Lochinvar Heating System SCH I O User Manual
SCH-I-O Rev A  
Installation & Operation  
Manual  
SCH Collectors  
ƽ 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.  
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SCH Collectors Installation & Operation Manual  
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 ft2 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 ft².  
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  
SCH Collector  
Type  
SCH065  
3
SCH090  
SCH110  
5
SCH130  
6
Quantity of Glass Panels  
Gross area  
4
2
2
2
2
65.66 ft  
87.19 ft  
108.72 ft  
130.24 ft  
116.90 ft  
119.59 ft  
2
2
2
2
2
Aperture surface area  
Absorber surface area  
External Dimensions (L x W)  
Weight Ratings  
58.45 ft  
77.93 ft  
97.95 ft  
2
2
2
59.85 ft  
79.76 ft  
99.67 ft  
1
6'-7" x 9'-10"  
309 lbs.  
6'-7" x 13'-2"  
411 lbs.  
6'-7" x 16'-4"  
513 lbs.  
6'-7" x 19'-7"  
614 lbs.  
SCH mounting hardware + hydraulic connection kits  
Needed quantities for:  
Part-number Description  
SCH065 SCH090 SCH110 SCH130  
Parallel installation:  
SCA20001 Horizontal aluminum bar 10 ft  
SCA20002 Horizontal aluminum bar 13 ft  
SCA20003 Horizontal aluminum bar 16 ft  
SCA20004 Horizontal aluminum bar 20 ft  
2
2
2
2
SSK20004  
SSK20005  
End bracing kit  
Z-hook kit  
2
2
2
3
2
3
2
3
Inclined (20°,40°,60°) installation:  
SCA20001 Horizontal aluminum bar 10 ft  
SCA20002 Horizontal aluminum bar 13 ft  
SCA20003 Horizontal aluminum bar 16 ft  
SCA20004 Horizontal aluminum bar 20 ft  
SCA20005 Aluminum U-channel 10 ft  
SCA20006 Aluminum U-channel 13 ft  
SCA20007 Aluminum U-channel 16 ft  
SCA20008 Aluminum U-channel 20 ft  
2
3
2
3
2
3
2
3
4
4
4
SSK20001  
SSK20002  
SSK20003  
A-frame 20° inclined  
A-frame 40° inclined  
A-frame 60° inclined  
2
2
2
3
3
3
3
3
3
Hydraulic connection kits: (1 array is max. 2 SCH’s!)  
HYK20001 Hydr. conn. kit 2x 6.5' + plug + sensor well  
HYK20002 Hydr. conn. kit 1x 6.5'/1x 13' + plug + sensor well  
HYK20003 Serial hydr. exp. kit for stacked installation  
HYK20004 Parallel hydr. exp. kit for side by side installation  
HYK20005 Serial hydr. exp. kit for side by side installation  
1x per collector or array  
1x per collector or array  
1x per array  
1x per array  
1x per array  
Mechanical connection kits: (optional for installation!)  
MCK20001 Mechanical conn. kit for side by side installation  
MCK20002 Mechanical conn. kit for stacked installation  
MCK20003 Cover for piping (for side by side installations)  
1x per array  
1x per array  
1x per array  
Gable bracing kits: (required for non-south facing installation!)  
GBK20003 Bracing kit w/ diagonal support  
1x per collector  
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3
SCH Collectors Installation & Operation Manual  
1 Introduction  
How it works...  
6. Inlet connection  
Copper pipes, .86" diameter.  
1. Housing  
7. Outlet connection  
Powder coated (RAL7016)aluminum frame structure with  
PU rigid foam and an aluminum rear wall.  
Copper pipes, .86" diameter.  
8. Absorber coils  
2. Cover  
10 mm copper, serpentine arrangement.  
Prismatic solar safety glass, .15" thick, for maximum light  
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.  
10. Sensor well  
4. Absorber  
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  
the end of the sensor well.  
Full surface absorber, laser welded with highly-selective PVD  
coating (PVD = Physical Vapor Deposition), serpentine flow.  
5. Collector seal  
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  
1
7
7
5
3
2
4
8
6
10  
9
11  
4
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SCH Collectors Installation & Operation Manual  
1 Introduction  
(continued)  
Before getting started on your installation be sure to carefully  
read the preparation instructions in this section.  
Lochinvar/TiSun Solar Thermal Collectors  
are not specifically designed for drain back  
ƽ CAUTION  
installations. Consult the factory if drain  
back utilization is necessary.  
Installer – Read all instructions, including  
ƽ WARNING  
this manual before installing. Perform  
steps in the order given.  
•
•
The mounting substructure must be  
capable of withstanding the local  
snow and wind loads and permit  
correct anchoring of the collectors.  
ƽ CAUTION  
Have your collector(s) serviced/inspected  
by a qualified service technician, at least  
annually.  
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.  
Failure to comply with the above could  
result in severe personal injury, death or  
substantial property damage.  
When calling or writing about the collector  
NOTICE  
– 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.  
•
•
Hydraulic connection of the collectors  
must be performed according to  
Lochinvar/TiSun specifications.  
Factory warranty (shipped with the  
collector) does not apply to collectors  
improperly installed or improperly  
operated.  
The collector connections must not be  
damaged,soiledormisaligned. Takecare  
during transport, installation, and  
connection of the modules. Do not  
remove the header protection caps at the  
top and bottom connections of the  
collector 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.  
•
You must comply with local  
regulations, laws and standards of the  
local governing authority.  
ƽ CAUTION  
•
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.  
•
•
•
Always connect the collector outlet and  
inlet flow to each other diagonally,  
•
•
The load bearing capacity of the  
roofing and the frame shall be specially  
checked or analyzed by a structural  
engineer.  
please  
follow  
the  
connection  
example (see FIG. 1-1 on page 6).  
Do not twist the headers when screwing  
theconnectionstogether. Holdthreaded  
connection in the desired position and  
tighten clamping ring union nut to  
torque.  
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  
•
•
•
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.  
permissible collector loading per  
square foot may be calculated from the  
number of mounting brackets, taking  
into consideration the permissible  
loading on the mounting brackets. If a  
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.  
All piping should be properly insulated to  
avoid freezing and/or burn potential.  
ƽ CAUTION  
5
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SCH Collectors Installation & Operation Manual  
1 Introduction  
•
Check the materials for any damage  
A properly sized expansion tank must be  
ƽ WARNING  
NOTICE  
sustainedintransportanddescribeany  
damage in writing on the packing slip  
where necessary. This is important to  
process any needed freight or delivery  
damage claims.  
used to avoid damage to the Solar Thermal  
System.  
If copper pipe is being used, all joints  
MUST BE brazed, no soldering allowed.  
ƽ WARNING  
•
Carefully read through the relevant  
installation instructions before  
starting the installation and follow Figure 1-1 Connection Diagram  
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  
manufacturer shall void the warranty.  
Noliabilitycanbeacceptedfordamage  
resulting from failure to observe the  
installation instructions.  
Only authorized solar companies familiar  
with our products may handle them.  
ƽ WARNING  
There is a risk of injury when handling  
collectors and mounting accessories as  
these have sharp edges.  
ƽ WARNING  
The collector becomes very hot in the  
sunlight. There is a risk of burn.  
ƽ WARNING  
Comply with all safety regulations and  
applicable OSHA requirements.  
ƽ WARNING  
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.  
ƽ 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.  
6
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SCH Collectors Installation & Operation Manual  
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 the enclosed documents and to install an appropriate pump if necessary. The maximum collector area per collector  
array connected in series is 260 ft2. 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  
PARALLEL SIDE BY SIDE  
PARALLEL WITH BALANCING VALVES  
(ON ROOF ONLY)  
SERIES SIDE BY SIDE  
Figure 2-2 Multiple Array Piping  
7
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SCH Collectors Installation & Operation Manual  
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  
that the collectors face true south.  
Collector incline should be at least 15° and  
no more than 70° for best performance.  
NOTICE  
NOTICE  
NOTICE  
Avoid installation in shaded areas. Shaded  
areas will reduce the performance of the  
solar collectors.  
It is not recommended for the collector  
field to deviate any further than 45°  
from true south.  
NOTICE  
8
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SCH Collectors Installation & Operation Manual  
2 Location  
(continued)  
Handling and storing  
•
•
Only loosen the crane connection  
when the collectors are completely  
fixed to the substructure.  
Pay special attention to roof-work  
near an electric grid. If need be, the  
constructor must take security  
precautions such as isolation,  
covering, etc.  
Inspect the roof surface in the area of  
the installation for cracks, water  
leakage, and roofing material quality  
and uniformity. This is especially  
important if the roof is more than 10  
years old.  
ƽ WARNING  
•
Installation of LOCHINVAR/TiSun  
ƽ WARNING  
SCH collectors is only allowed for  
professional staff.  
•
•
Local instructions, laws and standards  
are to be kept.  
Collectors are to be located so  
falling of snow and ice does not  
endanger any person or property.  
Use personal protection equipment  
(helmet, belt, security shoes) when on  
the roof.  
•
•
•
•
Secure tools and materials against  
falls.  
It is forbidden to stand under  
hanging load.  
•
•
Inspect the roof for sags and other  
abnormalities.  
A
sag or deep  
depression in the roof may indicate a  
structural weakness in the support  
system that may require correction.  
Check that all rafters, trusses and  
other materials are in good condition.  
•
•
Danger area has to be closed.  
Put ladders up properly and check  
stability.  
ƽ CAUTION  
•
Check the under roof construction on  
the building before installation.  
NOTICE  
•
•
Avoid rotating movements of the  
load through wind. Secure load  
before lifting.  
Only move collectors on the given  
fixing loops.  
What to avoid  
ƽ WARNING  
•
Collectors are to be located such that  
eventual sliding of snow and ice does  
not endanger any person.  
ƽ CAUTION  
•
See FIG. 2-6 for crane transportation  
connection points and positioning.  
NOTICE  
Figure 2-6 Crane Transportation Connection Points and Positioning  
< 30°  
< 30°  
6.5 ft.  
6.5 ft.  
< 30°  
< 30°  
8.5 ft.  
6.5 ft.  
9
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SCHCollectorsInstallation&OperationManual
3 Roof Attachment Installation  
Roof attachment types  
Table 3A Roof Fastenings - Parts  
Installation Type  
SOLAR ROOF MOUNTS  
Parallel Inclined Free-  
standing  
See  
Page  
Description  
Lochinvar  
Name  
Part #  
Stainless steel attachment for universal heavy duty  
installations, on parallel and inclined roofs and  
freestanding installations on sufficiently anchored  
bases.  
BOLT,  
DOUBLE  
HANGER  
SRM20001  
X
X
X
X
X
X
13  
15  
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,  
SRM20003 RAFTER, STD  
ROOF TILE  
-
Stainless steel attachment for parallel and inclined  
installations on various types of tiled roofs. Standard  
installations for tile heights of up to 2". Package is  
complete with fasteners and spacers.  
ANCHOR,  
SRM20004 RAFTER, TALL  
ROOF TILE  
X
X
X
15  
16  
18  
-
-
-
Stainless steel attachment for parallel installations on  
plain tile, slate, and flat cement tiled roofs with pitches  
in excess of 30 degrees.  
HOOK, FLAT  
SRM20005  
-
TILE  
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.  
SRM20006 CLAMP, JOINT  
PLATE,  
X
Galvanized steel attachment for parallel, inclined and  
freestanding installations on asphalt or elastomer  
roofs.  
SRM20007  
FLANGE,  
SHINGLE, STD.  
X
-
X
X
X
X
20  
22  
PLATE,  
FLANGE,  
SHINGLE,  
RAISED  
Galvanized steel attachment for inclined and  
freestanding installations on asphalt or elastomer  
roofs. Also recommended for flat roofs.  
SRM20008  
BOLT,  
ANCHOR,  
CONCRETE W/  
ADJ  
Galvanizedsteelattachmentforinclinedorfreestanding  
installations with 2.75" height adjustment. For use in  
applications with no more than a 5 degree inclination.  
SRM20009  
SRM20010  
SRM20012  
X
X
X
X
26  
26  
-
Galvanized steel attachment for inclined or  
freestanding installations with no height adjustment.  
For use in applications with no more than a 5 degree  
inclination.  
BOLT,  
ANCHOR,  
CONCRETE  
-
Stainless steel cable set for securing collectors on  
inclined jointed roofs. Kit includes cable, turnbuckle,  
hardware for attachment to frame, and joint clamp.  
For inclined installations only.  
KIT, UNIV  
CABLE  
SECURING  
X
X
19  
23  
-
-
-
ATTACHMENT,  
SRM20013 ROOF CORR  
METAL  
Stainless steel attachment for parallel and inclined  
installations on profiled and corrugated roofs.  
X
Galvanized steel attachment for installations on  
concrete corrugated roofs with 5 corrugations per  
meter. For parallel and inclined installations.  
ATTACHMENT,  
SRM20014 WAVE ROOF  
SM  
X
X
X
X
25  
25  
-
-
Galvanized steel attachment for installations on  
concrete corrugated roofs with 8 corrugations per  
meter. For parallel and inclined installations.  
ATTACHMENT,  
SRM20015 WAVE ROOF  
LG  
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10  
SCH Collectors Installation & Operation Manual  
3 Roof Attachment Installation  
(continued)  
Roof attachment quantities for SCH collectors snow loading  
Table 3B Parallel Installations  
SRM: 20001, 20003, 20004, 20006, 20007,  
SRM: 20005  
20013, 20014, 20015  
area load up to  
32 lb/sq-ft  
area load up to  
64 lb/sq-ft  
area load up to  
16 lb/sq-ft  
area load up to  
32 lb/sq-ft  
SCH065  
SCH090  
SCH110  
SCH130  
6
8
10  
12  
14  
18  
6
8
10  
12  
14  
18  
8
8
10  
10  
Table 3C Inclined (20°, 40°, and 60°) Installations  
SRM: 20001, 20003, 20004, 20007, 20008,  
20009, 20010, 20013, 20014, 20015  
SRM: 20006  
+ 20012  
area load up to 32 lb/ area load up to 64 lb/  
area load up to 64 lb/sq-ft  
sq-ft  
sq-ft  
SCH065  
SCH090  
SCH110  
SCH130  
6
8
10  
12  
14  
18  
12  
14  
18  
22  
2
3
3
4
8
10  
11  
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SCH Collectors Installation & Operation Manual  
3 Roof Attachment Installation  
Figure 3-1 Spacing Distance  
a
a
x
a
a
a = 2 - 10 in.  
X
55 - 63 in.  
Spacing Distance  
Equally space the center roof attachments starting in the  
middle, the two (2) end attachments will be spaced according  
to the inner measurement (start in the middle and work  
outwards). The remaining roof mounts should be equally  
spaced in between the two (2) end roof attachments.  
Each collector will have its own independent substructure set.  
Ensure there is ample room on the chosen roof area for the  
number of collectors chosen.  
Note: For multiple collector installations reference the  
Collector Mounting Section of this manual for spacing  
between collectors.  
12  
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SCH Collectors Installation & Operation Manual  
3 Roof Attachment Installation  
(continued)  
Installation of roof attachment types  
The solar thermal collectors are capable of being mounted to several different types of roofing with a wide variety of  
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.  
Install double hanger bolt  
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).  
•
The hanger bolt must be screwed  
into a support capable of bearing  
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.  
ƽ CAUTION  
•
•
4. Pre-drill two 9mm holes, a minimum of 4 inches deep  
into the roof substructure (see FIG. 3-3), perpendicular  
to the roof with a spacing of 4 3/4" to 6 3/4".  
•
Beware of linear expansion in sheet  
5. Install the hanger bolts into the pre-drilled holes  
until the threads are level with the roof’s surface.  
metal that prevents  
a
linear  
expansion and can cause lifting of  
the sheet.  
Figure 3-3 Pre-Drill 9mm Holes Into Substructure  
Unpacking and checking parts  
PRE-DRILL TWO (2) 9MM HOLES  
PERPENDICULAR TO THE ROOF  
(APPROX. 4 IN. DEEP)  
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).  
INSTALL  
HANGER  
BOLT(S)  
Figure 3-2 Kit #SRM20001 - Double Hanger Bolt Kit  
Components  
6. Slide the hanger bolt seals over the machine threads until  
the seal is touching the roof’s surface (FIG. 3-4A).  
7. Slide the washer (M12) on top of the hanger bolt seal  
(FIG. 3-4A).  
HANGER BOLT (M12) (2X)  
8. 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).  
DOUBLE HANGER BOLT PLATE (1X)  
WASHER (M12) (2X)  
9. Install the second hex nut with flange (flange side up)  
until the hex nut reaches the desired substructure height  
(FIG. 3-4B).  
HEX NUT W/FLANGE (M12) (6X)  
HANGER BOLT SEAL (2X)  
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.  
SQUARE DISK (1X)  
HEX BOLT (M8) (1X)  
12. Make certain all double hanger bolt plates are facing the  
same direction.  
HEX NUT (M8) (1X)  
WASHER (M8) (1X)  
13  
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SCH Collectors Installation & Operation Manual  
3 Roof Attachment Installation  
Figure 3-4A Install Double Hanger Bolt Components  
Figure 3-5 Install Hex Bolt(s)  
HEX BOLT  
SQUARE DISK  
HEX NUT W/FLANGE  
HANGER BOLT PLATE  
DOUBLE HANGER  
BOLT PLATE  
HEX NUT W/FLANGE  
WASHER (M12)  
HANGER BOLT SEAL  
HANGER BOLT  
min.  
4”  
Figure 3-4B Compress Washer and Hanger Bolt Seal  
DOUBLE HANGER BOLT PLATE  
HEX NUT  
FLANGE UP  
NUT  
WASHER  
SEAL  
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)  
14  
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SCH Collectors Installation & Operation Manual  
3 Roof Attachment Installation  
(continued)  
Rafter anchor for roof tiles  
#SRM20003 & #SRM20004  
Install rafter anchor  
1. Determine roof type. Inspect the structural integrity of  
the roof and the durability of the roof materials.  
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/ft2. Can be used for various types  
of roofing tiles.  
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.  
•
The anchors must be screwed into  
a support capable of bearing the  
required static load (generally  
rafters or concrete).  
ƽ CAUTION  
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).  
•
Complies with the requirements of  
DIN1055.  
•
•
Roof batten height at least 1".  
The gap between rafter anchor  
and top edge of the tile must be at  
4. Number two (2) tiles, one above the other. The upper  
tile will be removed to install the rafter anchor.  
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).  
5. Mark the edge of the upper tile on the lower tile to  
ensure proper alignment upon assembly.  
6. Using the rafter anchor as a template, pre-drill two (2)  
6 mm holes, approximately 4 inches deep into the roof  
substructure (see FIG. 3-7), perpendicular to the roof.  
Unpacking and checking parts  
Figure 3-7 Pre-Drill 6mm Holes Into Roof Substructure  
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).  
USE RAFTER ANCHOR  
AS A TEMPLATE  
Figure 3-6 Kit #SRM20003 & #SRM20004 - Rafter  
Anchor Kit Components  
PRE-DRILL TWO (2)  
6MM HOLES  
APPROX. 4” DEEP  
PERPENDICULAR TO  
THE ROOF  
7. 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).  
SPACER PLATE (3X)  
RAFTER ANCHOR (1X)  
8. Place the rafter anchor on the spacer plate (if used).  
9. Place the heavy duty washers over the holes pre-drilled in  
Step 6.  
SQUARE DISK (1X)  
WOOD SCREW (2X)  
10. Install the wood screws through the washers and rafter  
anchor into the roof substructure.  
HEX NUT (M8) (1X)  
WASHER (M8) (1X)  
Note: It may be necessary to grind the upper tile to assure a  
better fit (FIG. 3-9).  
HEAVY DUTY WASHER (2X)  
HEX BOLT (M8) (1X)  
15  
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3 Roof Attachment Installation  
Flat tile hook  
#SRM20005  
Figure 3-8 Install Rafter Anchor  
COLLECTOR SUBSTRUCTURE  
HEX BOLT  
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.  
INSTALL WASHER  
AND WOOD SCREW  
Unpacking and checking parts  
SPACER PLATE  
(IF NECESSARY)  
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).  
RAFTER ANCHOR  
Figure 3-9 Grind Tile (if necessary)  
Figure 3-10 Kit #SRM20005 - Flat Tile Hook Kit  
Components  
IF NECESSARY, GRIND  
THE TILE FOR A BETTER  
FIT  
FLAT TILE HOOK (1X)  
METAL SHEET (1X)  
11. Slide the square disk onto the hex bolt (see FIG. 3-8).  
HEX NUT (M8) (1X)  
SQUARE DISK (1X)  
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.  
HEX BOLT (M8) (1X)  
WASHER (M8) (1X)  
13. Thread the hex nut (M8) and washer (M8) onto the bottom of  
the hex bolt installed in Step 12.  
WOOD SCREW (1X)  
NAIL (3X)  
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  
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3 Roof Attachment Installation  
(continued)  
Install flat tile hook  
Figure 3-12 Grind Tile(s) (if necessary) / Install Hex Bolt  
1. Determine roof type. Inspect the structural integrity of  
the roof and the durability of the roof materials.  
COLLECTOR  
SUBSTRUCTURE  
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.  
HEX BOLT  
SQUARE DISK  
FLAT TILE  
HOOK  
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).  
IF NECESSARY, GRIND  
THE TILE(S) FOR A BETTER  
FIT  
4. Number two (2) tiles, one above the other. The top tile  
will be removed to install the flat tile hook.  
5. Remove the top tile from the roof (set aside for  
reassembly).  
10. Slide the square disk onto the hex bolt (see FIG. 3-12).  
6. Place the tiled roof hook over the roof batten of  
the bottom tile (FIG. 3-11).  
11. Install the hex bolt with square disk attached into the  
opening of the flat tile hook as shown in FIG. 3-12.  
7. 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).  
Note: Do not tighten hex bolt until ready to install on the  
collector substructure.  
8. Secure the tiled roof hook to the roof substructure using  
the screws provided in the kit (FIG. 3-11).  
12. Thread the hex nut (M8) and washer (M8) onto the bottom  
of the hex bolt installed in Step 11.  
9. Replace the tile removed in Step 5.  
13. Repeat Steps 4 - 12 until installation is complete.  
Note: It may be necessary to grind the top tile to assure a  
better fit (FIG. 3-12).  
Install hex bolt onto collector substructure (reference Section 4 -  
Collector Installation)  
Figure 3-11 Install Flat Tile Hook and Metal Sheet  
HOOK FLAT TILE HOOK  
ONTO ROOF BATTEN  
WOOD  
SCREW  
NAIL  
NAIL  
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  
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3 Roof Attachment Installation  
Joint clamp  
#SRM20006  
Install joint clamp  
1. Determine roof type. Inspect the structural integrity of  
the roof and the durability of the roof materials.  
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.  
2. Determine the number of collectors needed for the  
installation and the number of required roof attachments  
from Table 3B and 3C on page 11.  
•
Not  
recommended  
for  
ƽ CAUTION  
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).  
titanium-zinc sheet due to  
danger of cracks at low  
temperature.  
Do not reuse any stainless steel  
screws as there is  
breakage.  
•
a
risk of  
4. Assemble joint clamp as shown in FIG. 3-14 (be sure to  
loosely assemble the screws on the joint clamp  
assembly).  
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).  
5. Place the joint clamp assembly at the appropriate  
location on the joint of the tin roof.  
6. Tighten the screws on the joint clamp to 26 ft./lbs.  
Figure 3-13 Kit #SRM20006 - Joint Clamp Kit Components  
Figure 3-14 Assemble / Install Joint Clamp & Hex Bolt  
COLLECTOR  
SUBSTRUCTURE  
HEX BOLT  
SQUARE DISK  
JOINT CLAMP 2 (1X)  
ASSEMBLE JOINT CLAMP  
INSTALL ON THE TIN  
ROOF JOINT  
JOINT CLAMP 1 (1X)  
JOINT  
HEX NUT (M8) (1X)  
SQUARE DISK (1X)  
HEX BOLT (M8) (1X)  
WASHER (M8) (1X)  
7. Slide the square disk onto the hex bolt (see FIG. 3-14).  
8. Install the hex bolt with square disk attached into the  
opening of the joint clamp as shown in FIG. 3-14.  
MUSHROOM HEAD BOLT (M10) (2X)  
HEX NUT (M10) (2X)  
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)  
18  
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3 Roof Attachment Installation  
(continued)  
Universal cable securing kit  
#SRM20012  
Install cable securing kit  
1. Install the anchor bracket on the A-frame using the hex  
bolt, square disk, washer, and hex nut.  
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- 2. Assemble the joint clamp as shown in FIG. 3-17 (be sure to  
steel.  
loosely assemble the screws on the joint clamp  
assembly).  
Joint clamp for cable set is required for mounting the guy  
cable set on joint tin roofs with galvanized or coated sheet 3. Place the joint clamp assembly at the appropriate  
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).  
location on the joint of the tin roof.  
Figure 3-16 Attach Cable Fastening Bracket to A-Frame  
•
•
Not recommended for titanium-  
zinc sheet due to danger of  
cracking at low temperatures.  
ATTACH CABLE FASTENING BRACKET  
TO THE COLLECTOR  
ƽ CAUTION  
CABLE FASTENING BRACKET  
INSTALLED ON COLLECTOR  
Do not reuse any stainless steel  
screws as there is  
breakage.  
a
risk of  
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).  
Figure 3-15 Kit #SRM20012 - Universal Cable Securing Kit  
Components  
Figure 3-17 Assemble Joint Clamp  
ASSEMBLE JOINT CLAMP LOOSELY  
AND PLACE ON JOINT  
JOINT CLAMP  
JOINT CLAMP  
PART 1 (1X)  
PART 2 (1X)  
NUT (2X)  
HEX BOLT W/FLANGE (2X)  
SQUARE DISK (2X)  
HEX BOLT (M10) (1X)  
HEX BOLT  
(M8) (2X)  
HEX NUT (M8) (2X)  
WASHER (1X)  
WASHER  
(M10) (1X)  
SQUARE NUT (1X)  
CABLE KIT (1X)  
19  
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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  
Flange plate shingle (standard)  
#SRM20007  
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  
support capable bearing the  
required load (generally rafters or  
concrete).  
ƽ CAUTION  
INSERT PIN  
USE PIN CLIP TO SECURE  
THE CABLE  
•
Once installed, the plates must be  
sealed to the 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).  
CABLE (TURNBUCKLE)  
INSTALL CABLE  
INSTALLED  
Figure 3-21 Kit #SRM20007 - Flange Shingle Plate  
(TURNBUCKLE)  
(Standard) Kit Components  
6. Attach the steel cable to the joint clamp (fashioned after  
the cable orientations in FIG. 3-18.  
Extend turnbuckle to its fullest extent.  
NOTICE  
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).  
PLATE FLANGE (STD) (1X)  
SCREW (M10) (4X)  
SCREW (M6) (4X)  
8. Tighten the joint clamp.  
9. Use the turnbuckle to tighten the cable.  
SQUARE DISK (1X)  
HEX NUT (M8) (1X)  
HEX BOLT (M8) (1X)  
WASHER (M8) (1X)  
20  
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3 Roof Attachment Installation  
(continued)  
Install flange plate shingle (standard)  
Figure 3-23 Drill Holes and Attach Flange Plate  
COLLECTOR  
SUBSTRUCTURE  
1. Determine roof type. Inspect the structural integrity of  
the roof and the durability of the roof materials.  
HEX BOLT  
SQUARE DISK  
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).  
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  
4. Caulk (field supplied) around the perimeter of the flange  
plate (FIG. 3-22).  
5. Using the flange plate as a template, place the flange plate  
on the roof and drill four (4) 6 mm holes as shown in Figure 3-24 Cover Flange Plate with Roofing Material  
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).  
COVER FLANGE PLATE WITH  
ROOFING MATERIAL, SEALING  
IT TO THE ROOF  
2”  
6. 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).  
6”  
7. Cover flange plate with roofing material, sealing it to the  
roof (FIG. 3-24).  
4.7”  
4.7 mm  
> 4.7”  
Figure 3-22 Caulk Around Perimeter of Flange Plate  
CAULK AROUND  
THE PERIMETER  
OF THE FLANGE PLATE  
~ Ø 5 mm  
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 installed in Step 9.  
11. Repeat Steps 4 - 10 until installation is complete.  
Install hex bolt onto collector substructure (reference Section 4 -  
Collector Installation)  
21  
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3 Roof Attachment Installation  
Flange plate shingle (raised)  
#SRM20008  
Install flange plate shingle (raised)  
1. Determine roof type. Inspect the structural integrity of  
the roof and the durability of the roof materials.  
The raised flange shingle plate is used for inclined installations  
on asphalt and elastomer roofs; also suitable for flat roofs.  
2. Determine the number of collectors needed for the  
installation and the number of required attachments  
from Table 3B or 3C on page 11.  
•
The plates must be screwed into a  
member capable of bearing the  
required static load (generally  
rafters or concrete).  
Once installed, the panels  
must be sealed to the roof sheet  
material (FIG. 3-28), and  
only then can the collector be  
fitted.  
ƽ CAUTION  
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. Caulk (field supplied) around the perimeter of the flange  
plate (FIG. 3-26).  
Unpacking and checking parts  
5. 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).  
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).  
Figure 3-25 Kit #SRM20008 - Flange Plate (Raised) Kit  
Components  
6. 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).  
7. Cover the flange plate with roofing material, sealing it to  
the roof (FIG. 3-28).  
Figure 3-26 Caulk Around Perimeter of Flange Plate  
FLANGE PLATE RAISED (1X)  
CAULK AROUND  
THE PERIMETER  
OF THE FLANGE PLATE  
~ Ø 5 mm  
SCREW (M10) (4X)  
SCREW (M6) (4X)  
SQUARE DISK (1X)  
HEX NUT (M8) (1X)  
HEX BOLT (M8) (1X)  
WASHER (M8) (1X)  
22  
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3 Roof Attachment Installation  
(continued)  
Corrugated metal roof attachment  
#SRM20013  
Figure 3-27 Drill Holes and Attach Flange Plate  
The corrugated metal roof attachment is used for parallel  
and inclined mounting on profiled or corrugated sheet metal  
roofs. The console is mounted above the mounting screws  
of the profiled or corrugated sheet metal. The two sealing  
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.  
COLLECTOR  
SUBSTRUCTURE  
HEX BOLT  
SQUARE DISK  
USE THE SMALLER SCREWS  
IN THE PERIMETER OF THE  
FLANGE PLATE  
•
•
The console must be ordered to  
fit the relevant profiled or  
corrugated sheet metal.  
The mounting screws supplied  
with the console must be  
appropriate in type and length for  
the particular roof construction.  
ƽ CAUTION  
PRE-DRILL FOUR (4) 6 MM  
HOLES - USE THE LARGER  
SCREWS TO SECURE THE  
FLANGE PLATE  
Figure 3-28 Cover Flange Plate with Roofing Material  
Unpacking and checking parts  
COVER FLANGE PLATE WITH  
ROOFING MATERIAL, SEALING  
IT TO THE ROOF  
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. 3-29).  
2”  
Figure 3-29 Kit #SRM20013 - Corrugated Metal Roof  
Attachment Kit Components  
6”  
> 4.7”  
4.7”  
4.7 mm  
HEX NUT (M10) (1X)  
STUD (M10) (1X)  
PROFILE CONNECTOR (1X)  
8. Slide the square disk onto the hex bolt (see FIG. 3-27).  
HEX BOLT (M8) (1X)  
WASHER (M10) (2X)  
9. Install the hex bolt with square disk attached into the  
opening of the flange plate as shown in FIG. 3-27.  
Note: Do not tighten hex bolt until ready to install on the  
collector substructure.  
HEX NUT (M10) (2X)  
WASHER (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)  
23  
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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)  
INSTALL  
HEX BOLTS & STUD  
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. 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 top of the metal roof  
attachment (see FIG. 3-31).  
11. Drill a 6.5 mm hole into the horizontal bar.  
12. Place the horizontal bar into the profile connector  
installed in Step 10.  
7. Install hex bolts into pre-drilled holes as shown in  
FIG. 3-32.  
13. Using the remaining bolts and washers secure the horizontal  
bar into the profile connector.  
8. Install the four (4) self tapping screws provided in kit  
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  
ATTACH PROFILE CONNECTOR  
Figure 3-30 Install Rubber Seals  
METAL ROOF ATTACHMENT  
INSTALL SEALING PADS  
METAL ROOF  
ATTACHMENT  
Figure 3-31 Pre-drill 6.5 mm Holes  
PRE-DRILL 6.5 MM HOLES  
FIXING POINT  
24  
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3 Roof Attachment Installation  
(continued)  
Wave roof attachment  
Install wave roof attachment  
#SRM20014 & #SRM20015  
1. Determine roof type. Inspect the structural integrity of  
the roof and the durability of the roof materials.  
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.  
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).  
•
•
Various  
sizes:  
Profile  
5
ƽ CAUTION  
corrugations per meter; profile 8  
corrugations per meter.  
The wood screws must be screwed  
into a member capable of bearing  
the required static load (generally  
rafters). Longer wood screws are  
necessary if the roof construction  
is higher (e.g. roof insulation).  
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).  
Unpacking and checking parts  
6. Place the wave roof attachment, angle bracket and  
washer over the 6 mm hole on the roof (FIG. 3-36).  
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).  
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).  
Figure 3-34 Kit #SRM20014 & #SRM20015 - Wave Roof  
Attachment Kit Components  
Figure 3-35 Pre-Drill 6 mm Hole and Seal  
SEAL  
WAVE ROOF ATTACHMENT (1X)  
PRE-DRILL A 6 MM  
HOLE AND SEAL  
ANGLE BRACKET (1X)  
WASHER (M12) (1X)  
HEX WOOD SCREW (M12) (1X)  
HEX BOLT (M8) (1X)  
25  
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3 Roof Attachment Installation  
Unpacking and checking parts  
Figure 3-36 Attach Wave Roof Attachment Assembly  
and Hex Bolt  
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).  
HEX BOLT  
SQUARE DISK  
Figure 3-37 Kit #SRM20009 & #SRM20010 - Anchor Bolt  
Kit Components  
ATTACH WAVE  
ROOF ATTACHMENT  
ASSEMBLY (WASHER, ANGLE  
BRACKET AND SCREW)  
TO THE ROOF  
ANCHOR BOLT W/ADJUSTMENT (1X)  
WASHER (M10) (3X)  
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.  
HEX NUT (M10) (3X)  
9. Thread the hex nut (M8) and washer (M8) onto the  
bottom of the hex bolt installed in Step 8.  
Install anchor bolt  
10. Repeat Steps 4 - 9 until installation is complete.  
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.  
Install hex bolt onto collector substructure (reference  
Section 4 - Collector Installation)  
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).  
Anchor bolts for concrete with or without  
height adjustment  
#SRM20009 & #SRM20010  
3. Pre-drill a 10 mm hole a minimum of 3 inches into the  
concrete (FIG. 3-38).  
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 and nut.  
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.  
•
There are two (2) models  
of concrete anchor bolts, one with  
adjustment and one without. The  
adjustable dimensions are up to  
2 3/4".  
ƽ CAUTION  
•
The anchor bolt may have a  
maximum deviation from vertical  
of 5°.  
26  
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3 Roof Attachment Installation  
(continued)  
Figure 3-38 Pre-Drill 10 mm Hole & Attach to Concrete  
USE THE WASHER AND NUT  
TO SECURE THE ANCHOR BOLT  
TO THE CONCRETE  
22 ft./lbs.  
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  
DRILL 10.5 MM HOLE  
22 ft./lbs.  
27  
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Installation & Operation Manual  
4 Collector Installation  
Horizontal bar lengths  
Figure 4-1A Horizontal Bar Lengths  
x
x
6’7”  
SCH065 = 9’10”  
(x)  
SCH090 = 13’2”  
(x)  
SCH110 = 16’4”  
(x)  
SCH130 = 19’7”  
(x)  
Figure 4-1B Spacing Information for Location of A-frames for Inclined Installations  
28  
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4 Collector Installation  
(continued)  
4. Ensure lifting rings are installed and properly spaced as  
per FIG. 4-4.  
SCH parallel mounting instructions  
1. Install roof attachments (see the Roof Attachment  
Section on pages 13 - 27 of this manual).  
Figure 4-4 Lifting Rings  
2. Install the horizontal bar(s) (FIG.'s 4-2A and 4-2B)  
using the square disk, hex bolt, and washers provided  
in the kit.  
< 30°  
Figure 4-2A Install Horizontal Bars  
< 30°  
6.5 ft.  
6.5 ft.  
ENDS OF HORIZONTAL BARS  
MUST BE PARALLEL TO ENSURE  
PROPER COLLECTOR  
ORIENTATION  
< 30°  
< 30°  
6.5 ft.  
8.5 ft.  
Figure 4-2B Spacing  
5. Position the collector onto the substructure and hanger  
brackets (FIG. 4-5).  
a
Only loosen the crane connection when  
the collectors are completely fixed to the  
a
ƽ WARNING  
substructure.  
x
Figure 4-5 Position Collector On Substructure  
POSITION PANEL ONTO  
SUBSTRUCTURE  
a
a = 2 - 10 in.  
x
55 - 63 in.  
3. Install the Z-hooks per FIG. 4-3 using the  
specified number of brackets.  
Z-HOOK  
Figure 4-3 Install Z-Hooks  
SCH090, 110, AND 130  
3 x / per collector  
SCH065  
6. Secure the collector to the Z-hook(s) using the  
square disk and hex bolt provided in the kit (FIG. 4-6).  
2 x / per collector  
29  
INSTALL Z-HOOKS  
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4 Collector Installation  
Figure 4-9 For Stacked Series Installations - Use Self  
Tapping Screws and Spacers  
Figure 4-6 Secure Collector  
USE SELF TAPPING  
SCREWS AND SPACERS  
TO SEPARATE THE TOP PANEL  
FROM THE BOTTOM PANEL  
10. Install top collector on the horizontal bars and slide it  
onto the spacers (FIG. 4-10). Repeat Steps 7 and 8 for  
the top collector.  
HEX BOLT  
SQUARE DISK  
7. Position the collector on the horizontal bars so that the  
collector overhangs approximately 5mm (.2")  
(FIG. 4-7).  
Figure 4-10 Install Top Collector  
INSTALL TOP COLLECTOR  
Figure 4-7 Position Collector on Horizontal Bars  
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  
END STACKING BRACKET  
INSTALLED  
INSTALL END STACKING BRACKET  
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  
side installations.  
5.1”  
NOTICE  
INSTALL  
ENSURE COLLECTORS  
ARE 5.1” APART  
HYDRAULIC  
CONNECTION KIT  
Make certain collectors are 5.1" apart.  
30  
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SCH Collectors Installation & Operation Manual  
4 Collector Installation  
(continued)  
The Mechanical Connection Kit is an  
optional kit available through the  
manufacturer.  
15. Install the side by side bracket using the square disks and  
hex bolts provided in the kit (FIG. 4-16).  
NOTICE  
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  
14. Reinstall the collector railing removed in Step 13  
(FIG. 4-15).  
Figure 4-15 Reinstall Collector Railing  
Figure 4-19 Install Hydraulic Connections  
REINSTALL COLLECTOR RAILING  
SENSOR  
WELL  
EXPANSION  
SET (HYDRAULIC  
CONNECTION)  
OPTIONAL MECHANICAL  
CONNECTION KIT  
EXPANSION  
SET (HYDRAULIC  
CONNECTION)  
PLUG  
31  
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4 Collector Installation  
SCH inclined / non-south facing roof  
mounting instructions  
Figure 4-22 Drill 9 mm Hole in Horizontal Bar(s)  
DRILL 9 MM HOLE TO CONNECT  
A-FRAME  
1. Install roof attachment (see the Roof Attachment Section  
on pages 12 - 26 of this manual).  
2. Install the horizontal bar(s) (FIG. 4-20) 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  
6. Repeat Steps 3 - 5 for each A-frame making sure all  
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  
3. Assemble A-frame.  
DRILL A 4 MM HOLE THROUGH  
THE BRACKET AND A-FRAME  
4. Position A-frame to horizontal bars within 6" of the roof  
attachments as shown in FIG. 4-21.  
Figure 4-21 Mount A-frame to Horizontal Bars  
Diagonal supports are needed on non-south  
NOTICE  
facing installations ONLY.  
8. In the case of a non-south facing installation install  
diagonal supports (see FIG. 4-24). Drill 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.  
Figure 4-24 Install Diagonal Supports  
6”  
SECURE DIAGONAL SUPPORTS  
WITH THE BOLTS, NUTS AND  
WASHERS PROVIDED IN THE KIT  
6”  
5. 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  
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4 Collector Installation  
(continued)  
9. Ensure lifting rings are installed and spaced properly per  
FIG. 4-25.  
Figure 4-27 Connect Collector to Bottom End Brace  
Figure 4-25 Lifting Rings  
CONNECT COLLECTOR  
TO BOTTOM END BRACE  
SQUARE DISK  
HEX BOLT  
< 30°  
< 30°  
6.5 ft.  
6.5 ft.  
13. Install the top end brace using the bolt provided in the  
kit (FIG. 4-28).  
14. Connect 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.  
< 30°  
< 30°  
6.5 ft.  
8.5 ft.  
Figure 4-28 Install Top End Brace  
CONNECT COLLECTOR TO END BRACE  
10. Position the collector onto the substructure (FIG. 4-26).  
Only loosen the crane connection when  
ƽ WARNING  
the collectors are completely fixed to the  
substructure.  
Figure 4-26 Position Collector On Substructure  
16. For side by side installations repeat Steps 1 - 15 and  
install horizontal hydraulic connections (see FIG. 4-29).  
POSITION COLLECTOR  
ONTO SUBSTRUCTURE  
Figure 4-29 Install Horizontal Hydraulic Connections  
ENSURE .2”  
OVERHANG  
The Mechanical Connection Kit is an  
NOTICE  
optional kit available through the  
manufacturer.  
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.  
12. Position the collector on the U-channels so that the  
collector overhangs approximately 5 mm (.2") (FIG.  
4-26). Tighten square disk.  
33  
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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  
Figure 4-31 Install Mechanical Connection Kit  
BEND TABS DOWN  
Figure 4-35 Install Sensor Well  
18. Reinstall the collector railing removed in Step 17  
(FIG. 4-32).  
Figure 4-32 Reinstall Collector Railing  
REINSTALL COLLECTOR RAILING  
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  
hex bolts provided in the kit (FIG. 4-33).  
EXPANSION  
SET (HYDRAULIC  
CONNECTION)  
PLUG  
34  
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4 Collector Installation  
(continued)  
SCH A-frame dimensions  
Table 4A Inclined and Non-South Facing Installations  
A
B
c
d
20°  
40°  
60°  
6 ft. 7 in.  
6 ft. 7 in.  
6 ft. 7 in.  
24 in.  
47 in.  
69 in.  
6 in.  
7 in.  
8 in.  
4 in.  
4 in.  
4 in.  
35  
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4 Collector Installation  
Table 4B SCH Mounting Hardware + Hydraulic Connection Kits  
Needed quantities for:  
Part-number Description  
SCH065 SCH090 SCH110 SCH130  
Parallel installation:  
SCA20001 Horizontal aluminum bar 10 ft  
SCA20002 Horizontal aluminum bar 13 ft  
SCA20003 Horizontal aluminum bar 16 ft  
SCA20004 Horizontal aluminum bar 20 ft  
2
2
2
2
SSK20004  
SSK20005  
End bracing kit  
Z-hook kit  
2
2
2
3
2
3
2
3
Inclined (20°,40°,60°) installation:  
SCA20001 Horizontal aluminum bar 10 ft  
SCA20002 Horizontal aluminum bar 13 ft  
SCA20003 Horizontal aluminum bar 16 ft  
SCA20004 Horizontal aluminum bar 20 ft  
SCA20005 Aluminum U-channel 10 ft  
SCA20006 Aluminum U-channel 13 ft  
SCA20007 Aluminum U-channel 16 ft  
SCA20008 Aluminum U-channel 20 ft  
2
3
2
3
2
3
2
3
4
4
4
SSK20001  
SSK20002  
SSK20003  
A-frame 20° inclined  
A-frame 40° inclined  
A-frame 60° inclined  
2
2
2
3
3
3
3
3
3
Hydraulic connection kits: (1 array is max. 2 SCH’s!)  
HYK20001 Hydr. conn. kit 2x 6.5' + plug + sensor well  
HYK20002 Hydr. conn. kit 1x 6.5'/1x 13' + plug + sensor well  
HYK20003 Serial hydr. exp. kit for stacked installation  
HYK20004 Parallel hydr. exp. kit for side by side installation  
HYK20005 Serial hydr. exp. kit for side by side installation  
1x per collector or array  
1x per collector or array  
1x per array  
1x per array  
1x per array  
Mechanical connection kits: (optional for installation!)  
MCK20001 Mechanical conn. kit for side by side installation  
MCK20002 Mechanical conn. kit for stacked installation  
MCK20003 Cover for piping (for side by side installations)  
1x per array  
1x per array  
1x per array  
Gable bracing kits: (required for non-south facing installation!)  
GBK20003 Bracing kit w/ diagonal support  
1x per collector  
36  
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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 hydraulic expansion kits are hydraulic connections  
between collectors in one array. The hydraulic expansion kits  
consist of two (2) nipples with compression rings and unions.  
302°F  
Note: Hydraulic connections and expansion kits are included  
with the substructure material.  
Brazing ONLY, no soldering. When  
brazing you must protect the stainless  
ƽ WARNING  
steel connection to the copper to ensure  
that the temperature does not rise above  
302°F.  
A properly sized expansion tank must  
ƽ WARNING  
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.  
2
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.  
NOTICE  
37  
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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.  
2
Do not exceed 260 ft of collector area. Be aware of pressure drop  
NOTICE  
(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 compensates 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.  
2
Do not exceed 260 ft of collector area. Be aware of pressure drop  
NOTICE  
(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.  
If using a series connection, it is strongly recommended that a calculated pressure drop be done to ensure  
proper pump installation.  
NOTICE  
38  
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5 Hydraulic Connections  
(continued)  
Figure 5-5 Pressure Drop Chart  
MODEL NO.  
SCH065  
RECOMMENDED FLOW (GPM)  
PRESSURE DROP (FT OF HD)  
0.656  
0.872  
1.090  
1.300  
1.06  
1.66  
2.51  
3.59  
SCH090  
SCH110  
SCH130  
The above chart references recommended flow per collector. Lochinvar recommends .01 GPM per square  
foot of collector area in each array.  
NOTICE  
39  
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SCH Collectors Installation & Operation Manual  
6 System Start-up  
Start-up  
Failure to heed these instructions, especially  
ƽ WARNING  
the safety instructions, can result in the  
Check/control water chemistry  
destruction of and defects on the expansion  
tank, endanger persons, and impair the  
operation.  
Do not use petroleum-based cleaning  
ƽ CAUTION  
or sealing compounds in the system.  
Damage to elastomer seals and gaskets  
in the system could occur, resulting in  
substantial property damage.  
Final checks before starting the system  
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.  
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.  
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.  
Freeze protection  
1. Determine freeze protection fluid quantity using  
system water content, following fluid manufacturer’s  
instructions. Remember to include expansion tank  
water content.  
All piping should be properly insulated to  
ƽ WARNING  
avoid freezing and burn potential.  
Filling, flushing and bleeding  
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.  
■
■
■
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 filling connection under the pressure gauge and  
open fill/flush valve.  
3. The freeze protection set points may be lowered when  
freeze protection fluid is used (see the Lochinvar Solar  
Differential Control Manual).  
Connect the flushing hose (return) to the flushing  
connection on the sensor measuring section and open  
fill/flush valve.  
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.  
■
■
■
■
Refer to “Operation, multi-function ball valve and check  
valve” on page 38.  
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.  
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.  
Thermal protection  
Thermal expansion tanks should be sized  
to account for 1.5 times the solar system  
ƽ WARNING  
■
■
■
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.  
circuit volume.  
A properly sized expansion tank must  
ƽ WARNING  
be used to avoid damage to the Solar  
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.  
Thermal System.  
The expansion tank may be hot, ensure  
ƽ WARNING  
scalding does not occur.  
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.  
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  
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SCH Collectors Installation & Operation Manual  
6 System Start-up  
(continued)  
Flat seal screw connections  
■
■
■
■
■
Close the fill/flush valve (forward flow) and switch off the  
filling and flushing pump.  
■ All pre-fitted solar station screw connections are firmly  
tightened in the factory so that they do not need to be  
retightened.  
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 until the solar liquid exits free of air bubbles.  
Torque levels when tightening flat seal screw connections  
using AFM 34 flat seals, s = 2mm.  
Only if collector bleeder is installed: Bleed the system on  
the collector until the solar liquid exits free of bubbles.  
– 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  
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.  
Operation, multi-function ball valve and  
check valve  
■
■
Set the operating pressure to 60 psi as prescribed by the  
system manufacturer.  
■ 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.  
Start up the circulation pump at maximum speed and  
allow liquid to circulate for at least 15 min.  
■ Both flow checks should be opened in order to bleed the  
solar system (thermometer handles in 45° position).  
■
■
Remove the filling station hoses and screw the caps on the  
flushing and filling valves.  
■ 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).  
Check the system again for leaks. Use the red and blue  
thermometer handles to fully open the forward flow and  
return ball valves.  
Figure 6-1 Forward flow multi-functioning instruments  
■
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.  
■
■
Once the installation settings have been completed and  
checked, fit the solar station’s front insulation shell.  
SETTING FOR OPERATIONS,  
FILLING, FLUSHING, DRAINING  
FLOW CHECK CLOSED  
DRAINING  
SERVICE  
BALL VALVE  
CLOSED  
FLOW CHECK OPEN  
BALL VALVE 1/2 OPEN  
Refer to the collector manufacturer’s recommendations for  
minimum flow requirements.  
BALL VALVE OPEN  
Figure 6-2 Return multi-functioning instruments  
Clamp ring screw connections  
■ Cut the copper pipe to length and deburr.  
■ First, slide the clamp ring nut over the pipe, then clamp the  
ring itself.  
■ Insert the prepared pipe into the screw connection until its  
stop is reached.  
SETTING FOR OPERATIONS  
FLOW CHECK CLOSED  
BALL VALVE OPEN  
DRAINING  
FLOW CHECK OPEN  
BALL VALVE 1/2 OPEN  
SERVICE, FILLING FLUSHING  
■ Tighten clamp ring nut by hand.  
BALL VALVE CLOSED  
■ Use open-ended wrench to tighten clamp ring screw  
connection (approximately 33 ft. lb.), retighten if necessary.  
■ When tightening the clamp ring screw connection, use two  
wrenches–using one wrench to prevent the pumping station  
from turning.  
41  
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SCH Collectors Installation & Operation Manual  
7 Maintenance  
Follow the service and maintenance  
Fluid installation  
ƽ WARNING  
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  
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.  
manual and component literature could 2. Extensively corroded existing systems should be cleaned by  
result in severe personal injury, death or  
substantial property damage.  
an industrial cleaning company and all corroded  
components should be replace.  
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.  
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++). Distilled or deionized water is  
recommended.  
ƽ WARNING  
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.  
Turn off power to electrical components  
before 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.  
ƽ WARNING  
Technical data  
Typical Properties of Dowfrost HD Fluid*  
Composition (% by weight)  
Propylene Glycol  
Performance Additives  
94  
6
These maintenance items must be performed annually to  
ensure proper operation of the solar collection system.  
Color  
Fluorescent Yellow  
1.053 - 1.063  
Specific Gravity  
15/15°C (60/60°F)  
Address reported problems  
1. Inspect any problems reported by the owner and correct  
before proceeding.  
pH of Solution  
(50% glycol)  
9.5 - 10.5  
15.0 ml  
Reserve Alkalinity (min.)  
*Typical properties, not to be construed as specifications.  
Complete sales specifications are available on request.  
Freezing and boiling points of Aqueous Solutions  
Freezing  
% Glycol  
Boiling  
Temperature, °F  
by Volume  
Temperature, °F  
26  
19  
8
10  
20  
30  
40  
50  
212  
213  
216  
219  
222  
-7  
-28  
42  
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SCH Collectors Installation & Operation Manual  
7 Maintenance  
(continued)  
Typical properties of Aqueous Solutions+  
(Glycol percentage by volume)  
Physical  
Property  
Temp.  
°F  
30% Glycol  
Solution  
40% Glycol  
Solution  
50% Glycol  
Solution  
40  
180  
325  
40  
0.247  
0.279  
0.268  
0.894  
0.947  
1.002  
5.75  
0.225  
0.249  
0.238  
0.847  
0.916  
0.987  
9.63  
0.204  
0.221  
0.210  
0.794  
0.878  
0.965  
14.28  
1.08  
Thermal  
Conductivity  
2
Btu/(hr•ft )(°F/ft)  
Specific Heat,  
Btu/(lb•°F)  
180  
325  
40  
Viscosity,  
Centipoise  
180  
325  
40  
0.68  
0.85  
0.31  
0.39  
0.40  
65.30  
62.60  
57.89  
66.03  
63.09  
58.18  
66.68  
63.50  
58.41  
Density,  
3
(lb/ft )  
180  
325  
Solar circuit  
Collector  
1. Verify all system components are correctly installed  
and operational.  
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.  
2. Check for leaks - inspect all water lines for signs of  
leakage and correct any problems found.  
3. Visually inspect the collector piping to ensure that there  
are no leaks.  
3. 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.  
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  
4. Check Relief Valve - Inspect the relief valve and lift the  
lever to verify flow.  
1. Check to ensure that the pump station is in working order  
and creates the minimum flow recommended in this  
manual.  
Before operating any relief valve ensure  
that it is piped with its discharge in a safe  
ƽ WARNING  
2. Check control sensors to ensure that they are fully inserted  
into the appropriate sensing well.  
area to avoid severe scald potential.  
5. Check Freeze Protection Fluid - ensure that the heat  
transfer fluid has the proper concentration of glycol as  
recommended in this manual.  
3. See pump manufacturer’s recommendation for required  
maintenance procedure.  
Control settings  
6. Remove any air that may have accumulated in the  
system.  
1. Check sensor readings to ensure that the values being  
displayed are accurate.  
7. Check Flow Rate  
-
ensure that the minimum  
recommended flow rate can be achieved as described in  
this manual.  
2. Check control settings to ensure that they are programmed  
per the control specification.  
3. See controller manufacturer’s recommendations for the  
8. Visually inspect the dirt separator (if installed) and clean  
if necessary.  
required maintenance procedure.  
43  
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Revision Notes: Revision A (ECO #C06510) initial release.  
SCH-I-O Rev A  
9/10  
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