6720887693 (2018/10) KEN
Installation and maintenance instructions for specialists
Thermosiphon system, on-roof installation
TSS
TSS150-2E/FCC-2, TSS200-2E/FCC-2, TSS300-2E/FCC-2
Table of contents
TSS – 6720887693 (2018/10)
2
Table of contents
1 Explanation of symbols and safety instructions . . . . . . . . . . . 3
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Supplied parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Product data for energy consumption. . . . . . . . . . . . . . . 7
2.3 Performance data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Selecting the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Recommendations for energy savings . . . . . . . . . . . . . . 8
2.8 Declaration of conformity (collector) . . . . . . . . . . . . . . . 8
3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Determining the space required . . . . . . . . . . . . . . . . . . . 9
4.3 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Installing the roof connection . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Transferring the clearances of the roof connection
to the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Installing the double-ended screws . . . . . . . . . . . . . . . 11
6.3 Fitting the roof hooks with roof tiles . . . . . . . . . . . . . . . 12
6.4 Fitting roof hooks with plain tiles . . . . . . . . . . . . . . . . .14
6.5 Fitting special roof hooks for slate/shingles . . . . . . . . . 15
6.6 Installing the profile rails . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Installing the storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Installing the collectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Preparing the collector installation . . . . . . . . . . . . . . . .17
8.2 Installing the collector clamp on the right side. . . . . . . 18
8.3 Place first collector on the profile rail . . . . . . . . . . . . . . 18
8.4 Inserting the double-sided collector clamp . . . . . . . . . 18
8.5 Placing the second collector on the profile rails. . . . . . 18
8.6 Installing the collector clamp on the left. . . . . . . . . . . . 19
9 Hydraulic connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.1 Connecting the flow pipe. . . . . . . . . . . . . . . . . . . . . . . . 20
9.2 Connecting the return pipe . . . . . . . . . . . . . . . . . . . . . .20
9.3 Connecting potable water pipe . . . . . . . . . . . . . . . . . . . 21
10 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10.1 Lightning protection and equipotential bonding . . . . . 22
10.2 Filling the potable water circuit . . . . . . . . . . . . . . . . . . . 22
10.3 Filling the solar circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10.4 Carrying out checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.5 Insulating the connection lines and pipework . . . . . . . 23
11 Environmental protection, shutdown, disposal. . . . . . . . . . . 24
11.1 Environmental protection and disposal . . . . . . . . . . . . 24
11.2 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Maintenance, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Explanation of symbols and safety instructions
3
TSS – 6720887693 (2018/10)
1 Explanation of symbols and safety instructions
1.1 Explanation of symbols
Warnings
In warnings, signal words at the beginning of a warning are used to
indicate the type and seriousness of the ensuing risk if measures for
minimising danger are not taken.
The following signal words are defined and can be used in this document:
DANGER:
DANGER indicates that severe or life-threatening personal injury will
occur.
WARNING:
WARNING indicates that severe to life-threatening personal injury may
occur.
CAUTION:
CAUTION indicates that minor to medium personal injury may occur.
NOTICE:
NOTICE indicates that material damage may occur.
Important information
The info symbol indicates important information where there is no risk to
people or property.
Additional symbols
Table 1
1.2 General safety instructions
H Notice for the target group
These installation instructions are intended for
competent persons who are skilled in dealing with
water installations, heating and electrical systems.
▶ Read the installation instructions before starting
the installation.
▶ Observe the safety and warning instructions.
▶ Observe national and regional regulations,
technical rules and guidelines.
▶ Document all work performed.
H Intended use
The collectors are designed to produce heat in a
thermal solar system (thermosiphon system). The
installation set is exclusively designed for the safe
installation of collectors and the storage tank.
▶ Only operate collectors in hydraulically sealed
unvented thermal solar systems (no oxygen in the
pipework).
▶ Do not place other objects on the collectors.
H Risk of scalding at the DHW draw-off points
▶ In order to avoid scalding a mixer must be installed
in the DHW system that restricts the DHW
temperature to 60 °C. If in doubt, ask the specialist.
H Load bearing capacity of the roof
▶ Only install the product on roofs with sufficient load
bearing capacity.
▶ If in doubt, consult a structural engineer and/or
roofer.
H Storing the components
The supplied components may cause burns when
exposed to solar radiation.
▶ Protect the components from solar exposure. Wear
personal protective equipment.
▶ Store the collectors in dry conditions. If stored
outside, use a rain cover.
▶ Do not stand on the collectors.
H Working on the roof
There is a danger of falling when working on the roof if
measures are not taken to prevent accidents.
▶ If there is no independent anti-fall safety device,
wear personal protective equipment or safety
equipment.
▶ Observe accident prevention regulations.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document
• a list entry
– a list entry (second level)
Product Information
TSS – 6720887693 (2018/10)
4
H Handover to the user
When handing over the thermal solar system, explain
the operation and operating conditions to the user.
▶ Explain operation – with particular emphasis on all
safety-related actions.
▶ Point out that the system can be used by children
aged 8 years or older and persons with limited
physical, sensory or mental capacities or
insufficient experience and knowledge, providing
they are supervised or have been instructed on safe
use of the system and understand the associated
dangers.
▶ Children shall not play with the appliance. Cleaning
and user maintenance shall not be made by children
without supervision.
▶ If an immersion heater is used, advise the user on
energy-saving operation.
▶ As hot liquid may be discharged from apertures in
the pressure relief valves, avoid standing in this
area.
▶ Point out that the valves on the
cylinder can become very hot and that
these parts pose a risk of burning.
Babies in particular must be kept away
from the cylinder.
▶ Point out that conversion or repair may be carried
out only by a licensed contractor.
▶ Also point out the need for inspection and
preventative maintenance for safe and
environmentally friendly operation.
▶ Hand over the installation and operating
instructions to the user for safekeeping.
2 Product Information
The heat transfer medium circulating through different densities heats
the potable water in the storage tank.
The thermosiphon systems differ in the following:
• Number of collectors
• Size of the storage tanks
Fig. 1 Differentiation of the systems
The graphics in these instructions use the example of a roof connection
with double-ended screws. If the installation varies for other types of
roof connections, this is indicated in the text.
TSS150
TSS200
0010015758-01
0010015758-01
TSS300
Product Information
5
TSS – 6720887693 (2018/10)
2.1 Supplied parts
▶ Check that the delivery is complete and undamaged.
On-roof installation set
Fig. 2 Installation set (TSS300)
Table 2 On-roof installation set
Fig. 3 Double-ended screw installation set
Table 3 Double-ended screw installation set
Alternative roof connections for the collector are described in the
section "Installing the roof connection".
1
12
11
10
2
9
3
4
6
7
8
0010015338-01
0010015338-01
5
No. Component TSS150
TSS200
TSS300
1 Storage tank strap 2 3
2 Double-sided collector clamp -- 2
3 Aluminium nut M8 6 9
4 Oval head screw M8 × 20 4 6
5 Oval head screw M8 × 16 8 12
6 Hexagon bolt M8 × 50 2 3
7 Washer 2 3
8 Storage tank protection adhesive strip 2 3
9 Profile rail, long 2 2
10 Anti-slip protection 2 4
11 Single-sided collector clamp 4 4
12 Profile rail, short 2 3
No. Component Number
1 Retaining block 4
2 Nut M12 4
3 Sealing washer 4
4 Double-ended screw M12 × 180 4
5 Oval head screw M8 × 16 4
6 Washer 4
0010015735-01
0010015735-01
1
2
3
4
6
5
Product Information
TSS – 6720887693 (2018/10)
6
Connection set
Fig. 4 Connection set
Table 4 Connection set
Memory
Fig. 5 Storage tank for thermosiphon system
Table 5 Storage tank for thermosiphon system
Collector
Fig. 6 Collector
Table 6 Collector
14
13
11
2
10 8
7 6
5
1
3 4
1
0010015800-01
9
12
No. Component Number
1 Solar hose (TSS150/300: 3.3 m / TSS200: 2.9 m) 1
2 Return pipe bracket 1
3 Cap ½" 1
4 Gasket 24 × 17 2
5 Angled ferrule G1xD21 1
6 Clamping washer 1
7 Nut G1 1
8 Solar hose, 97 mm (TSS300) 2
9 Hose clip TSS150/200 4
Hose clip TSS300 8
10 Solar hose, 55 mm with plug and hose clip 2
11 Solar pressure relief valve 2.5 bar 1
12 Potable water pressure relief valve 8 bar 1
13 Storage tank connection pipe, bent 1
1)
1) TSS200: 2
14 Storage tank connection pipe, straight 1
2)
2) TSS200: 0
0010014993-01
7
4
68
9
1 2
5
3
No. Component
1 Connection G½for solar pressure relief valve
2 Filler Solar G½
3 Integrated nuts for handle accessories
4 Data plate position
5 Handhole cover
6 Cold water connection G½
7 Solar return connection G¾
8 Domestic hot water connection G½
9 Solar flow connection G¾
No. Component
1 Flow connection
2 Return connection
3 Data plate position
0010014994-01
1
2
2
1
3
Product Information
7
TSS – 6720887693 (2018/10)
2.2 Product data for energy consumption
Detailed information about energy consumption can be found on our
website.
2.3 Performance data
Table 7 Calculated annual result, location: Athens
For an optimal cost/benefit ratio, we recommend solar coverage of
60-75 %.
2.4 Selecting the system
Fig. 7 Recommendation: selection of the thermosiphon system
according to daily DHW consumption
2.5 Specification
Table 8 Collector
Table 9 Memory
Table 10 Entire thermosiphon system
2.6 Intended use
The installation system is intended solely for the secure mounting of
collectors and the storage tank.
It can be used on a roof with a slope of 25 - 45°.
▶ Never modify components.
▶ Do not damage the roof or building structure.
Mount the installation system parallel to the roof, as described in these
instructions.
▶ Do not raise the installation system on-site in order to increase the
solar yields. The additional solar yields are minimal.
Permissible heat transfer medium
▶ To protect the collectors against damage through frost and corrosion,
operate them with solar heat transfer medium L
(70 % water, 30 % propylene glycol).
▶ If water is used as a heat transfer medium, the following prerequisites
must be fulfilled:
– Continuous ambient temperatures above 5 °C.
– Closed circuit. This prevents the introduction of oxygen. In the
event of a pressure drop, remedy the fault immediately.
– Have the water checked ( table).
Limits for water as a heat transfer medium:
Table 11
1)
c (HCO
3
–
) = concentration of hydrogen carbonate ions (unit: m mol/l)
c (SO
4
2–
) = concentrate of sulphate ions (unit: m mol/l)
System Daily water consumption (litres/day)
110 l 140 l 170 l 200 l 250 l 300 l 400 l
Q
d
kWh/y annual heat demand
1270 1621 1962 2313 2891 3469 4625
Q
L
kWh/y annual system performance
TSS150 1025 1218 1367 1454 1577 1621
TSS200 1226 1384 1516 1638 1726 1787
TSS300 1454 1717 1954 2295 2593 2935
f
sol
% solar coverage
TSS150 81 75 70 63 55 47
TSS200 76 71 66 57 50 39
TSS300 90 87 84 80 75 64
FCC220-2
Certificate: CE marking,
Solar Keymark register no. 011-7S2181 F
Length mm 2025
Width mm 1030
Height mm 67
Clearance between collectors mm 69
Collector connection (in the shape of a ferrule) mm 23
Absorber capacity (V
F
) l 0.8
Total collector area (gross area, A
G
) m
2
2.09
Absorber surface area (net area, A
A
)m
2
1.92
Aperture area
(area on which the usable sunlight falls, A
a
)
m
2
1.94
Net weight excluding packaging (m
c
)kg30
Permissible collector operating pressure bar 6 (600 kPa)
0010015998-01
0010015998-01
TSS150
TSS200
TSS300
45°C
110 - 170 l/d
140 - 200 l/d
TSS...
200 - 350 l/d
+
150 l 200 l 300 l
Weight, empty (m
Tank
)kg617596
Weight, filled kg 215 275 384
Primary circuit contents
(heat transfer medium V
F
)
l 4 5.2 7.5
Secondary circuit contents
(potable water V
W
)
l 145 195 280
Max. operating pressure,
primary circuit (p
F
)
bar 2.5 (250 kPa)
Max. operating pressure,
secondary circuit (p
W
)
bar 8 (800 kPa)
Max. temperature, primary circuit °C 110
Max. temperature, secondary circuit °C 95
Heat loss W/K 1.44 1.61 2.57
Insulation mm 50
Diameter mm 580
Width mm 1100 1350 1820
150 200 300
Certificate: Solar Keymark,
register no. 011-7S2816 A
Total weight, filled (approximate) kg 290 340 510
Parameter Value
pH value 7.5 - 9
Electrical conductivity 100 - 1500 microS/cm
Carbonate hardness and
sulphate
1)
Chloride content maximum 30 mg/l
Regulations
TSS – 6720887693 (2018/10)
8
Permissible loads
▶ Only install collectors in locations with values lower than those shown
in the following. If required, consult a structural engineer.
Table 12 Maximum loads for the installation set
(with reference to DIN EN 1991, parts 3 and 4)
When determining the maximum wind speed, take the following factors
into account:
• Location of the thermal solar system
• Geographical height of the terrain
• Topography (terrain/buildings)
• Height of building
The maximum snow load is calculated using regional zones (snow load
zones) and the ground level elevation.
▶ Enquire about the locally applicable snow loads
( e.g. technical guide).
Permissible roof connections
▶ Collectors: use roof hooks or double-ended screws.
▶ Storage tanks: only double-ended screws are permissible.
▶ Only screw double ended screws into a substructure with sufficient
load bearing capacity.
Corrosion protection
All supplied components are protected against corrosion through either
the material (e.g. aluminium, plastic) or coatings.
▶ Only use materials on site that can withstand local weather
conditions.
The potable water area in the storage tank is protected against corrosion
through enamel coating and a magnesium anode. To maintain this
protection:
▶ Observe the maintenance intervals and instructions in the
"Maintenance, inspection" section.
2.7 Recommendations for energy savings
▶ Install the DHW mixing valve as close as possible to the storage tank
( section "Hydraulic connection" for system examples).
▶ When using an immersion heater:
– Only connect the immersion heater to the mains power supply
when insufficient solar exposure is expected (e.g. during winter,
at night).
– Disconnect the immersion heater from the mains power supply
when solar exposure is sufficient or during absences (e.g.
holidays).
– Use a timer or similar to ensure appropriate use of the immersion
heater.
– Set the temperature as low as possible.
▶ To be able to use as much solar-heated water as possible, draw hot
water only after the sun has peaked (midday).
▶ Connect dishwashers and washing machines (if suitable) to the DHW
pipe and where possible use these between 15:00 and 18:00.
▶ Position the thermosiphon system so that the DHW pipe is as short as
possible. Ensure the DHW pipe is very well insulated.
2.8 Declaration of conformity (collector)
This product, in design and operation, conforms to the
European Directives and supplementary national
requirements. Compliance is demonstrated by the CE
marking.
You can request the declaration of conformity of the product. For this see
the contact address on the back cover of these instructions.
3 Regulations
▶ Observe updated regulations or supplements. These regulations also
apply at the time of installation.
▶ Observe all standards and guidelines applicable to the installation
and operation of the system in your country and region.
Technical regulations applicable for the installation of collectors
• Rooftop installation:
– DIN EN 1991: Actions on structures
• Connection of thermal solar systems:
– EN 12976: Thermal solar systems and components
(factory-made systems)
– EN 12977: Thermal solar systems and components
(custom-built systems)
• Electrical connection:
– DIN EN 62305 Part 3 / VDE 0185-305-3: Protection against
lightning, physical damage to structures and life hazard
Technical rules for the installation of DHW cylinders
• DIN EN 12897: Water supply – specification for storage water
heaters (product standard)
• DIN EN 1717: Protection against pollution of potable water
installations
• DIN EN 806: Technical rules for potable water installations
4 Before installation
4.1 General notes
CAUTION:
Risk of burning from hot components!
The collector and installation materials can become very hot after being
exposed to solar radiation for prolonged periods of time.
▶ Wear personal protective equipment.
▶ Protect the collector and installation material from solar exposure.
We recommend that you engage the services of a roofing contractor, as
they are experienced in working on roofs and will be aware of the risk of
falling.
▶ Obtain information about on-site conditions and local regulations.
▶ Avoid potential shading.
▶ Whenever possible, align collectors so they are facing the midday
sun.
Load Roof slope 15-24° Roof slope 25-45°
Snow load
1)
1) Maximum snow load on the ground according to DIN EN 1991-1-3
-- < 1 kN/m
2
Wind load
2)
2) Maximum wind load according to DIN EN 1991-1-1-4
< 151 km/h (corresponds to a dynamic
pressure of 1.1 kN/m
2
)
Transport
9
TSS – 6720887693 (2018/10)
4.2 Determining the space required
WARNING:
Risk to life from incorrectly installed collectors!
Wind loads are especially high at the edges of the roof.
▶ Maintain the minimum clearance to the edge of the roof and roof
structures.
The clearances to be maintained to the edge of the roof (a) can be found
in DIN EN 1991-1-4 and the Code of Practice 61 of the BDH (Federal
Association of the German Heating Industry).
Fig. 8 Dimensions (value in brackets: system with 1 collector)
• Dim. a: Minimum clearance to the edge of the roof. Either formula
can be used. The lower value can be applied.
• Dim. X: At least two rows of tiles to ridge or chimney.
▶ For the pipes on the right and left of the collector array, allow an extra
0.5 m on either side.
▶ Allow sufficient space for maintenance and repair work at a later
date.
4.3 Required tools
Installation set:
• Allen key, 5 mm, with rounding
• Spanner, 19 mm (for installing the double-ended screws)
• Masonry drill bit, 14 mm; wood drill bit, 6 mm (for installing the
double-ended screws)
Connection set:
• Spanner 27, 30 and 37 mm
5 Transport
WARNING:
Risk to life from falling from roof!
▶ Never use a ladder to move components to the roof because the
installation material and collectors are heavy and difficult to handle.
▶ Whilst working on the roof, take all necessary precautions against a
possible fall.
▶ If there is not any independent anti-fall safety device, wear personal
protective equipment.
CAUTION:
Risk of injury from carrying heavy weights!
Incorrect lifting and carrying of heavy loads can cause injuries.
▶ Observe the transport instructions on the packaging.
▶ Only lift the appliance at the points provided for this purpose.
▶ Lift and carry the device with a sufficient number of persons.
- or -
▶ Use suitable means of transportation, (e. g. a pallet truck, hand truck
with strap).
▶ Secure the appliance to prevent it slipping, tilting and falling.
All packaging materials used are environmentally friendly and reusable.
▶ Dispose of shipping packaging by environmentally compatible
means.
▶ To make it easier to transport the components, you can use the
following aids, which have sufficient load-bearing capacity:
– Lifting/transportation devices as used by professional roofers
– Handles for the storage tank (accessories)
– Lifting belt
– 3-point suction lift
– Roofing ladder or equipment for sweeping chimneys
Transporting the collector
DANGER:
Risk to life from falling load.
▶ Never use the collector connections as lifting points!
▶ Collectors must always be carried by two people.
Fig. 9 Do not place any load on collector connections
Fig. 10 Only remove caps once on the roof
[1] Caps on the collector connection
a
bb
a =
b
10
a =
10
h
h
aa
aa
aa
X
2770
2120
(1345)
0010015736-01
0010015736-01
0010015284-01
0010015285-01
Installing the roof connection
TSS – 6720887693 (2018/10)
10
Transporting the storage tank
If you want to place the storage tank on level ground:
▶ Lay the storage tank on the styrofoam panel [1] of the packaging.
Fig. 11 Lay the storage tank on the styrofoam panel
To protect the storage tank during transport:
▶ Do not remove the DHW cylinder from its packaging until it has
reached the installation location.
▶ Position the hand truck at the side of the DHW cylinder with the
styrofoam panel.
▶ Secure the DHW cylinder to the means of transportation with a strap.
▶ Transport the DHW cylinder to the installation location.
▶ Remove the DHW cylinder from the packaging only at the installation
location.
Fig. 12 Transporting the storage tank with hand truck
6 Installing the roof connection
6.1 Transferring the clearances of the roof connection to the roof
NOTICE:
Roof leaks from incorrect positioning of the roof connection!
Roof tiles have a peak and a valley.
▶ Always install double-ended screws on the peak.
▶ Always install roof hooks in the valley.
▶ Determine the clearances and transfer to the roof.
Fig. 13 Roof connection clearances for: TSS300 (left) and TSS150/200 (right), values in brackets apply to TSS200
0010015281-01
1
0010015282-01
0010015737-01
0010015737-01
[mm]
1260-1620
1320 - 1680
1930 - 2000
520 - 590
610 - 910
1320 - 1680
1930 - 2000
520 - 590
740 - 890
(940 - 1090)
1690 - 1990
=
=
=
=
Installing the roof connection
11
TSS – 6720887693 (2018/10)
6.2 Installing the double-ended screws
WARNING:
Danger to life due to falling cylinder!
▶ Only screw double ended screws into a substructure with sufficient
load bearing capacity.
We recommend making a drilling template to ensure accurate vertical
drilling.
To create a drilling template:
▶ Drill vertically through the timber using a wood drill bit.
Fig. 14 Creating a drilling template
1. With a 14 mm drill bit, drill through the peaks of the roof tile.
However, do not drill into the timber below!
2. With a 6 mm wood drill bit, drill absolutely vertically through the
drilling template [1] and substructure.
Fig. 15 Drilling through roof tile and timber
NOTICE:
Roof leaks from damaged sealing washer!
▶ Only screw the nut over the sealing washer hand-tight onto the flat
washer.
▶ Turn the pre-assembled double-ended screw on the retaining block
with a 19 mm spanner until dim. Z ( tab.) is reached.
▶ Tighten the nut [2] by hand until the sealing washer [4] makes full
contact with the roof tile. Retighten nut with a ¼ to ½ turn of a
spanner.
Fig. 16 Fitted double-ended screw with retaining block
[1] Retaining block
[2] Nut M12
[3] Washer
[4] Sealing washer
[5] Double-ended screw M12 × 180 mm
Table 13 Dim. Y and Z
63043965.23-1.SD
63043965.23-1.SD
0010015740-01
0010015740-01
14 mm
1.
6 mm
2.
90°
1
Roof tile height, dim. Y Dim. Z
35 mm max. 70 mm
40 mm max. 65 mm
45 mm max. 60 mm
50 mm max. 55 mm
55 mm max. 50 mm
60 mm max. 45 mm
0010015741-02
0010015741-02
Y
Z
0 mm
19
1
2
3
4
5
Installing the roof connection
TSS – 6720887693 (2018/10)
12
6.3 Fitting the roof hooks with roof tiles
WARNING:
System damage from subsequent loosening of the long nuts on the
roof hooks!
When the nut is tightened, a lock is activated.
▶ If the long nut is undone more than once, secure it on site (such as
with suitable adhesive).
▶ Undo nut with a 5 mm Allen key to turn or move the bottom part of the
roof hook [1].
▶ If the combined thickness of the roof tile and batten is more than
70 mm, use the roof hook as a rafter anchor.
Fig. 17 Turn the lower part of the roof hook, dimensions in mm
Hooking the roof hooks into the roof batten
▶ Slide the roof tiles up around the roof hook positions.
Fig. 18 Roof hook hooked into place
▶ Place the roof hooks into the valley of the corrugation and hook under
the batten.
▶ Push the bottom part of the roof hook [1] up to the batten.
▶ Tighten nut [3] when the serrated washer [2] grips the teeth of the
bottom part of the roof hook.
Fig. 19 Pushing the bottom part of the roof hook
To prevent windblown snow from entering:
▶ Carefully remove the roof tile contact points in the roof hook area.
Fig. 20 Adjusting the roof tiles
6720640298-07.1ST
1
37-70
37-70
6720640298-08.1ST
6720640298.09-1.ST
6720640298.09-1.ST
1
2
3
6720803995-24.1ST
Installing the roof connection
13
TSS – 6720887693 (2018/10)
Fitting roof hooks as rafter anchors
NOTICE:
System damage from breaking roof hooks!
▶ Relocate the bottom part of the roof hook to the top hole.
▶ Relocate the bottom part of roof hook [1] with a screw in the top hole.
Do not yet tighten the nut.
Fig. 21 Preparing the rafter anchor
[1] Bottom part of roof hook
[2] Use the top hole
[3] Trim if required
▶ Where required, secure boards/planks with adequate load-bearing
capacity to the rafters (minimum thickness: 30 mm) [1]. Where
required, remove counter battens from this area.
▶ Lay the front support on the roof tile so that it lies in a tile valley [2]
when subjected to loads.
Fig. 22 Fitting rafter anchors on the board/plank
The roof hook needs a little room for movement at the top edge of the
roof tile [1].
▶ If required, trim the top of the roof tile.
▶ It may be necessary to underlay the lower part of the roof hook with
boards/planks so that the roof hook lies on top of the tile to the front [4].
When the serrated washer [2] grips the teeth of the bottom part of the
roof hook:
▶ Tighten the nut.
▶ Use three suitable screws, to be provided by the customer,
(e.g. 5 × 50 DIN EN 14592) to secure the bottom part to the rafter
(boards/planks) [3].
Fig. 23 Securing the rafter anchor
To prevent windblown snow from entering:
▶ Carefully remove the roof tile contact points in the roof hook area.
Fig. 24 Adjusting the roof tiles
6720640298-05.1ST
1
3
2
2
1
> 30 mm
6720640298-56.2ST
6720640298-55.1ST
3
4
2
1
> 3 mm
> 3 mm
6720803995-24.1ST
Installing the roof connection
TSS – 6720887693 (2018/10)
14
6.4 Fitting roof hooks with plain tiles
NOTICE:
Unprofessional work may lead to the roof leaking!
▶ Consult a roofer for advice and assistance.
WARNING:
System damage from subsequent loosening of the long nuts on the
roof hooks!
When the nut is tightened, a lock is activated.
▶ If the long nut is undone more than once, secure it on site (such as
with suitable adhesive).
▶ Relocate the bottom part of roof hook to the top hole of the roof hook.
Do not yet tighten the nut.
Fig. 25 Preparing the rafter anchor
[1] Bottom part of roof hook
[2] Use the top hole
[3] Trim if required
▶ If the combined thickness of the roof tile and batten is more than
70 mm, use the roof hook as a rafter anchor.
NOTICE:
Roof leaks from incorrectly positioned roof hooks!
▶ Position the roof hook centrally on the roof tile. The bottom part then
lies on the rafter (boards/planks).
▶ Where required, secure boards/planks with adequate load-bearing
capacity to the rafters. Where required, remove counter battens from
this area.
When the serrated washer [2] grips the teeth of the bottom part of the
roof hook:
▶ Tighten the nut [1].
▶ Use three suitable screws, to be provided by the customer,
(e.g. 5 × 50 DIN EN 14592) to secure the bottom part to the rafter
(boards/planks) [3].
Fig. 26 Fitting rafter anchors
▶ Trim adjacent roof tiles (dotted line [1]).
Fig. 27 Adjusting plain tiles
6720640298-05.1ST
1
3
2
6720640298-32.1ST
2
1
3
> 3 mm> 3 mm
1
0010014056-001
Installing the roof connection
15
TSS – 6720887693 (2018/10)
6.5 Fitting special roof hooks for slate/shingles
NOTICE:
Unprofessional work may lead to the roof leaking!
▶ Have a qualified roofer carry out the installation.
▶ To ensure a watertight installation, insert a plate on site [3]
underneath the special roof hook.
▶ Fit the special roof hook at the front with gaskets [2] and the screw
[1].
▶ Adequately secure the special roof hook at the back on the roof
substrate.
Fig. 28 Example figure
[1] Screw 6 × 70 (4 × )
[2] Gaskets (on site)
[3] Plate (on site)
[4] Fitted special roof hook
6.6 Installing the profile rails
Fig. 29 Correctly positioning the profile rails for the storage tank
▶ Place the the profile rails in the centre and screw in each retaining
block with two short screws M8 × 16.
Fig. 30 Installing the upper and lower profile rails
It is important for the subsequent collector installation that the profile
rails are accurately aligned! Use assembly aids, e.g. a roof batten [1].
▶ Level the profile rails horizontally and with the stated clearance. Use
a spirit level.
▶ Align sides of the upper and lower profile rails with each other.
▶ Check that they are at right angles. Measure the diagonals or place a
roof batten, for example, at the ends of the profile rails.
▶ Tighten screws M8.
Fig. 31 Precisely align the profile rails
3
4
1
2
6720640298.20-2.ST
6720640298.20-2.ST
0010015742-01
0010015742-01
1
1
2
2
M8x16
M8x16
M8x16
M8x16
0010015743-01
0010015743-01
0010015754-01
0010015754-01
90°
90°
90°
1
1
1
Installing the storage tank
TSS – 6720887693 (2018/10)
16
The triangles above the elongated holes mark the position of the anti-slip
protectors.
▶ Push the anti-slip protector down over the profile rail and let it click
into the slot.
Fig. 32 Installing anti-slip brackets on the lower profile rails
[1] Lower profile rail for two collectors
[2] Lower profile rail for one collector
7 Installing the storage tank
WARNING:
Risk to life from falling parts!
The accumulation of snow above the storage tank generates
considerable forces.
▶ Install a snow guard above the storage tank (maintain a clearance of
no more than 1 m between the storage tank and the snow guard).
▶ Alternatively: regularly clear snow build-up.
▶ Place the storage tank strap into the recesses of the short profile rails
and tighten.
Fig. 33 Installing the storage tank strap
The storage tank is heavy and awkward to handle. Note the position of
the storage tank on the installation set before carrying it.
▶ Adhere the adhesive strips to the storage tank straps as tank
protection [1].
▶ Place the storage tank in the middle of the storage tank straps and
rotate it until the storage tank connections are vertical [2].
Fig. 34 Placing and aligning the storage tank in the storage tank straps
▶ Align the storage tank so that the drainage pipe [1] is not closed off
at the bottom by the storage tank strap.
Fig. 35 Do not block the drainage pipe
▶ Install a hexagon bolt M8 × 50 with a flat washer and aluminium nut
[2] on the storage tank [1].
▶ Slide the aluminium nut into the profile rail and tighten the
connection.
Fig. 36 Tightening the storage tank strap
0010014827-01
1
2
click!
1
1
2
2
0010015744-01
0010015744-01
M8x20
M8x20
0010015745-01
0010015745-01
2
1
1
0010016282-01
0010016090-01
2
1
Installing the collectors
17
TSS – 6720887693 (2018/10)
8 Installing the collectors
WARNING:
Risk to life from falling from roof!
▶ Installation of the collectors on the roof must be performed by at least
2 people.
WARNING:
Risk of injury from falling parts!
▶ During transport, secure the collectors and installation material to
prevent them from falling.
▶ After completing installation, check that the installation set and
collectors are securely positioned.
Important information on handling solar hoses
CAUTION:
Risk of injury from tightened circlip prior to installation!
▶ Tighten the circlip only after the hose clip has been placed over the
solar hose.
The solar hoses [2] are secured with the hose clip [1] by tightening the
circlip [3].
Fig. 37 Securing solar hoses (here: with plugs)
NOTICE:
Leaks at the collector connection!
Subsequent loosening of the hose clip can impair its tensioning capacity.
▶ Push the hose clip immediately in front of the bead of the collector
connection. Only then should the circlip be tightened.
Fig. 38 Move hose clip without locking ring
NOTICE:
Leaks from the solar hose!
To make installation easier, we recommend placing the solar hoses in hot
water before installation.
▶ Do not use lubricants containing mineral oil (such as thread sealing
compound).
8.1 Preparing the collector installation
CAUTION:
Risk of injury and leaks from escaping solar heat transfer medium as
a result of unsecured solar hoses.
▶ Secure every solar hose to the collector connection using a hose clip.
▶ Rotate the collector so that the black sensor well [1] is always at the
top of the collector frame. The sensor well has no function.
Fitting the plug
▶ Push the solar hoses [2] with pre-assembled plugs onto the available
collector connections.
▶ Tighten the circlip when hose clip [3] is located directly in front of the
bead.
Fig. 39 Fitting the plug
Installing connection set for 2 collectors
The first collector is installed on the right (A). Then the collector is
installed on the left (B).
▶ Push solar hose [2] with hose clips onto the collector connection of
the collector on the left side.
▶ Tighten the circlip when hose clip [1] is located directly in front of the
bead.
Fig. 40 Installing the connection set on the collector on the left side
0010014490-01
0010014055-001
0010015571-02
55
3
0010014492-01
97
B
Installing the collectors
TSS – 6720887693 (2018/10)
18
8.2 Installing the collector clamp on the right side
▶ Slide the one-sided collector clamp into the profile rail and let it click
into the slot (only on the right; the left side is done later).
Fig. 41 Installing the collector clamp on the right side
8.3 Place first collector on the profile rail
WARNING:
Risk of injury from falling collectors.
▶ Ensure that the collector profile engages in the anti-slip protector.
▶ Place the collector on the right onto the profile rails and allow it to
slide into the anti-slip protectors [1].
Fig. 42 Let the collector slide into the anti-slip protectors
▶ Carefully push the collector up against the collector clamp and level
horizontally.
▶ Tighten the screw of the collector clamp.
Fig. 43 Tightening the screw of the collector clamp
If only one collector is installed, then install the collector clamp on the
left.
8.4 Inserting the double-sided collector clamp
If two collectors are installed:
▶ Place the double-sided collector clamp on the profile rail and push up
to the collector. Do not tighten yet.
Fig. 44 Only insert a double-sided collector clamp
8.5 Placing the second collector on the profile rails
▶ Place second collector along with the pre-assembled solar hoses
onto the profile rails and let it slide into the anti-slip protectors.
▶ Push the second hose clip [1] onto the solar hoses.
▶ Push the collector up to the first collector so that the solar hoses are
pushed onto the collector connections.
Fig. 45 Push the left collector to the right collector
▶ Tighten the screw of the double-sided collector clamp [1].
Fig. 46 Double-sided collector clamp
0010014493-01
1
0010015805-010010015805-01
A
0010014495-01
A
0010014496-01
0010014497-01
0010014498-01
Hydraulic connection
19
TSS – 6720887693 (2018/10)
CAUTION:
Risk of injury and leaks from escaping solar heat transfer medium as
a result of unsecured solar hoses.
▶ Secure every solar hose to the collector connection using a hose clip.
▶ Tighten the circlip when the hose clip is located directly in front of the
bead.
Fig. 47 Fully assembled connection hose
8.6 Installing the collector clamp on the left
▶ Push the collector clamp into the profile rail and let it click into the
slot.
▶ Tighten the screw of the collector clamp.
Fig. 48 Installing the collector clamp on the left
9 Hydraulic connection
NOTICE:
Leaks from using non-approved thread sealing compound!
If pipe threads are caulked with hemp:
▶ Use temperature-resistant thread sealing compound
(e.g. Neo Fermit).
NOTICE:
No solar-heated water from incorrectly installed flow and return
pipes!
To enable the heat transfer medium to flow from the collector into the
storage tank through different densities and for optimal venting:
▶ Always install flow and return pipes with a rising gradient to the
storage tank.
▶ Bend the flow and return pipes with a sufficiently large radius.
Fig. 49 Do not install a pipe trough (here: flow pipe)
Fig. 50 Ensure that the solar hose is not kinked
0010014499-01
0010014500-01
0010015761-02
0010015400-01
Hydraulic connection
TSS – 6720887693 (2018/10)
20
9.1 Connecting the flow pipe
The installation of the flow pipe depends on the solar thermal system.
▶ Remove transport protection from the collector connections.
▶ Shorten the solar hose [2] as required and push with hose clips onto
the collector connection.
▶ Tighten the circlip when hose clip is located directly in front of the
bead.
NOTICE:
Leak from the storage tank connection!
The gasket can be damaged by over-tightening of the screw connection.
▶ Hand-tighten the storage tank connection pipe and then tighten with
a ½ turn using a spanner (corresponds to approx. 35 Nm).
▶ Screw the storage tank connection pipe [4] with a gasket [1] onto the
storage tank connection (solar flow).
▶ Push the solar hose [2] with hose clip [3] onto the storage tank
connection pipe.
▶ Tighten the circlip when hose clip is located directly in front of the
bead.
Fig. 51 Installing the flow pipe (system TSS200)
Fig. 52 Installing the flow pipe (System TSS150, 300)
9.2 Connecting the return pipe
▶ Push union nut [1] over the collector connection.
▶ Place clamping washer [2] behind the bead on the collector
connection and press together.
NOTICE:
Collector damage from twisted pipes!
▶ Counterhold when tightening the fittings on the angled ferrule.
▶ Push angled ferrule with O-ring [3] against the collector connection
and secure with union nut.
NOTICE:
Leak from the storage tank connection!
The gasket can be damaged by over-tightening of the screw connection.
▶ Hand-tighten the storage tank connection pipe and then tighten with
a ½ turn using a spanner (corresponds to approx. 35 Nm).
▶ Screw the storage tank connection pipe [7] with a gasket [6] to the
solar return connection.
▶ Push the long solar hose [5] with hose clip onto the angled ferrule
and storage tank connection pipe.
▶ Tighten the circlip when hose clip [4] is located directly in front of the
bead.
Fig. 53 Installing the return pipe
Installing the return pipe bracket
▶ Position the bracket at the edge of the collector so that the pipework
runs with an ascending gradient to the storage tank connection.
▶ Tighten the screws.
Fig. 54 Installing the bracket on the collector frame
4
1
3
2
0010011157-02
0010011158-01
1
2
43
1
2
3
4
5
0010011159-02
6
7
4
5
0010014990-010010014990-01
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Bosch TSS200-2E/FCC-2 Installation And Maintenance Instructions Manual
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