empty

the collectors completely, it is imperative that the system be filled with the antifreeze mixture,

even for function tests. We recommend using premixed antifreeze mixtures; alternatively, the

water and antifreeze must be mixed outside the solar energy system.

Caution! As the collector can reach temperatures of over 200C, an antifreeze which is suitable for

use in such conditions must be chosen (e.g. with a propylene glycol base).

Bleeding

The solar circuit must generally be bled below the roof. If automatic bleed valves are used, it is

imperative that additional ball valves be installed for manual closure of the system. These ball

valves must be closed after filling the plant again. Otherwise, the antifreeze mixture might leak

during high temperatures and steam build-up in the collector.

Recycling

We guarantee that we will take back and recycle our products once they have come to the end of

their life cycle. We have already ensured that our products are suitable for recycling during the

development stage. This is therefore guaranteed.

Electrical connections

A dedicated electrical circuit/circuit breaker should be provided for the solar system.

Earthing and l ightning protectionIf the building already has lightning protection, the solar system's metal pipes must be connected

to the lightning protection by means of a green/yellow conductor of at least 6 mm Cu (H07 V-U

or R). Otherwise it is possible to earth the system to an earth rod.

Pictograms

Here you will find important

instructions which must be

observed under all

circumstances.

Here you will find notices regarding

dangers concerning health, damage

to equipment and financial losses.

Required tools

Cordless screw driver with

6 mm wood drill bit, 13 mm

socket wrench and 14 mm

masonry drill bit

Spanners

13/ 17/ 19/ 20/ 22

Measuring tape

Angle grinder with stone

cutoff wheel

6 mm Allen key


6/16


RAFTER ANCHOR AND HANGER BOLT INSTALLATION

Vertical

1. The collector array can be installed vertically or

horizontally.

For vertical installation, the rails (2/3) are installed

horizontally. The distance A of the profile rail can be

taken from the adjoining table. The distances B and C

from the rails to the outer edge of the collector must be

between 150 and 350 mm.

Up to 3 collectors can be connected in series (1 basic kit

and 2 extension kits).

A in m

M2 1,2 1,5

Horizontal

2. For horizontal installation, the rails (2/3) are installed

vertically. The distance A of the profile rail can be

taken from the adjoining table. The distances B and C

from the rails to the outer edge of the collector must be

between 150 and 500 mm.

Up to 3 collectors can be connected in series (1 basic kit

and 2 extension kits).

A in m

M2 0,9 1,5

A. Pan tiles and similar roof tiles

1. Remove one (or more) roof tiles above the planned

installation position of each rafter anchor (5). The

horizontal spacing is derived from the rafter spacing

and the vertical spacing is derived from the roof tiles.

The number of rafter anchors is derived from the size of

the collector array (basic kit: 4 rafter anchors, extension

kit: 2 rafter anchors)

2. Determine the position of the rafter anchor (5) so that it

is located in the trough of the roof tile. Mark two fixing

points on the rafter for each rafter anchor and pre-drill

them with a 6 mm wood drill bit.


7/16



3. If necessary, cut a recess in the lower tile with an angle

grinder at the point where the rafter anchor (5) comes

through.

Pay particular attention to the leak-tightness of the roof

at the position where the rafter anchor comes through.

The roof hook must not exert any pressure on the roof

tile.

4. Fix each rafter anchor (5) to the roof rafters with 2

wood screws (6.1) and washers (6.3).

The screws (6.1) must enter into the wood to a depth of

at least 40 mm.

The rafter anchors (5) must not rest on the roof tiles! A

spacing of 5 mm must be kept between the rafter and

the roof tile. If necessary, underlay the rafter anchors with

equalisation boards (6.6).

5. Cut a recess in the upper tile with an angle grinder at the

point where the rafter anchor (5) comes through.

6. Replace the upper roof tile.



The roof tile must not be pushed up by the rafter anchor

(5).


8/16



B. Plain tiles

1. Remove several roof tiles above the planned installation

position of each rafter anchor (11). The spacing to the side

is derived from the rafter spacing and the number of rafter

anchors. The spacing between the rails must be observed

as described on Page 6.

2. Determine the position of the rafter anchor (11) so that it

is located on a roof rafter directly above a roof batten.

Mark two fixing points on the roof rafter for each rafter

anchor and pre-drill them with a 6 mm wood drill bit.

3. Fix the rafter anchors (11) to the roof rafters using

wood screws (6.1) and the washers which go with these

(6.3).

The wood screws (6.1) must enter into the wood to a

depth of at least 40 mm.

4. Using an angle grinder, at the point where the rafter

anchor (11) comes through, cut a recess in the upper tile

which overlaps the crown of the rafter anchor.


9/16



5. Replace the roof tiles.



6. Cover each rafter anchor (11) with a metal sheet.

7. As you do so, hang the plate with the standing seam

edge on the upper edge of the roof tiles and fix it here.

Replace the roof tiles.

Once all the roof tiles have been replaced, check the

leak-tightness of the roof!

C. Corrugated slabs

1. In accordance with the planning, pre-drill the

corrugated slabs at the crest with a 14 mm drill bit.

Remove existing hanger bolts as an alternative. The

spacing to the side is derived from the rafter spacing and

the number of rafter anchors. The spacing between the

rails must be observed as described on Page 6.

Do not drill the rafters!


10/16


11/16


12/16


INSTALLING THE RAILS ON THE ROOF

Vertical

4. Lock the lower rail (2/3) with the studs into the

mounting profiles (4.2); mount the rail facing upwards. To

do so, position the M10 hexagonal bolt (6.2) with slot nut

(6.5) in the rail according to the positions of the rafter

anchors and fix it to the rafter anchor (5/11) by hand with a

washer (6.3) and an M10 hexagonal bolt (6.4).

Vertical

5. Attach the upper rail (2/3) as described in steps 1 to 3

and position it sideways.

To do so, position the rails with respect to each other so

that the diagonals D and E are of equal length. Mark the

correct position before installing them. Next, fasten both

rails in place by tightening the M10 hexagonal bolts (6.4).

The rail end pieces (8) must be on the side where the first

collector is to be installed.

Horizontal

4.1 Mount the first rail (2/3). Lock the stud into the

mounting profiles (4.2), align towards the planned position

of the collector connections. To do so, position the M10

hexagonal bolt (6.2) with slot nut (6.5) in the rail according

to the positions of the rafter anchors and fix it to the rafter

anchor (5/11) by hand with a washer (6.3) and an M10

hexagonal bolt (6.4).

Horizontal

5.1 Attach the second rail (2/3) as described in steps 1 to

3 and position it vertically.

To do so, position the rails with respect to each other so

that the diagonals D and E are of equal length. Mark the

correct position before installing them. Next, fasten both

rails in place by tightening the M10 hexagonal bolts (6.4).

The rail end pieces (8) must be at the bottom end of the

rails.


13/16


PREPARING THE COLLECTORS

1. Position the square nuts in the slot on the back of the

collector with a screwdriver and secure them with the

installation aid (4.4).

Using the installation aid, the square nut can easily be

positioned for further installation of the fixing profile (4.2)

when the collector (1) has been erected.

2. Preassemble the mounting profile (4.2) with an M8

hexagonal bolt (4.1) and washer (4.3) on the square nuts

on the rear side of the collector.

3. Determine the definitive lower spacing C of the

mounting profiles (4.2) on the collector. To do so, keep a

distance from the lower edge of the collector of 150-

350 mm for vertical installation and 150-500 mm for

horizontal installation.

Attach the upper mounting profiles (4.2) in accordance

with the spacing A of the rails (2/3) to the lower

mounting rails (4.2). The distance B to the top edge of

the collector must also be within the range given above.

The mounting profiles must be facing downwards.

Preassemble the securing screw (4.5) 100 mm beneath

the lower mounting profiles.

4. Punch the two drainage holes at each bottom corner of

the collector, according to how it is positioned on the

roof, with the aid of a slotted screwdriver. To do so,

punch at the bottom edge.

To ensure that water can drain properly from the

collector, it is absolutely essential that all drainage holes

are punched at the bottom of the collector (depending

how it is oriented on the roof).


14/16


INSTALLING THE COLLECTORS ON THE ROOF

5. Hoist the collectors (1) onto the roof. For hoisting onto

the roof, fix two sufficiently sturdy ropes to the collector

as shown in the diagram. When doing so, make sure that

the ropes are not fed over the plastic edges of the

collector. We recommend using a crane for doing the

lifting If necessary, carefully hoist the collector up onto

the roof via a ladder. Work as a pair: one installer secures

the collector, the second guides it

Observe the labour safety regulations! Do not walk under

suspended loads. Secure the collectors (1) to prevent

them falling!

Vertical

6. Carefully lift the collector (1) onto the rails (2), remove

the hoisting guys and position the collector. To do so,

position the collector against the rail end pieces (8) and

slowly let it slide downwards until the mounting profiles

(4.2) lock into the rails (2). Next, position the securing

screws (4.5) against the rail from underneath and tighten

it.

Horizontal

6.1 Carefully lift the collector (1) onto the rails (2), remove

the hoisting guys and position the collector. To do so, let

the collector slowly slide downwards against the rail end

pieces (8) and move it sideways until the mounting

profiles (4.2) lock into the rails (2). Next, position the

securing screws (4.5) against the rail from the side and

tighten it.

7. Installing more collectors

For both horizontal and vertical installation, first stick the

spacer (7.5) onto the rails with the stopper against the

first collector. Install another collector as described in

subsection 5 and 6 or 6.1. This collector must be

positioned next to the spacers.

After installing the last collector, attach two rail end

pieces (8) to the open ends of the rails (2/3).


15/16


HYDRAULIC CONNECTION

1. Replace one roof tile with a ventilation tile above each

connecting pipes (9.1) feed-through.

2. Feed the connecting pipes (9.1) through the ventilation

tile into the interior of the building. Next, if necessary,

seal the sarking membrane with suitable adhesive tape.

The piping (9.1) should be laid so that it rises upwards in

order to allow ventilation at the highest point of the solar

energy system.

3. Install the connecting pipes (9.1) to each of the

external collector connections. To do so, insert the

support sleeve (9.2) into the connecting pipe. Push the

screw connection until it meets the collector

connections. Tighten the nut by hand first, then tighten

by one turn with the spanner. Push the previously pulled

back insulation tube over the connection until it meets

the collector frame.

When tightening, make sure you keep the screw fitting

tight with a second spanner in order to prevent damageto the collector!

4. Connect the collectors together in series. To do so,

attach the connection pipe (10.1) to the appropriate

collector connection. Insert the support sleeves (10.2) into

the connecting pipes. Push the screw connection until it

meets the collector connections. Tighten the nut by hand

first, then tighten by one turn with the spanner. Push the

previously pulled back insulation tube over the connection

until it meets the collector frame.


16/16


INSTALLING THE SENSOR

1. Carefully remove the plugs from the collector frame.

2. Slide the plugs over the temperature sensor (included

with the solar controller).

3. Coat the temperature sensor with heat-conducting

paste (included with the solar controller).

4. Insert the temperature sensor fully into the immersion

sleeve. Seal the collector frame with plugs. To do so, make

sure that the plugs are positioned correctly.

Documents

SunMaxx TitanPower-AL2 Flush Mounting Instructions