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Lochinvar TISUN SCH-I-O User's Manual

1. Lochinvar LS SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 5 Hydraulic Connections Figure 5 3 Expansion Kits Side by Side Parallel CONNECTION EXPANSION SET SIDE BY SIDE PARALLEL Description Set for hydraulic connection of two 2 collectors side by side The set consists of two 2 pieces of corrugated stainless steel pipe with one compression ring at each end and insulation The headers of the left and right collectors are connected using these corrugated stainless steel pipes The corrugated pipe absorbs and compensates for thermal expansion The distance of 5 1 between the collectors must be maintained precisely Once the installation is complete the insulation supplied is pulled over the corrugated pipe and fixed in place with the adhesive tape included in the set The insulation is suitable for temperatures up to 347 F and resistant to UV radiation NOTICE Do not exceed 260 ft of collector area Be aware of pressure drop see the diagram on page 38 Use a more powerful solar pump if necessary Figure 5 4 Expansion Kits Side by Side Serial CONNECTION EXPANSION SET SIDE BY SIDE SERIES Description Set for hydraulic connection of two 2 collectors side by side in series Ready to fit corrugated stainless steel pipe DN20 with two 2 soldered elbow joints for 22 mm copper pipe Used to make the connection side by side The corrugated pipe absorbs and com
2. 1 Introduction continued Before getting started on your installation be sure to carefully read the preparation instructions in this section A WARNING NOTICE A CAUTION Installer Read all instructions including this manual before installing Perform steps in the order given Have your collector s serviced inspected by a qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage When calling or writing about the collector Please have the collector model and serial number Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with the collector does not apply to collectors improperly installed or improperly operated You must comply with local regulations laws and standards of the local governing authority The frame must be capable of withstanding the local snow and wind loads and permit the correct anchoring of the collectors in accordance with all applicable local regulations The load bearing capacity of the roofing and the frame shall be specially checked or analyzed by a structural engineer The number of mounting brackets specified by the Lochinvar TiSun manuals and parts sheets is based on an average collector load bearing per square foot The maximum permissible collecto
3. Insert the screw through the washer and angle bracket into the 6 mm hole securing the wave roof attachment to the roof caulk around screws before tightening FIG 3 35 Figure 3 35 Pre Drill 6 mm Hole and Seal SEAL PRE DRILLA 6 MM HOLE AND SEAL z 25 m Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation Figure 3 36 Attach Wave Roof Attachment Assembly and Hex Bolt HEX BOLT SQUARE DISK ATTACH WAVE ROOF ATTACHMENT ASSEMBLY WASHER ANGLE BRACKET AND SCREW TO THE ROOF 7 Slide the square disk onto the hex bolt see FIG 3 36 8 Install the hex bolt with square disk attached into the opening of the wave roof attachment as shown in FIG 3 36 Note Do not tighten hex bolt until ready to install on the collector substructure 9 Thread the hex nut M8 and washer M8 onto the bottom of the hex bolt installed in Step 8 10 Repeat Steps 4 9 until installation is complete Install hex bolt onto collector substructure reference Section 4 Collector Installation Anchor bolts for concrete with or without height adjustment SRM20009 amp SRM20010 Anchor bolts are used for inclined and freestanding mounting on concrete The anchor bolt is inserted at least 2 1 4 into the 10 mm hole pre drilled in the concrete The aluminum profile with a 10 5 mm clearance hole is threaded over the bolt and fixed with a washer a
4. CONCRETE 6 Place the second nut and washer on the anchor bolt at the desired height if using the anchor bolt with adjustments 7 Drill a 10 5 mm hole in the horizontal bar see FIG 3 39 8 Place the horizontal bar onto the anchor bolt and use the remaining washer and nut to secure the horizontal bar to the substructure as shown in FIG 3 39 Figure 3 39 Attach Horizontal Bar DRILL 10 MM HOLE ATTACH HORIZONTAL BAR HORIZONTAL BAR INSTALLED ON ANCHOR BOLT Lochinvar HE SCH Collectors Installation amp Operation Manual E 57 Lochinvar LEZ Installation amp Operation Manual Commercial Solar Thermal Syst Commercial Solar Thermal Systems 4 Collector Installation Horizontal bar lengths Figure 4 1A Horizontal Bar Lengths EZEZE hat E a rta i T si ssi dd SCH065 9 10 x Figure 4 1B Spacing Information for Location of A frames for Inclined Installations SCH130 SCH110 tri LL mi S 64 GA a4 red y A 3 SCH090 SCHO65 28 Lochinvar HE SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 4 Collector Installation continued SCH pa rallel mou nting instructions 4 Ensure lifting rings are installed and properly spaced as per FIG 4 4 1 Install roof attachments see the Roof Attachment Section on pages 13 27 of this manual Figure 4 4 Lifting Rings
5. a 9 mm hole through the support and the A frame Secure the diagonal support using the bolts washers and nuts provided in the kit e _ 35 di i rijiiIIII IEEE Cc c ET i i Figure 4 24 Install Diagonal Supports SECURE DIAGONAL SUPPORTS WITH THE BOLTS NUTS AND WASHERS PROVIDED IN THE KIT Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 4 Collector Installation continued 9 Ensure lifting rings are installed and spaced properly per FIG 4 25 Figure 4 25 Lifting Rings ENSURE LIFTING RINGS ARE INSTALLED PROPERLY nin BULLI SCH065 SCH090 SCH130 10 Position the collector onto the substructure FIG 4 26 A WARNING Only loosen the crane connection when the collectors are completely fixed to the substructure Figure 4 26 Position Collector On Substructure POSITION COLLECTOR ONTO SUBSTRUCTURE ENSURE 2 OVERHANG 11 Connect the collector to the bottom end brace using the square disk and bolt provided in the kit FIG 4 27 Do not tighten Position the collector on the U channels so that the collector overhangs approximately 5 mm 2 FIG 4 26 Tighten square disk 12 Figure 4 27 Connect Collector to Bottom End Brace CONNECT COLLECTOR TO BOTTOM END BRACE SQUARE DISK HEX BOLT Install the top end brace using the bolt provided in the kit FIG 4 28 LS C
6. bearing the required static load generally rafters Longer wood screws are necessary if the roof construction is higher e g roof insulation Various sizes Profile 5 Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 34 E Figure 3 34 Kit SRM20014 amp SRM20015 Wave Roof Attachment Kit Components WAVE ROOF ATTACHMENT 1X w ANGLE BRACKET FE SQUARE DISK 1X WASHER M12 1X HEX NUT M8 1X HEX ra HEX BOLT M8 1X WASHER M8 1X Install wave roof attachment 1 Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials 2 Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11 3 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 4 Using the wave roof attachment as a template place the wave roof attachment on the roof and pre drill a 6 mm hole as shown in FIG 3 35 5 Caulk field supplied inside the 6 mm hole pre drilled in Step 4 FIG 3 35 6 Place the wave roof attachment angle bracket and washer over the 6 mm hole on the roof FIG 3 36
7. its stop is reached m Tighten clamp ring nut by hand Use open ended wrench to tighten clamp ring screw connection approximately 33 ft lb retighten if necessary m When tightening the clamp ring screw connection use two wrenches using one wrench to prevent the pumping station from turning SCH Collectors Installation amp Operation Manual Flat seal screw connections m All pre fitted solar station screw connections are firmly tightened in the factory so that they do not need to be retightened Torque levels when tightening flat seal screw connections using AFM 34 flat seals s 2mm 3 4 screw connection 26 Ft lb 1 screw connection 40 Ft lb 1 1 4 screw connection 66 Ft lb 1 1 2 screw connection 96 Ft lb Operation multi function ball valve and check valve m The forward flow ball valve must be open for filling flushing and bleeding solar systems with a filling and flushing pump The return ball valve should be closed m Both flow checks should be opened in order to bleed the solar system thermometer handles in 45 position m The two mult function ball valves must be fully open in order to bleed the solar system turn the red and blue thermometer handles counter clockwise until the stop is reached Figure 6 1 Forward flow multi functioning instruments SETTING FOR OPERATIONS DRAINING SERVICE FILLING FLUSHING DRAINING FLOW CHECK OPEN BALL VALVE FLOW CHECK CLOSED BALL
8. roof sheet material see FIG 3 24 and only then can the collector be fitted Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 21 INSTALL CABLE CABLE TURNBUCKLE TURNBUCKLE INSTALLED Figure 3 21 Kit SRM20007 Flange Shingle Plate Standard Kit Components 6 Attach the steel cable to the joint clamp fashioned after the cable orientations in FIG 3 18 NOTICE Extend turnbuckle to its fullest extent 7 Before tightening the joint clamp set the angle of the cable to greater than or equal to 30 but less than or equal to 45 see FIG 3 20 8 Tighten the joint clamp 9 Use the turnbuckle to tighten the cable HEX NUT M8 1X A WASHER M8 1X HEX BOLT M8 1X 20 Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation continued Install flange plate shingle standard l Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference t
9. 2 Install the horizontal bar s FIG s 4 2A and 4 2B using the square disk hex bolt and washers provided ENSURE LIFTING RINGS ARE INSTALLED PROPERLY in the kit Figure 4 2A Install Horizontal Bars ENDS OF HORIZONTAL BARS MUST BE PARALLEL TO ENSURE di PROPER COLLECTOR ORIENTATION lopun SCH065 i ENDS SCH110 SCH130 Figure 4 2B Spacing 4 n Z PA EE 5 Position the collector onto the substructure and hanger brackets FIG 4 5 Only loosen the crane connection when A WARNING the collectors are completely fixed to the substructure Figure 4 5 Position Collector On Substructure POSITION PANEL ONTO iN SUBSTRUCTURE 3 Install the Z hooks per FIG 4 3 using the specified number of brackets Figure 4 3 Install Z Hooks SCH065 SCH090 110 AND 130 UNO SERRE FETERE 6 Secure the collector to the Z hook s using the 3x per collector square disk and hex bolt provided in the kit FIG 4 6 29 INSTALL Z HOOKS Lochinvar HET SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 4 Collector Installation Figure 4 6 Secure Collector Figure 4 9 For Stacked Series Installations Use Self Tapping Screws and Spacers USE SELF TAPPING La SCREWS AND SPACERS TDN TO SEPARATE THE TOP PANEL FROM THE BOTTOM PANEL HEX BOLT 10 Install top collector on the horizontal bars and slide it SAVARD DISA onto the spacers FIG 4 10 R
10. 20 using the square disk hex bolt and washers provided in the kit reference the Roof Attachment Spacing Section on page 11 of this manual Figure 4 20 Install Horizontal Bars ENDS OF HORIZONTAL BARS MUST BE PARALLEL TO ENSURE PROPER COLLECTOR ORIENTATION pena ai Fa 3 Assemble A frame Position A frame to horizontal bars within 6 of the roof attachments as shown in FIG 4 21 4 Figure 4 21 Mount A frame to Horizontal Bars Drill a 9 mm hole through the horizontal bar s and A frame s use the bolts washers and nuts provided in the kit to attach the A frame s to the horizontal bar s see FIG 4 22 32 SCH Collectors Installation amp Operation Manual Figure 4 22 Drill 9 mm Hole in Horizontal Bar s DRILL 9 MM HOLE TO CONNECT A FRAME Repeat Steps 3 5 for each A frame making sure all 6 A frames are square and aligned with each other 7 Install three 3 U channel supports FIG 4 23 Drill a 4 mm hole through the bracket and U channel use pop rivets to attach the U channels perpendicular to the A frame Figure 4 23 Install Horizontal Supports INSTALL HORIZONTAL U CHANNELS DRILL A 4 MM HOLE THROUGH THE BRACKET AND A FRAME Hood 4 mm J Ly a d 4 F F MAD 4 Diagonal supports are needed on non south facing installations ONLY NOTICE 8 In the case of a non south facing installation install diagonal supports see FIG 4 24 Drill
11. ICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage 6 Lochinvar LMA SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 1 Introduction The SCH collector is suitable for parallel installations and inclined installations on pitched and flat roofs as well as freestanding on the ground It is available as a single piece large collector in sizes ranging from 65 to 130 ft with inlet and outlet connections of 86 in diameter Suitable mounting systems are available for various types of roofing The SCH collector is delivered in standard lengths of 9 10 to 19 7 and a height of 6 7 resulting in gross surface areas between 65 and 130 ft Area of use Parallel inclined on roof mounting on tiles plain tiles slate Spanish tiles tin roofing flat roofs and as a freestanding unit Technical data Or fr Lal is ered SCH065 SCH090 SCH110 SCH130 is a _ 65 66 ft 87 19 ft 108 72 ft 6 7 x 9 10 6 7 x 13 2 6 7 x 16 4 6 7 x 19 7 SCH mounting hardware hydraulic connection kits scA20007 Aluminum U channeligft S O o a _ 2 3 3 4 2 3 3 l 4 X VE x peraray o o oer arra Lochinvar ESMA SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 1 Introduction How it works 6 In
12. M8 1X 10 Thread the hex nut M8 and washer M8 onto the bottom of the hex bolt installed in Step 9 11 Repeat Steps 4 10 until installation is complete Install hex bolt onto collector substructure reference Section 4 Collector Installation 6 Lochinvar HE SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 3 Roof Attachment Installation Install metal roof attachment Figure 3 32 Install Hex Bolts and Stud 1 Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials INSTALL STUD ALL THREAD 2 Determine the number of collectors needed for the INSTALL installation and the number of required roof attachments HEX BOLTS amp STUD from Table 3B or 3C on page 11 3 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 4 Attach the rubber seals provided in the kit to each end of the metal roof attachment as shown in FIG 3 30 INSTALL SELF TAPPING SCREWS 5 Place the metal roof attachment on top of an existing fixing point of the metal roof FIG 3 31 10 Attach the profile connector to the stud using the washers and hex nuts provided in the kit FIG 3 33 6 Using the metal roof attachment as a template pre drill two 2 6 5 mm holes into the to
13. SCH I O Rev A amp t Lochinvar PE Commercial Solar Thermal Systems Installation amp Operation Manual SCH Collectors A WARNING This manual must only be used by a qualified heating installer service technician Read all instructions before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Contents HAZARD DEFINITIONS 2 5 HYDRAULIC CONNECTIONS 1 INTRODUCTION 0022 e eee 3 6 SCH Connections KIS spina Guweu caw ee oe 37 Technical Data 2 0 0 cee eee 3 Hydraulic Expansion Kits 37 38 HOW IT WORKS scorre awd seemed ded ea 4 Pressure Drop Chart ns salario ie ssa 39 COMPONENIS asc adire rta 4 6 SYSTEM STARTUP DESCIPHONS ss afidi eo eine 4 SU LEETE PEE E pase ees eee se eee eee 40 2 LOCATION Filling Flushing and Bleeding 005 40 Amay OPOS 2 ei erede boos ered eee Vi Clamp Ring Screw Connections 41 Installation Positions 0 0 00 cee eee eee 8 Flat Seal Screw Connections 0005 41 Handing and SIONO s ss o s ve ewes oGc on ds a 9 Operation Multi function Ball Valve amp Check Valve 41 What to AVOId 1 6 ce es 9 7 MAINTENANCE 3 ROOF ATTACHMENT INSTALLATION Fluid WStAIAION s ones einen a 42 Roof Attachment Types 0 0000 c ee eee 10 System Design Considerations 42 Roo
14. VALVE 1 2 OPEN CLOSED BALL VALVE OPEN Figure 6 2 Return multi functioning instruments SETTING FOR OPERATIONS FLOW CHECK CLOSED BALL VALVE OPEN DRAINING FLOW CHECK OPEN BALL VALVE 1 2 OPEN SERVICE FILLING FLUSHING BALL VALVE CLOSED 41 Lochinvar HE F Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the solar components Failure to perform the service and maintenance could result in damage to the solar system Failure to follow directions in the manual and component literature could result in severe personal injury death or substantial property damage The solar heating system should be inspected annually only by a qualified service technician In addition the maintenance and care of the solar collection system explained in the following pages must be performed to assure maximum system efficiency and reliability Failure to service and maintain the solar system could result in equipment failure i off power to electrical components efore any service operation on the solar system except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death These maintenance items must be performed annually to ensure proper operation of the solar collection system Address reported problems 1 Inspect any problems repo
15. are to be located such that eventual sliding of snow and ice does not endanger any person before lifting Only move collectors on the given fixing loops f NOTICE 966 FIG 2 6 or crane transportation connection points and positioning Figure 2 6 Crane Transportation Connection Points and Positioning ENSURE LIFTING RINGS ARE INSTALLED PROPERLY SCH065 SCH110 Lochinvar LETTA Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation Roof attachment types Table 3A Roof Fastenings Parts SOLAR ROOF MOUNTS Parallel Free See li Lochinvar AL Stainless steel attachment for universal heavy duty BOLT DOUBLE X X HANGER installations on parallel and inclined roofs and freestanding installations on sufficiently anchored bases op JJ lt N D Stainless steel attachment for parallel and inclined installations on various types of tiled roofs Standard installations for tile heights of up to 1 5 Package is complete with fasteners and spacers ANCHOR lt N ee J gt n m po Cp J gt gt ROOF TILE Stainless steel attachment for parallel and inclined prio installations on various types of tiled roofs Standard ROOF TILE installations for tile heights of up to 2 Package is complete with fasteners and spacers Stainless steel attachment for parallel installations o
16. ature F a 42 213 216 219 222 t Lochinvar WE Commercial Solar Thermal Systems F Maintenance continued Typical properties of Aqueous Solutions Glycol percentage by volume Property F O 575 Wis Btu hreft2 F ft Thermal Conductivity Specific Heat Btu Ibe F Viscosity Centipoise 29 3 Density lb ft Solar circuit l A WARNING Verify all system components are correctly installed and operational Check for leaks inspect all water lines for signs of leakage and correct any problems found Check System Pressure monitor system pressure as the circuit heats up during testing to ensure that the pressure does not rise above the designed system pressure Excessive pressure rise indicates expansion tank sizing or performance problems See the expansion tank manufacturer s instruction manual for required maintenance See the expansion tank manufacturer recommendations for sizing and pressure settings Check Relief Valve Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Check Freeze Protection Fluid ensure that the heat transfer fluid has the proper concentration of glycol as recommended in this manual Remove any air that may have accumulated in the system Check Flow Rate ensure that the minimum recomme
17. d in Step 9 11 Repeat Steps 4 10 until installation is complete Install hex bolt onto collector substructure reference Section 4 Collector Installation 7 E 57 Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation Flange plate shingle raised SRM20008 The raised flange shingle plate is used for inclined installations on asphalt and elastomer roofs also suitable for flat roofs A CAUTION The plates must be screwed into a member capable of bearing the required static load generally rafters or concrete e Once installed the panels must be sealed to the roof sheet material FIG 3 28 and only then can the collector be fitted Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 25 pece __ __ fiii iiiiiiii OG Figure 3 25 Kit SRM20008 Flange Plate Raised Kit Components FLANGE PLATE RAISED 1 VAI SCREW M10 SCREW M6 SQUARE DISK 1X HEX NUT M8 a oe HEX BOLT M8 1X WASHER MB 1X Gi 29 E Install flange plate shingle raised l Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials Determine the number of collectors needed for the installation and the numb
18. ep 17 FIG 4 32 Figure 4 35 Install Sensor Well E TE E _ ik INSTALL SENSOR WELL Figure 4 32 Reinstall Collector Railing REINSTALL COLLECTOR RAILING gg Figure 4 36 Install Hydraulic Connections SENSOR WELL EXPANSION SET HYDRAULIC CONNECTION OPTIONAL MECHANICAL CONNECTION KIT 19 Install the side by side bracket using the square disks and Expansion hex bolts provided in the kit FIG 4 33 SET HYDRAULIC CONNECTION 34 Lochinvar HEM SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 4 Collector Installation continued SCH A frame dimensions Table 4A Inclined and Non South Facing Installations 35 T Lochinvar EU Commercial Solar Thermal Sys 4 Collector Installation Table 4B SCH Mounting Hardware Hydraulic Connection Kits Installation amp Operation Manual scA20005 Aluminum U channelioft o a LL 35 x per arra Lochinvar HE SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 5 Hydraulic Connections Hydraulic connection kits Figure 5 1 SCH Hydraulic Expansion Kit The hydraulic connection kits are used to connect the collector to the main pipework The hydraulic connections kits consist of two 2 flexible corrugated stainless steel pipe with insulation sensor well plug and support sleeves Hydraulic expansion kits The hydrau
19. epeat Steps 7 and 8 for 7 Position the collector on the horizontal bars so that the the top collector collector overhangs approximately 5mm 2 FIG 4 7 Figure 4 10 Install Top Collector E Figure 4 7 Position Collector on Horizontal Bars E T E 11 Install end stacking brackets FIG 4 11 Figure 4 11 Install End Stacking Bracket s 8 Connect the horizontal end brace to the collector using the square disk hex bolt washer and nut on each side of the collector FIG 4 8 Figure 4 8 Connect Horizontal End Brace to Collector INSTALL END STACKING BRACKET END STACKING BRACKET INSTALLED 12 For side by side installations repeat Steps 1 8 and install horizontal hydraulic connections see FIG 4 12 Figure 4 12 Install Horizontal Hydraulic Connections on Side by Side Installations CONNECT HORIZONTAL END BRACE TO HORIZONTAL BAR 9 For stacked series installations repeat steps for the top collector and install self tapping screws and spacers to separate the top collector from the bottom collector as shown in FIG 4 9 Go to Step 12 for instructions on side by ET NOTICE side installations INSTALL ial HYDRAULIC CONNECTION KIT 30 NOTICE Make certain collectors are 5 1 apart ENSURE COLLECTORS ARE 5 1 APART 6 Lochinvar HE SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 4 Collector Installation continued The Mechanical Connection Kit
20. er Bolt Components Figure 3 5 Install Hex Bolt s HEX BOLT _ HEX NUT W FLANGE el ra HANGER BOLT PLATE POUF ANGER HEX NUT W FLANGE BOLT PLATE _ WASHER M12 HANGER BOLT SEAL _ HANGER BOLT Figure 3 4B Compress Washer and Hanger Bolt Seal DOUBLE HANGER BOLT PLATE HEX NUT FLANGE UP 13 Slide the square disk onto the hex bolt see FIG 3 5 14 Install the hex bolt with square disk attached into the opening of the double hanger bolt plate as shown in FIG 3 5 Note Do not tighten hex bolts until ready to install on the collector substructure 15 Thread the hex nut M8 and washer M8 onto the bottom of the hex bolt installed in Step 14 FIG 3 5 16 Repeat Steps 4 15 until installation is complete Install hex bolt onto collector substructure reference Section 4 Collector Installation dl 14 Es Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation continued Install rafter anchor Rafter anchor for roof tiles SRM20003 amp SRM20004 The rafter anchor is used for parallel and inclined mounting on tiled roofs with a roof pitch of at least 15 and an area loading greater than 6 lb ft Can be used for various types of roofing tiles A CAUTION The anchors must be screwed into a support capable of bearing the required static load generally rafters or concrete Complies with the req
21. er of required attachments from Table 3B or 3C on page 11 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 Caulk field supplied around the perimeter of the flange plate FIG 3 26 Using the flange plate as a template place the flange plate on the roof and drill four 4 6 mm holes as shown in FIG 3 27 Install the larger screws provided in the kit into the 6mm holes securing the flange plate to the roof caulk around screws before tightening Install the four 4 remaining smaller screws in the perimeter of the flange plate as shown in FIG 3 27 caulk around screws before tightening Cover the flange plate with roofing material sealing it to the roof FIG 3 28 Figure 3 26 Caulk Around Perimeter of Flange Plate CAULK AROUND THE PERIMETER OF THE FLANGE PLATE Lochinvar BEG SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 3 Roof Attachment Installation continued Corrugated metal roof attachment Figure 3 27 Drill Holes and Attach Flange Plate SRM20013 The corrugated metal roof attachment is used for parallel COLLECTOR and inclined mounting on profiled or corrugated sheet metal SUBSTRUCTURE roofs The console is mounted above the mounting screws HEX BOLT I of the profiled or corrugated she
22. et metal The two sealing SQUARE DISK as screws are first screwed onto the underlying mounting screw of the sheet The sealing is done before the console is mounted using the sealing pads supplied The sections are fixed to the section connectors on the console USE THE SMALLER SCREWS IN THE PERIMETER OF THE ine A CAUTION The console must be ordered to PRE DRILL FOUR 4 6 MM fit the relevant profiled or HOLES USE THE LARGER SCREWS TO SECURE THE corrugated sheet metal FLANGE PLATE e The mounting screws supplied with the console must be appropriate in type and length for the particular roof construction Figure 3 28 Cover Flange Plate with Roofing Material Unpacking and checking parts COVER FLANGE PLATE WITH When unpacking the system check the model names of the ROOFING MATERIAL SEALING IT TO THE ROOF components of each system and check to be sure you have the correct number of parts see FIG 3 29 Figure 3 29 Kit 4SRM20013 Corrugated Metal Roof Attachment kit Components ao HEX NUT M10 1X STUD M10 1X PROFILE CONNECTOR 1X dd 8 Slide the square disk onto the hex bolt see FIG 3 27 HEX BOLT M8 1X 9 Install the hex bolt with square disk attached into the opening of the flange plate as shown in FIG 3 27 WASHER M10 2X Note Do not tighten hex bolt until ready to install on the collector substructure HEX NUT M10 2X _ 4 HEX NUT M8 1X WASHER
23. f the roof and the durability of the roof materials Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B and 3C on page 11 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 Assemble joint clamp as shown in FIG 3 14 be sure to loosely assemble the screws on the joint clamp assembly Place the joint clamp assembly at the appropriate location on the joint of the tin roof Tighten the screws on the joint clamp to 26 ft lbs Figure 3 14 Assemble Install Joint Clamp amp Hex Bolt I 8 COLLECTOR HEX BOLT SUBSTRUCTURE SQUARE DISK ASSEMBLE JOINT CLAMP INSTALL ON THE TIN ROOF JOINT JOINT Slide the square disk onto the hex bolt see FIG 3 14 Install the hex bolt with square disk attached into the opening of the joint clamp as shown in FIG 3 14 Note Do not tighten hex bolt until ready to install on the collector substructure 9 Thread the hex nut M8 and washer M8 onto the bottom of the hex bolt installed in Step 8 10 Repeat Steps 4 9 until installation is complete Install hex bolt onto collector substructure reference Section 4 Collector Installation Lochinvar ZZZ SCH Collectors Installation amp Operation Manual Com
24. f Attachment Quantities for SCH Collectors 11 Technical Dales icv wd ode spider pe ta 42 Roof Attachment Spacing Distance 12 Solar CMCUIL ate ssassn anse amp avery ee ee ow ioe oe ar 43 Installation of Roof Attachment Types 13 27 CONCCION orarie paia niente Sg oes cee 43 4 COLLECTION INSTALLATION Pump Control Function 00000 ee 43 Horizontal Bar Lengths pini pr 28 Control SCWINGS sasi sran n i ta 43 Spacing Information 28 Revision Notes Back Cover SCH Parallel Mounting Instructions 29 31 SCH Inclined Non South Facing Mounting Instructions 32 34 SCH Frame Dimensions 00 00 eee 35 SCH Mounting Hardware Hydraulic Connection Kits 36 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER vaN indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING A indicates a potentially hazardous situation which if not avoided could result in death or serious A CAUTION a indicates a potentially hazardous situation which if not avoided may result in minor or moderate CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not CAUTION i avoided may result in property damage NOTICE NOT
25. he Roof Attachment Spacing Section on page 12 Caulk field supplied around the perimeter of the flange plate FIG 3 22 Using the flange plate as a template place the flange plate on the roof and drill four 4 6 mm holes as shown in FIG 3 23 Install the larger screws provided in the kit into the 6mm holes securing the flange plate to the roof caulk around screws before tightening Install the four 4 remaining smaller screws in the perimeter of the flange plate as shown in FIG 3 23 caulk around screws before tightening Cover flange plate with roofing material sealing it to the roof FIG 3 24 Figure 3 22 Caulk Around Perimeter of Flange Plate CAULK AROUND THE PERIMETER OF THE FLANGE PLATE Figure 3 23 Drill Holes and Attach Flange Plate COLLECTOR SUBSTRUCTURE HEX BOLT SQUARE DISK USE THE SMALLER SCREWS IN THE PERIMETER OF THE FLANGE PLATE PRE DRILL FOUR 4 6MM HOLES USE THE LARGER SCREWS TO SECURE THE FLANGE PLATE Figure 3 24 Cover Flange Plate with Roofing Material COVER FLANGE PLATE WITH ROOFING MATERIAL SEALING IT TO THE ROOF 8 Slide the square disk onto the hex bolt see FIG 3 23 9 Install the hex bolt with square disk attached into the opening of the flange plate as shown in FIG 3 23 Note Do not tighten hex bolt until ready to install on the collector substructure 10 Thread the hex nut M8 and washer M8 onto the bottom of the hex bolt installe
26. holes approximately 4 inches deep into the roof substructure see FIG 3 7 perpendicular to the roof Figure 3 7 Pre Drill 6mm Holes Into Roof Substructure USE RAFTER ANCHOR AS A TEMPLATE PRE DRILL TWO 2 6MM HOLES APPROX 4 DEEP PERPENDICULAR TO THE ROOF To achieve the recommended 3 5 mm clearance above the tile place the spacer plate s provided in the kit between the rafter anchor and the roof substucture if necessary FIG 3 8 Place the rafter anchor on the spacer plate if used Place the heavy duty washers over the holes pre drilled in Step 6 10 Install the wood screws through the washers and rafter anchor into the roof substructure Note It may be necessary to grind the upper tile to assure a better fit FIG 3 9 15 Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation Figure 3 8 Install Rafter Anchor COLLECTOR SUBSTRUCTURE Va HEX BOLT INSTALL WASHER A AND WOOD SCREW f SPACER PLATE IF NECESSARY RAFTER ANCHOR Figure 3 9 Grind Tile if necessary IF NECESSARY GRIND THE TILE FORA BETTER FIT 11 Slide the square disk onto the hex bolt see FIG 3 8 12 Install the hex bolt with square disk attached into the opening of the rafter anchor as shown in FIG 3 8 Note Do not tighten hex bolt until ready to install on the collector substructure 13 Thread the he
27. ial Solar Thermal Systems SCH I O Rev A 9 10
28. il the solar liquid exits free of air bubbles Only if collector bleeder is installed Bleed the system on the collector until the solar liquid exits free of bubbles m If necessary increase the test pressure again to 60 psi and check the system for leaks If the pressure gauge shows the pressure dropping substantially you have a leak in the system Set the operating pressure to 60 psi as prescribed by the system manufacturer Start up the circulation pump at maximum speed and allow liquid to circulate for at least 15 min Remove the filling station hoses and screw the caps on the flushing and filling valves m Check the system again for leaks Use the red and blue thermometer handles to fully open the forward flow and return ball valves Activate speed control on solar control unit The highest speed level should be set on the pump phase control Note The minimum speed set on the solar control unit must not fall below the pump s minimum nominal speed Note instructions for pump and solar control unit m Once the installation settings have been completed and checked fit the solar station s front insulation shell m Refer to the collector manufacturers recommendations for minimum flow requirements Clamp ring screw connections Cut the copper pipe to length and deburr E First slide the clamp ring nut over the pipe then clamp the ring itself Insert the prepared pipe into the screw connection until
29. ing connection under the pressure gauge and open fill flush valve Connect the flushing hose return to the flushing connection on the sensor measuring section and open fill flush valve Refer to Operation multi function ball valve and check valve on page 38 Open the supply ball valve by turning the red thermometer handle counter clockwise until it stops Close return ball valve by turning the blue thermometer handle clockwise until it stops If necessary the supply and return check valve can be opened by moving the thermometer handles to the 45 position Put sufficient solar liquid in the tank of a filling and flushing pump not supplied The mixing ratio should be adapted to local conditions in terms of freeze protection Fill the solar system via the filling and flushing pump and then flush the solar circuit for at least 15 min to purge all of the air out of the circuit Close the fill flush valve return with the filling and flushing pump running and increase the system pressure to 60 psi The system pressure can be read at the pressure gauge Lochinvar Wa Commercial Solar Thermal Systems 6 System Start up continued m Close the fill flush valve forward flow and switch off the filling and flushing pump Open return ball valve by turning the blue thermometer handle 90 counter clockwise until it stops The solar system features an air separator Open the bleeder valve unt
30. is an 15 Install the side by side bracket using the square disks and NOTICE l l j j optional kit available through the hex bolts provided in the kit FIG 4 16 manufacturer r q f80o vE ess Figure 4 16 Install Side by Side Bracket 13 Remove the collector railing and install the Mechanical Connection Kit FIG s 4 13 and 4 14 Note Be sure to bend the tabs down on the Mechanical Connection Kit Figure 4 13 Remove Collector Railing REMOVE COLLECTOR RAILING INSTALL SIDE BY SIDE BRACKET 16 Install the plug sensor well and hydraulic connections to complete the installation see FIG s 4 17 4 18 and 4 19 Figure 4 17 Install Plug Figure 4 14 Install Mechanical Connection Kit BEND TABS DOWN Figure 4 18 Install Sensor Well INSTALL SENSOR WELL 14 Reinstall the collector railing removed in Step 13 FIG 4 15 Figure 4 15 Reinstall Collector Railing ene riLo siena Figure 4 19 Install Hydraulic Connections SENSOR WELL EXPANSION SET HYDRAULIC CONNECTION OPTIONAL MECHANICAL EXPANSION CONNECTION KIT SET HYDRAULIC CONNECTION 31 Lochinvar HEP Commercial Solar Thermal Systems 4 Collector Installation SCH inclined non south facing roof mounting instructions 1 Install roof attachment see the Roof Attachment Section on pages 12 26 of this manual Install the horizontal bar s FIG 4
31. ld be sized to account for 1 5 times the solar system circuit volume A properly sized expansion tank must be used to avoid damage to the Solar Thermal System A WARNING The expansion tank may be hot ensure scalding does not occur A WARNING In heated water systems a warning instruction must be provided by the operator near the expansion tank if persons are endangered by excessive surface temperatures 40 A WARNING SCH Collectors Installation amp Operation Manual Failure to heed these instructions especially the safety instructions can result in the destruction of and defects on the expansion tank endanger persons and impair the operation Final checks before starting the system E E A WARNING Read the Lochinvar TiSun Differential Control Installation and Operation Manual to familiarize yourself with differential control operation Read this manual and follow the proper steps to start system Verify the collector and system are full of water and all system components are correctly set for operation Verify electrical connections are correct and securely attached All piping should be properly insulated to avoid freezing and burn potential Filling flushing and bleeding There is one fill valve with hose connection for filling flushing and draining the solar system on both the safety group and sensor measurement section Connect the pressure hose forward flow to the safety group s fill
32. led in Step 11 13 Repeat Steps 4 12 until installation is complete Install hex bolt onto collector substructure reference Section 4 Collector Installation HOOK FLAT TILE HOOK ONTO ROOF BATTEN USE THE NAILS AND WOOD SCREW TO SECURE THE METAL SHEET AND FLAT TILE HOOK TO ROOF SUBSTRUCTURE PLACE METAL SHEET UNDER FLAT TILE HOOK 17 Lochinvar ESTA Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation Joint clamp SRM20006 The Joint clamp is only used for parallel and inclined mounting on folded seam tin roofs with galvanized or coated sheet steel or copper reference the Universal Cable Securing Kit on page 19 A CAUTION Not recommended for titanium zinc sheet due to danger of cracks at low temperature e Do not reuse any stainless steel screws as there is a risk of breakage Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 13 Figure 3 13 Kit 4SRM20006 Joint Clamp Kit Components JOINT CLAMP 2 1X JOINT CLAMP 1 1X HEX NUT M8 1X SQUARE DISK 1X gt WASHER M8 1X HEX NUT M10 2X HEX BOLT M8 1X 4 MUSHROOM HEAD BOLT M10 2X 18 Install joint clamp l 6 Determine roof type Inspect the structural integrity o
33. let connection Copper pipes 86 diameter 1 Housing Powder coated RAL7016 aluminum frame structure with PU rigid foam and an aluminum rear wall 7 Outlet connection Copper pipes 86 diameter 8 Absorber coils 2 Cover 10 mm copper serpentine arrangement Prismatic solar safety glass 15 thick for maximum light pper serp 8 l transmission 9 Hydraulic connection kit Connection set with stainless steel corrugated pipe For connecting the collector supply and return to the riser The corrugated pipes are available in kits with 2 x 6 7 or 2 x 13 1 length including sensor well and plug 3 Insulation 76 heat resistant special PU rigid foam and 1 57 mineral wool with high pressure resistance emission free non flammable 4 Absorber Full surface absorber laser welded with highly selective PVD coating PVD Physical Vapor Deposition serpentine flow 10 Sensor well For measuring the collector outlet temperature directly in the fluid The sensor well can be installed on the outlet connection as shown on the collector label The sensor must be inserted up to 5 Collector seal the end of the sensor well Aluminum profile system with double temperature and UV resistant silicone seals emission free 11 Plug This plug is used on the end collector of each array to complete the water flow path SCH Collector SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems
34. lic expansion kits are hydraulic connections between collectors in one array The hydraulic expansion kits consist of two 2 nipples with compression rings and unions Note Hydraulic connections and expansion kits are included with the substructure material Brazing ONLY no soldering When A WARNING oe razing you must protect the stainless steel connection to the copper to ensure that the temperature does not rise above 302 F A WARNING A properly sized expansion tank must be used to avoid damage to the Solar Thermal System Figure 5 2 Expansion Kits Stacked CONNECTION EXPANSION SET STACKED COLLECTOR IN SERIES Description Set for hydraulic connection of two collectors stacked in series Ready to fit corrugated stainless steel pipe with two 2 soldered elbow joints for 86 copper pipe Center to center distance 9 1 4 The collector outlet of the lower collector is connected to the inlet of the upper collector The corrugated pipe absorbs and compensates for thermal expansion Rubber insulation temperature resistant to 347 F is fitted on the corrugated pipe Two plugs are included in the scope of delivery for closing the remaining header ends The compression ring and nut are already fitted on the collector NOTICE Do not exceed 260 ft for the collectors connected in this way Be aware of pressure drop see the Recommended Flow Chart on page 38 Use a more powerful solar pump if necessary 37
35. mercial Solar Thermal Systems 3 Roof Attachment Installation continued Universal cable securing kit Install cable securing kit SRM20012 For securing inclined collectors on tin joint roofs comprising a guy cable turnbuckle and hardware for collector frames and joint clamp for guy cable tensioning Material stainless steel Joint clamp for cable set is required for mounting the guy cable set on joint tin roofs with galvanized or coated sheet steel or sheet copper one in each guy cable set The guy cable set is fastened to the joint clamp Note The joint clamp can also be used with a 1 pipe provided on site as an additional snow guard above the collector does not replace the snow guard system provided on site which is a requirement A CAUTION Not recommended for titanium zinc sheet due to danger of cracking at low temperatures Do not reuse any stainless steel screws as there is a risk of breakage Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 15 r__ ___T_T_ _ fia Eee Figure 3 15 Kit SRM20012 Universal Cable Securing Kit Components JOINT CLAMP 2 PART 1 1X A NUT 2X an ra Min JOINT CLAMP PART 2 1X M8 2X r WASHER M10 1X HEX NUT M8 2X f WASHER 1X SQUARE NUT 1X Sani a CABLE KIT 1X 1 Install the anch
36. n X plain tile slate and flat cement tiled roofs with pitches in excess of 30 degrees HOOK FLAT TILE SRM20006 CLAMP O ep ep I I I lt lt N N S SI gt JJ gt n m JJ Stainless steel attachment for parallel and inclined installations on jointed tin galvanized or copper roofs Additional securing cables Lochinvar Part SRM20012 are required for inclined installations cH O Z PLATE Galvanized steel attachment for parallel inclined and FLANGE freestanding installations on asphalt or elastomer SHINGLE STD roofs PLATE e FLANGE Galvanized steel attachment for inclined and SHINGLE freestanding installations on asphalt or elastomer RAISED roofs Also recommended for flat roofs BOLT Galvanized steel attachmentfor inclined or freestandin ANCHOR l i Ig CONCRETE W installations with 2 75 height adjustment For use in ADJ applications with no more than a 5 degree inclination BOLT Galvanized steel attachment for inclined or ANCHOR freestanding installations with no height adjustment CONCRETE For use in applications with no more than a 5 degree inclination KIT UNIV Stainless steel cable set for securing collectors on CABLE inclined jointed roofs Kit includes cable turnbuckle SECURING hardware for attachment to frame and joint clamp For inclined installations only ATTACHMENT SRM20013 ROOF CORR Stainless steel attachment for parallel and incli
37. nd nut A CAUTION There are two 2 models of concrete anchor bolts one with adjustment and one without The adjustable dimensions are up to 2 3 4 e The anchor bolt may have a maximum deviation from vertical of 5 26 Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 37 Figure 3 37 Kit SRM20009 amp SRM20010 Anchor Bolt Kit Components ANCHOR BOLT W ADJUSTMENT 1X WASHER M10 3X HEX NUT M10 3X Install anchor bolt 1 Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11 2 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 3 Pre drill a 10 mm hole a minimum of 3 inches into the concrete FIG 3 38 4 Place the anchor bolt into the pre drilled hole using a field supplied hammer 5 Use the washer and nut provided in the kit to secure the anchor bolt to the concrete as shown in FIG 3 38 Commercial Solar Thermal Systems 3 Roof Attachment Installation continued Figure 3 38 Pre Drill 10 mm Hole amp Attach to Concrete USE THE WASHER AND NUT TO SECURE THE ANCHOR BOLT TO THE
38. nded flow rate can be achieved as described in this manual Visually inspect the dirt separator if installed and clean if necessary 30 Glycol Solution SCH Collectors Installation amp Operation Manual 40 Glycol Solution 50 Glycol Solution 14 28 Collector 1 Visually inspect the collectors to ensure that they are in proper working condition 2 Visually inspect the collector substructure to ensure that no components have become loose or disconnected 3 Visually inspect the collector piping to ensure that there are no leaks 4 Visually inspect roof penetrations to ensure that environmental elements can not enter the building 5 Visually inspect the piping insulation to ensure the proper orientation around piping Pump control function l Check to ensure that the pump station is in working order and creates the minimum flow recommended in this manual Check control sensors to ensure that they are fully inserted into the appropriate sensing well See pump manufacturers recommendation for required maintenance procedure Control settings l Check sensor readings to ensure that the values being displayed are accurate Check control settings to ensure that they are programmed per the control specification See controller manufacturers recommendations for the required maintenance procedure 43 dg o oi Revision Notes Revision A ECO C06510 initial release 2 Lochinvar Ue Commerc
39. ne collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 Number two 2 tiles one above the other The top tile will be removed to install the flat tile hook Remove the top tile from the roof set aside for reassembly Place the tiled roof hook over the roof batten of the bottom tile FIG 3 11 Place the metal sheet provided in the kit under the flat tile hook FIG 3 11 Using the nails provided in the kit secure the metal sheet to the roof substructure FIG 3 11 Secure the tiled roof hook to the roof substructure using the screws provided in the kit FIG 3 11 9 Replace the tile removed in Step 5 Note It may be necessary to grind the top tile to assure a better fit FIG 3 12 Figure 3 11 Install Flat Tile Hook and Metal Sheet Figure 3 12 Grind Tile s if necessary Install Hex Bolt COLLECTOR SUBSTRUCTURE HEX BOLT SQUARE DISK a FLAT TILE X HOOK IF NECESSARY GRIND THE TILE S FOR A BETTER FIT 10 Slide the square disk onto the hex bolt see FIG 3 12 11 Install the hex bolt with square disk attached into the opening of the flat tile hook as shown in FIG 3 12 Note Do not tighten hex bolt until ready to install on the collector substructure 12 Thread the hex nut M8 and washer M8 onto the bottom of the hex bolt instal
40. ned ep O ep O fp O I I I I I I lt z lt lt z lt N N N N N o N 0 J METAL installations on profiled and corrugated roofs ATTACHMENT Galvanized steel attachment for installations on M20014 WAVE ROOF concrete corrugated roofs with 5 corrugations per SM meter For parallel and inclined installations ATTACHMENT Galvanized steel attachment for installations on SRM20015 WAVE ROOF concrete corrugated roofs with 8 corrugations per LG meter For parallel and inclined installations Lochinvar EZUS SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 3 Roof Attachment Installation continued Roof attachment quantities for SCH collectors snow loading Table 3B Parallel Installations SRM 20001 20003 20004 20006 20007 7 20013 20014 20015 SRM 20005 area load up to area load up to area load up to area load up to 32 b sa ft 64 b sa ft 16 b so ft 32 b sa ft ECC E scuo e Scano e Table 3C Inclined 20 409 and 609 Installations SRM 20001 20003 20004 20007 20008 se 20009 20010 20013 20014 20015 ai aiai jia area load up to 32 Ib area load up to 64 Ib area load up to 64 Ib so ft sq ft sq ft SCH065 E I schoo e e sesto e w c O amp i a Vv S ta o A o O o o 6 pi os Sa O oc sT 11 Lochinvar ESMA SCH Collecto
41. of substructure see FIG 3 3 perpendicular to the roof with a spacing of 4 3 4 to 6 3 4 Install the hanger bolts into the pre drilled holes until the threads are level with the roof s surface Tra _ d _ ere _ __ Fel gt ee Figure 3 3 Pre Drill 9mm Holes Into Substructure PRE DRILL TWO 2 9MM HOLES PERPENDICULAR TO THE ROOF APPROX 4 IN DEEP INSTALL HANGER BOLT S 6 Slide the hanger bolt seals over the machine threads until the seal is touching the roof s surface FIG 3 4A Slide the washer M12 on top of the hanger bolt seal FIG 3 4A Thread the hex nut with flange flange side down onto the washer compressing the washer and hanger bolt seal to the roof FIG 3 4B Install the second hex nut with flange flange side up until the hex nut reaches the desired substructure height FIG 3 4B 10 Slide the hanger bolt plate onto the flange of the hex nut installed in Step 9 FIG s 3 4A and 3 4B 11 Install the remaining hex nut with flange flange side down to the top of the double hanger bolt plate Tighten and secure both hex nuts top and bottom to the double hanger bolt plate 12 Make certain all double hanger bolt plates are facing the same direction 13 Lochinvar BE SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 3 Roof Attachment Installation Figure 3 4A Install Double Hang
42. onnect the collector to the end brace using the square disk and bolt provided in the kit FIG 4 28 15 Ensure all bolts are tightened Figure 4 28 Install Top End Brace CONNECT COLLECTOR TO END BRACE 16 For side by side installations repeat Steps 1 15 and install horizontal hydraulic connections see FIG 4 29 SS SS SSS tg q WgB1 Sg 6Q g gIIt9 Figure 4 29 Install Horizontal Hydraulic Connections INSTALL HORIZONTAL HYDRAULIC CONNECTION NOTICE The Mechanical Connection Kit is an optional kit available through the manufacturer 33 Z Lochinvar ET 4 Lochinvar STIA Commercial Solar Thermal Syst Commercial Solar Thermal Systems Installation amp Operation Manual 4 Collector Installation 17 Remove the collector railing and install the Mechanical Connection Kit FIG s 4 30 and 4 31 Note Be sure to bend the tabs down on the Mechanical Connection Kit Figure 4 33 Install Side by Side Bracket Figure 4 30 Remove Collector Railing REMOVE COLLECTOR RAILING INSTALL SIDE BY SIDE BRACKET 20 Install the plug sensor well and hydraulic connections to complete the installation see FIG s 4 34 4 35 and 4 36 Figure 4 34 Install Plug INSTALL PLUG ___ wt e ee _ _ 4_ 4ii ii Figure 4 31 Install Mechanical Connection Kit BEND TABS DOWN ta i 18 Reinstall the collector railing removed in St
43. or bracket on the A frame using the hex bolt square disk washer and hex nut 2 Assemble the joint clamp as shown in FIG 3 17 be sure to loosely assemble the screws on the joint clamp assembly 3 Place the joint clamp assembly at the appropriate location on the joint of the tin roof Figure 3 16 Attach Cable Fastening Bracket to A Frame ATTACH CABLE FASTENING BRACKET TO THE COLLECTOR CABLE FASTENING BRACKET INSTALLED ON COLLECTOR Figure 3 17 Assemble Joint Clamp ASSEMBLE JOINT CLAMP LOOSELY AND PLACE ON JOINT 19 Lochinvar SUA SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 3 Roof Attachment Installation 4 Choose a cable orientation to ensure proper degree of angle see FIG 3 18 Figure 3 20 Cable Angle 5 Install the steel cable on the A frame bracket using the pin and pin clip provided in the kit see FIG 3 19 Figure 3 18 Cable Orientations A oo 0 1 9 di g Flange plate shingle standard SRM20007 o oo SE The standard flange shingle plate is used for parallel and inclined installations on asphalt and elastomer roofs Figure 3 19 Install Steel Cable on A frame The plates must be screwed into a A CAUTION support capable bearing the INSERT PIN VSEIRINIGLIP TO SECURE required load generally rafters or THE CABLE concrete Once installed the plates must be sealed to the
44. p of the metal roof 11 Drill a 6 5 mm hole into the horizontal bar attachment see FIG 3 31 12 Place the horizontal bar into the profile connector 7 Install hex bolts into pre drilled holes as shown in installed in Step 10 FIG 3 32 13 Using the remaining bolts and washers secure the horizontal 8 Install the four 4 self tapping screws provided in kit bar into the profile connector into each side of the metal roof attachment FIG 3 32 9 Insert the stud all thread into the center of the roof attachment Figure 3 33 Install Profile Connector EE ATTACH PROFILE CONNECTOR Figure 3 30 Install Rubber Seals INSTALL SEALING PADS lt J METAL ROOF ATTACHMENT METAL ROOF ATTACHMENT SN Figure 3 31 Pre drill 6 5 mm Holes PRE DRILL 6 5 MM HOLES 24 FIXING POINT Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation continued Wave roof attachment SRM20014 amp SRM20015 The wave roof attachment is for parallel and inclined mounting on corrugated cement roofs The wave roof attachment is screwed to the load bearing wooden frame using mounting screws and then sealed with caulk The horizontal bars are then screwed to the angle bracket that has been bolted to the wave roof attachment corrugations per meter profile 8 A CAUTION corrugations per meter The wood screws must be screwed into a member capable of
45. pensates for thermal expansion Rubber insulation temperature resistant to 347 F is fitted on the corrugated pipe Two 2 plugs are included in the scope of delivery for closing the remaining header ends The compression ring and nut are already fitted on the collector NOTICE Do not exceed 260 ft of collector area Be aware of pressure drop see the diagram on page 38 Use a more powerful solar pump if necessary Expansion kits that are side by side in series are known to have a high pressure drop A pressure drop calculation is recommended NOTICE If using a series connection it is strongly recommended that a calculated pressure drop be done to ensure proper pump installation 38 Lochinvar EZ SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 5 Hydraulic Connections continued Figure 5 5 Pressure Drop Chart MODEL NO RECOMMENDED FLOW GPM PRESSURE DROP FT OF HD The above chart references recommended flow per collector Lochinvar recommends 01 GPM per square NOTICE foot of collector area in each array SCHO65 SCH090 SCH110 Feetof Head SCH130 39 Lochinvar KI Commercial Solar Thermal Systems 6 System Start up Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning or sealing compounds in the system Damage to elastomer seals and gaskets in the system could occur resulting in substan
46. r loading per square foot may be calculated from the number of mounting brackets taking into consideration the permissible loading on the mounting brackets Ifa higher collector wind and snow loading including snow sliding off the roof per square foot is required additional mounting brackets will have to be used Roof pitches in excess of 30 also represent increased loading additional mounting brackets must also be used for this variant A CAUTION Lochinvar TiSun Solar Thermal Collectors are not specifically designed for drain back installations Consult the factory if drain back utilization is necessary A CAUTION A CAUTION The mounting substructure must be capable of withstanding the local snow and wind loads and permit correct anchoring of the collectors To avoid damage to the collectors and mounting frames from snow sliding off the roof additional snow guards must be placed in sufficient numbers around the collectors and above the collectors The collectors must be linked with a lightning arrester system and or the building s ground system by a licensed electrician Hydraulic connection of the collectors must be performed according to Lochinvar TiSun specifications The collector connections must not be damaged soiled or misaligned Take care during transport installation and connection of the modules Do not remove the header protection caps at the top and bottom connections of the collecto
47. r until just before installation When connecting the modules to the riser the Hydraulic Connection Kit corrugated pipe supplied must be installed Otherwise the warranty is invalidated Always connect the collector outlet and inlet flow to each other diagonally please follow the connection example see FIG 1 1 on page 6 Do not twist the headers when screwing the connections together Hold threaded connection in the desired position and tighten clamping ring union nut to torque Roof penetrations for solar piping must be adequately sealed against water ingress Use only the original sensor well supplied Use only high temperature and glycol pipe sealing materials All piping should be properly insulated to avoid freezing and or burn potential Lochinvar ET Commercial Solar Thermal Systems 1 Introduction NOTICE i Check the materials for any damage sustainedintransportand describe any damage in writing on the packing slip where necessary This is important to process any needed freight or delivery damage claims Carefully read through the relevant installation instructions before starting the installation and follow each step Use only the original mounting components Stainless steel screws may not be used again once they have been removed because of the possibility of breaking Any conversion or modification of the Lochinvar TiSun product not expressly approved in writing by the manufact
48. rs Installation amp Operation Manual Commercial Solar Thermal Systems 3 Roof Attachment Installation Figure 3 1 Spacing Distance Spacing Distance Equally space the center roof attachments starting in the Each collector will have its own independent substructure set middle the two 2 end attachments will be spaced according Ensure there is ample room on the chosen roof area for the to the inner measurement start in the middle and work number of collectors chosen outwards The remaining roof mounts should be equally spaced in between the two 2 end roof attachments Note For multiple collector installations reference the Collector Mounting Section of this manual for spacing between collectors 12 Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation continued Installation of roof attachment types The solar thermal collectors are capable of being mounted mounting hardware available from Lochinvar Double hanger bolt for universal fastening SRM20001 Universal fixture for parallel and inclined installation on various roof types and freestanding installation on sufficiently anchored frames Two hanger bolts are to be installed on the roof as vertically as possible with a spacing of 4 3 4 to 6 3 4 The two are connected by an intermediate plate A CAUTION The hanger bolt must be screwed into a support capable of bearing
49. rted by the owner and correct before proceeding Freezing Temperature F SCH Collectors Installation amp Operation Manual Fluid installation Follow these installation procedures 1 Clean new or lightly corroded existing systems with a 1 or 2 solution of trisodium phosphate in water prior to the installation of industrially inhibited propylene glycol fluid 2 Extensively corroded existing systems should be cleaned by an industrial cleaning company and all corroded components should be replace 3 Use only quality water in solution with the propylene glycol fluid Use water with low levels less than 25 ppm of chloride and sulfate and less than 50 ppm of hard water ions Ca Mg recommended Distilled or deionized water is System design considerations Avoid use of automatic water make up systems to prevent undetected dilution of the propylene glycol and possible contamination of the water system Technical data Typical Properties of Dowfrost HD Fluid Composition by weight Propylene Glycol Performance Additives Color Specific Gravity 15 15 C 60 60 F pH of Solution 50 glycol Reserve Alkalinity min 94 6 Fluorescent Yellow 1 053 1 063 9 5 10 5 15 0 ml Typical properties not to be construed as specifications Complete sales specifications are available on request Freezing and boiling points of Aqueous Solutions Glycol by Volume Boiling Temper
50. stems 2 Location continued Handling and storing A WARNING Only loosen the crane connection Installation of LOCHINVAR TiSun when the collectors are completely A WARNING fixed to the substructure SCH collectors is only allowed for i i Pay special attention to roof work professional staff De Local instructions laws and standards near an electric grid If need be the constructor must take security are to be kept 1 Collectors are to be located so precautions such as isolation covering etc falling of snow and ice does not A aria f endanger any person or property Inspect t C top surface in the area o the installation for cracks water Use personal protection equipment j E lino leakage and roofing material quality the roof and uniformity This is especially Secure tools and materials against important if the roof is more than 10 falls years old toob ee a craic ander e Inspect the roof for sags and other hanging load abnormalities A sag or deep depression in the roof may indicate a A CAUTION Danger area has to be closed structural weakness in the support Put ladders up properly and check system that may require correction stability e Check that all rafters trusses and other materials are in good condition e Check the under roof construction on NOTICE the building before installation A WARNING Avoid rotating movements of the What to avoid load through wind Secure load A CAUTION e Collectors
51. the enclosed documents and to install an appropriate pump if necessary The maximum collector area per collector array connected in series is 260 ft Be aware of pressure drop reference the array options FIG s 2 1 and 2 2 Figure 2 1 Array Piping SERIES STACKED SINGLE COLLECTOR gt i i a SERIES SIDE BY SIDE I gt Figure 2 2 Multiple Array Piping PARALLEL SIDE BY SIDE PARALLEL WITH BALANCING VALVES gt ON ROOF ONLY MV Balancing Valve Needed For Multiple Arrays Balancing Valve Needed For Multiple Legs Lochinvar ZZZ SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Systems 2 Location Installation positions Figure 2 3 SCH Parallel Installations Figure 2 4 SCH Inclined Installations 20 40 60 min 15 max 70 min 15 max 70 Figure 2 5 SCH Freestanding Installations min 15 max 70 For best performance it is recommended Collector incline should be at least 15 and NOTICE that the collectors face true south NOTICE no more than 70 for best performance It is not recommended for the collector NOTICE Avoid installation in shaded areas Shaded NOTICE field to deviate any further than 45 NOTICE areas will reduce the performance of the from true south solar collectors Lochinvar ZZZ SCH Collectors Installation amp Operation Manual Commercial Solar Thermal Sy
52. the required static load generally rafters Install the hanger bolt using a field supplied anchoring adapter The roofing must be capable of withstanding the pressure needed to compress the gasket Beware of linear expansion in sheet metal that prevents a linear expansion and can cause lifting of the sheet Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 2 fees C O_ pnl Wiii iiii Figure 3 2 Kit SRM20001 Double Hanger Bolt Kit Components HANGER BOLT M12 WASHER M12 DOUBLE HANGER BOLT PLATE 1X HEX NUT W FLANGE M12 6X HANGER BOLT SEAL 2X SQUARE DISK 1X HEX BOLT M8 1X o ad HEX NUT M8 1X WASHER M8 to several different types of roofing with a wide variety of Install double hanger bolt 1 Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 Pre drill two 9mm holes a minimum of 4 inches deep into the ro
53. tial property damage Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection 1 Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Remember to include expansion tank water content 2 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level 3 The freeze protection set points may be lowered when freeze protection fluid is used see the Lochinvar Solar Differential Control Manual Glycol Aqueous solutions of Dowfrost HD fluid are designed to provide freeze burst and corrosion protection as well as efficient heat transfer in water based closed loop heating and air conditioning systems Dowfrost HD fluid has an operating temperature range of 50 F to 325 F with fluid freeze protection to below 60 F and system burst protection to below 100 F The fluid contains corrosion inhibitors that are specially formulated for HVAC systems to keep pipes free of corrosion without fouling Thermal protection A WARNING Thermal expansion tanks shou
54. uirements of DIN1055 Roof batten height at least 1 The gap between rafter anchor and top edge of the tile must be at least 3 5mm Under no circumstances may the rafter anchor be in contact with the tile if the overall height of roof batten and tile do not match the lower height must be packed out Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 6 Figure 3 6 Kit SRM20003 amp SRM20004 Rafter Anchor Kit Components RAFTER ANCHOR 1X SPACER PLATE 3X WOOD SCREW 2X SP WASHER M8 1X SS HEAVY DUTY WASHER 2X HEX BOLT M8 1X l Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11 Determine collector connection points spacing Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout reference the Roof Attachment Spacing Section on page 12 Number two 2 tiles one above the other The upper tile will be removed to install the rafter anchor Mark the edge of the upper tile on the lower tile to ensure proper alignment upon assembly Using the rafter anchor as a template pre drill two 2 6 mm
55. urer shall void the warranty No liability can be accepted for damage resulting from failure to observe the installation instructions A WARNING Only authorized solar companies familiar with our products may handle them There is a risk of injury when handling collectors and mounting accessories as these have sharp edges A WARNING A WARNING The collector becomes very hot in the sunlight There is a risk of burn Comply with all safety regulations and 4 WARNING applicable OSHA requirements Check the load bearing capacity and stability of the substructure onto which the collector is to be installed and will need to be accessed during the installation process A WARNING Dismantling and Disposal The units are dismantled in the reverse sequence of installation The roofing shall be properly sealed after the mounting brackets have been removed Materials shall be disposed of in an environmentally conscious manner A WARNING A WARNING SCH Collectors Installation amp Operation Manual A properly sized expansion tank must be used to avoid damage to the Solar Thermal System If copper pipe is being used all joints MUST BE brazed no soldering allowed Figure 1 1 Connection Diagram 2 Location Array options For series and parallel connection of multiple collectors it is advisable to calculate the pressure drop over the entire system with the aid of
56. x nut M8 and washer M8 onto the bottom of the hex bolt installed in Step 12 14 Repeat Steps 4 13 until installation is complete 15 Replace tiles removed in Step 4 Install hex bolt onto collector substructure reference Section 4 Collector Installation 16 Flat tile hook SRM20005 The flat tile hook is only used for parallel installation on plain tiled roofs generally steep roofs with a pitch of over 30 the hooked ends are hung over the roof battens and screwed in place an inclined collector installation is not possible here Unpacking and checking parts When unpacking the system check the model names of the components of each system and check to be sure you have the correct number of parts see FIG 3 10 Figure 3 10 Kit SRM20005 Flat Tile Hook Kit Components e FLAT TILE HOOK fo po METAL SHEET 1X HEX NUT M8 1X Q SQUARE DISK 1X gt WASHER M8 1X m SZ NAIL 3X HEX BOLT M8 1X di WOOD SCREW 1X Lochinvar GETZ Commercial Solar Thermal Systems SCH Collectors Installation amp Operation Manual 3 Roof Attachment Installation continued Install flat tile hook 1 Determine roof type Inspect the structural integrity of the roof and the durability of the roof materials Determine the number of collectors needed for the installation and the number of required roof attachments from Table 3B or 3C on page 11 Determi

Lochinvar TISUN SCH-I-O User's Manual

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