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SOLAR
SOL202SIP – SOL808SIP
Slate Integrated Roof Kit
Installation Manual
SOL202SIP – SOL808SIP - Slate integrated roof kit manual
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0 Contents
0 CONTENTS 2
1 BEFORE YOU START 3
1.1 GENERAL 3
1.2 COMPETENCE 3
1.3 HEALTH AND SAFETY 3
1.4 RISK ASSESSMENT 5
1.5 TOOLS REQUIRED 5
1.6 EARTHING AND LIGHTNING PROTECTION 5
1.7 PIPE WORK 5
2 SCOPE OF DELIVERY 6
3 PRODUCT FEATURES AND DESCRIPTIONS 12
4 COLLECTOR CONNECTIONS 12
4.1 SINGLE COLLECTOR PORTRAIT CONNECTION 12
4.2 MULTIPLE COLLECTOR PORTRAIT CONNECTION 13
INSTALLATION 14
5 OPERATION & MAINTENANCE 56
6 SPARE PARTS 57
7 DECOMMISSIONING 58
8 TECHNICAL DATA 58
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1 Before you start
1.1 General
Thank you for choosing a Dimplex product. We ensure you that every effort has been
made at the design, manufacture and delivery stages to produce a product with superi-
or quality. We will provide you with the best possible support throughout the product’s
lifespan.
As part of ongoing product development and improvement Dimplex reserves the right to
undertake changes to the product without prior notice. Great care has been taken to
ensure this manual was correct at the time of print. Should you however discover any
issues with the information contained therein please do not hesitate to contact your
vendor.
We strongly recommend reading the whole contents of this manual before commencing
the work.
1.2 Competence
Dimplex products have been designed and manufactured to the current relevant standards and under stringent quality control procedures. It is therefore imperative that the
product is only installed by a:
- trained and
- competent
person as defined in the relevant regulations. Dimplex does not accept any liability for
damage done to persons or property resulting from undue handling and usage of this
product.
All regulations current at the time of installation are to be considered alongside the content of this manual as they form the code of best practice.
The warranty of this product is linked to the ability to prove that the product was installed, commissioned and maintained:
- by a competent person
- in accordance with Dimplex instructions and the current relevant regulations and legislation
- the product being registered with Dimplex at the time of installation using the form in
the Dimplex On Site Guide
- records showing the date of maintenance in accordance with the maintenance schedule as detailed in the On Site Guide
1.3 Health and Safety
The installation of this product is subject to the Health and Safety at Work Act. It is
your responsibility to ensure that the transport, storage, installation and operation of
the product is carried out in a safe manner.
Dimplex will not accept any liability due to damage caused to people or property resulting from negligence or not adhering to the relevant Health and Safety practices.
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Figure 1: Safety information
The manufacturer hereby guarantees to take back
products identif ied with an eco-label and to recycle
the materials used. Only the heat transfer medium
specifi ed may be used!
Wear a helmet when carrying out installation
work!
Wear protective goggles whe n drilling and
handling coll ectors!
Wear cut-proof safety gloves when mounting
collectors!
Wear safety shoes when carrying out installation
work!
1 m ................voltages up to 1000V
2 m ................voltages from 1000V to 11000V
3 m ................voltages from 11000V to 22000V
4 m ................voltages from 22000V to 38000V
> 5 m in case of unknown voltages
Whenever you are near live overhead electric cables
where contact is possible, only work if:
- it is ensured that they are voltage-free and this
is secured for the duration of work.
- the live parts are secured by covering them or
cordoning them off.
- the prescribed safe ty distances are maintained.
Voltage radius:
If non-personal fall protection or fall-arrest systems
are not provided, working without the use of
suitable safety harnesses may lead to fall s from
heights and therefore cause serious or lethal
injuries!
Only lean ladders against secure points. Secure
ladders in traffi c areas by suitable cordoning.
Ladders not properly secured against sinki ng in,
slidi ng or falling over may lead to dangerous fall s!
Contact with live electric overhead cables can be
lethal.
If non-personal fall protection or fall-arrest systems
cannot be installe d for technical reasons, all
personnel must be secured by means of suitable
safety harnesse s!
Never use damaged ladders (e.g., woode n ladders
with spli t runners or rungs, or bent or buckled
metal ladders). Never try to repair broken runners,
rungs or steps on wooden ladders!
Only use safe ty harnesses (safety belts, lanyards and
straps, shock absorbers, fall arresters) that were
tested and certifi ed by authorized testi ng bodies.
Ensure that ladders are put up safely. Observe the
correct leaning angle (68° - 75°). Prevent ladde rs
from slidi ng, falling over or sinking into the ground
(e.g. usi ng wider feet, feet suited to the ground or
hooking devices).
Safety precautions: Bef ore commencing mounting
work on roofs, it must be ensured in all cases that the
non- personal fal l protection and fall-arrest systems
required by DIN 18338 (Roof Covering and Roof
Sealing Works) and DIN 18451 (Scaffolding Works) are
in place. See also Builders‘ Protection Ordinance
[Bauarbeiterschutzve rordnung], Federal Law Gazette
340/ 1994, paragraphs 7-10! Other country-specifi c
regulations must be observed!
Safety harnesses should be fixed above the users
whenever possible. Safety harnesses shoul d only
be fastene d to sufficientl y load-bearing structures
or fixing points!
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1.4 Risk assessment
The compilation of a risk assessment is strongly recommended before installing the
product. The following areas require particular consideration in addition to the information required by the Health and Safety at Work Act.
- scalding: where appropriate or required by law a thermostatic mixing valve is to be
fitted to the hot water outlet of the cylinder
- explosion: the unit is fully equipped with all relevant safety equipment to comply with
current regulations. The correct design and function has been verified by independent
third party testing. The correct application thereof is the responsibility of the competent installer.
- water borne organisms (i.e. Legionella): if applicable a risk assessment should be
carried out following the recommendations outlined in the Approved Code of Practice
L8.
- the user preference must be considered when commissioning the system, in particular
when adjusting the solar and auxiliary system temperature and timer settings.
1.5 Tools required
It is recommended that the below list of tools be used when installing the integrated
roof kit.
- 2 people required for installation
- Measuring tape
- Hammer
- Drill
- Adjustable pliers
- TX 25 x 25mm torque bit
- Spirit level
- Plumb line
- Additional wood (as required)
- Pop-rivet gun
In addition to the above tools it may be required to wear suitable safety gloves upon
installation as the kit consists of sheet metal which may cause cuts if care is not taken
during handling of the product.
1.6 Earthing and Lightning Protection
If a lightning arrester is available, the collector frame should be connected to it. This
may be performed using the collector frame, because the slot for mounting on the reverse side of the collector is ideally suited for fixing a thick cable. If no arrester is available, the potential equalization is carried out using a connection of a cable at the
pipe(s) which are led into the building. Please consult local regulations to ensure adherence.
1.7 Pipe Work
The pipe work from the collector to the pump unit and from the pump unit to the cylinder is to be all metal. The joints have to be high temperature resistant (compression or
high temperature flat seal). For more information please see Technical Manual.
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The connections of a mounted solar collector/collector array may become excessively
hot so care must be taken to avoid burns when working around collectors that are exposed to the rays of the sun.
2 Scope of delivery
Please check the contents and the condition of your delivery before signing the delivery
documentation against the content shown in Table 3 and mark as appropriate. Contact
your supplier immediately for any missing or damaged parts. Claims for missing or
damaged parts after signing for the delivery documentation will not be accepted.
Table 1: Overview of flashing components part 1
These mounting instructions
only apply to the installation of
the in roof flashing and the
fixation of the collectors!
Useable from 20° roof pitch!
Part No. Spare No. Descripti on
P31 74021 left front part
P32 74022 centre front part
P33 74023 right frontpart
P34 74220 lateral fixation bracket
P35 74222 centre fixation bracket
P36 74211 left lateral part
P37 74213 right lateral part
P38 74001 left collector cover
P39 74002 centre collector cover
P40 74003 right collector cover
P41 74230 connection strip
P42 74090 wooden wedge 600 mm
P43 74091 wooden wedge 1200 mm
P44 74061_SL left back part
P45 74062 centre back part
P46 74063_SL right back part
P47 74070 back part connection
P51 74224 slate lateral part
SOL202COL
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Table 2: Overview of flashing components part 2
Useable from 20° roof pitch!
P50
P43
P51
P51
P34
P34
P37
P48
P34
P49
P36
Part No. Spare No. Description
P48 74024 front part single collector
P34 74220 lateral fixation bracket
P36 74211 left lateral part
P37 74213 right lateral part
P49 74004 single collector cover
P43 74091 wooden wedge 1200 mm
P51 74224 slate lateral part
P50 74064_SL back part single collector
SOL202COL
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Table 3: Scope of components
# Letters D to N are for On-Roof Installation and Integrated Tile kits
SOL202SIP
A 1 2 3 4
B 1 1 1 1
P01
22mm x 90° elbow
x2
P02 22mm stop e nd x2
C 0 1 2 3
P03 22mm x 22mm straight compressio n x2
#O 1 0 0 0
P48 front par t single collector
P34 lateral fixation bracket
P49 single co llector cover
P36 left latera l part
P37 right latera l part
P43 wooden wedge 1200mm
P50 back part single collector
P51 slate lateral part
P 0 1 1 1
P31 left front pa rt
P33 right front part
P34 lateral fixation bracket
P35 centre fixation bracket
P38 left collector cove r
P40 right collec tor cove r
P36 left latera l part
P37 right latera l part
P41 connection strip
P42 wooden wedge 600mm
P43 wooden wedge 1200mm
P44 left back part
P46 right back part
P47 back part connec tion
Q 0 0 1 2
P32 centre front part
P35 centre fixation bracket
P39 centre collector cover
P41 connection strip
P43 wooden wedge 1200mm
P45 centre back part
P47 back part connec tion
SOL808SIP
No. Des ignatio n
Sola r fla t plate collecto r 2.02m ²
Hydr aulic conne ction set
Hydr aulic inter conne ction set
Slate integ rate d se t 2.02m²
Slate integ rate d se t 4.02m²
Slate integ rate d se t exte nsion
SOL404SIP
SOL606SIP
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Table 4: Images of components part 1
5
14
16
P31
P32
P33
P34
P35
P36
P37
P38
P39
P40
P41
P42
P43
P44
P45
17
P46
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Table 5: Images of components part 2
18
19
20
21
P47
P48
P49
P50
P51
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Table 6: Scope of components for generic bag of fittings
Table 7: Images of components in generic bag of fittings
No. Art. Code +74357 Generic fitting bag Content
1 Sealing screw 4.5 x 25mm anthracite 34
2 Torque bit TX25 x 25mm 1
3 Fixation bracket (for lateral parts) 10
4 Galvanise d nails 2.5 x 25mm 60
5 Rivet anthracite 4.1mm 2
6 Chipboard scre w SK TX 25 5.0 x 30mm 32
7 Chipboard scre w TX25 5.0 x 50mm 6
8 Chipboard scre w TG SK TX25 5.0 x 70mm 6
9 Lateral fixation bracket (for collector) 8
10 Centre fixation brack et (for collector) 4
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3 Product features and descriptions
The Dimplex Slate Integrated Roof kit offers a unique solution for mounting solar thermal collectors to the roof of a building. The concept of the product is to make the installation of the collectors a quick and simple process.
The Slate Integrated Roof Kit can cater for 2m² up to 8m² of collector area and comes
in three variations, 2m² kit, 4m² kit and extension kit.
The product consists of various aluminium flashings and fixings that seal the collector
against the roof covering in an aesthetically pleasing way. The collector is an integral
part of the assembly and forms part of the weather tightness of the roof.
4 Collector connections
Due to its four connections, the collector offers a wide choice of connection options.
Ensure that no part of the collector array or collector in the array is short circuited by
following these instructions.
When planning the collector array, the position of the various connection parts must be
in accordance with the diagrams, also pay attention to the position of the highlighted
sensor pocket position.
Table 8 illustrates the components required to make all the collector connections.
Table 8: Collector connection components
4.1 Single collector portrait connection
When installing a single collector installation, there is one connection option available.
The sensor must always be installed at the top of the collector and on the connection
where the heat transfer fluid leaves the collector.
Figure 2 illustrates the left hand side connection option that is applicable only to a single portrait collector connection.
Part No Image Description
P01 22mm x 90° elbow
P02 22mm stop end
P03 22mm x 22mm straight compression
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Figure 2: Left hand side connection option for single collector only
4.2 Multiple collector portrait connection
When installing multiple collectors, (2 up to 4), component P03 is used to connect one
collector to the next.
Figure 3: Multiple collector portrait connection
The sensor must always be installed at the top of the collector on the connection flow of
the system.
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Installation
NB: Ensure all the laths / roof battens under the area of the installation are in good
condition. Replace any damaged, week or broken laths and double nail or screw to the
rafters.
Figure 4: Mounted dimensions
240 mm
1225 mm
200 mm
SOL202COL
2390 mm
4100 mm
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Step: 2
90 mm
280-300mm
P31
P32
P33
P48
Step: 1
For the stabilisation of the front
parts mount an additional roof batten as shown in Step 1 and 2.
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Step: 4
6 x
P31
Step: 3
P31
Place the left front part on
the roof batten and fix it
with 12 sealing screws
(Step 4 and 5).
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Step: 6
P31
P31
P32
P32
Step: 5
6 x
P31
Place the centre front part on the
roof batten and plug it together with
the left front part until the first hole
on the centre part fits to the right
hole on the left part (Step 6).
In the case of a 2-collector installation please continue with Step 10.
Ensure the aluminium edges of both
parts are well aligned and the apron
forms a continuous overlapping
barrier to avoid any water ingress.
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Step: 8
6 x
P31
P32
Step: 7
P31
P32
Fix the centre front part with 12
sealing screws Step 8 and 9.
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Step: 10
P32
P32
P33
P33
Step: 9
6 x
P32
Place the right front part on the roof
batten and plug it together with the
centre (left) front part until the first
hole on the right front part fits to
the right hole on the centre front
part (Step 10).
Then fix it with 12 sealing screws
(Step 11).
Ensure the aluminium edges of both
parts are well aligned and the apron
forms a continuous overlapping
barrier to avoid any water ingress.
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Step: 12
Step: 11
12 x
P33
Place the first collector. Fit it into
the flaps on the front part as shown
in Step 13 and 14.
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Step: 14
P31
Step: 13
P31
P32
P33
P48
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Step: 16
5x30
mm
P34
P34
P34
P34
P34
Step: 15
Marking for
collector
Marking for
slate
Place the collector so that it
is aligned with the marking
on the left front part.
Fix the collector on the left
(outer) side with 4 lateral fixation
brackets.
Place the brackets to the collector
as shown in Step 17 and fix every
lateral fixation bracket with 2 No.
5x30mm wood screws.
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Step: 18
5x30
mm
P35
P35
P35
P35
P35
Step: 17
P34
Place 4 centre fixation brackets
to the collector as shown in Step
19. Fix every bracket with 2 No.
5x30mm wood screws.
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Step: 20
P03
P03
Step: 19
P35
Position 22 x 22mm straight
compression fittings on 1st collector
loosely before fitting 2nd collector.
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Step: 22
55mm
P35
Step: 21
Allow the 2nd collector to rest into the
flaps offset slightly to the right. Gently
taking the weight off the collector,
move it to the left, ensuring the collector engages in the centre fixation
brackets of the 1st collector (Step 22)
and into the flaps of the centre front
part (Step 13) and the loosely fitted
compression fittings (Step 20).
The distance between the collectors
should be about 55mm and this should
ensure a neat fit with the centre fixation brackets (Step 22).
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Step: 24
5x30
mm
P35
Step: 23
Fix every centre fixation bracket
with 2 additional 5x30mm wood
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Step: 26
P03
P03
Position 22 x 22mm straight compression fittings on 2nd collector
loosely before fitting 3rd collector.
Step: 25
5x30
mm
P35
P35
P35
P35
P35
Place 4 centre fixation brackets
on the right side of the 2nd collector (Step 19) and fix every
bracket with 2 No. 5x30mm
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Step: 28
5x30
mm
P35
Step: 27
Repeat steps 20 to 24
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Step: 30
P01
P02
sensor
P36
Step: 29
5x30
mm
Fix the right (outer) side of the
collector with 4 lateral fixation
brackets.
P34
P34
P34
P34
P34
P34
Fit collector connections and sensor
and pressure test and insulate.
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Step: 32
P36
Step: 31
P36
Fit the left lateral part to the collectors profile as shown in Step 32.
On the lower side the upper perforation should be aligned with the collectors profile as shown in Step 34.
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Step: 34
Align the upper perforation
with the collector edge!
P36
P31
Step: 33
P36
P31
Bend the lateral part along
the perforation as shown
in Step 34 and 35.
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Step: 36
P31
P36
Step: 35
P36
P31
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Step: 38
Fit collector connections and pressure test and insulate.
P02
P01
Step: 37
P36
P36
P31
Fix the left lateral part with
a nail on every roof batten.
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Step: 40
P36
P31
P38
Step: 39
P37
P33
Mount the right lateral part
in the same way as the left
one.
Mount the left collector cover
and fit into the collector profile
as shown in Step 41 and 42.
Important!
Check the engraved number on the cover.
Cover for left collector: 74001
Cover for centre collector: 74002
Cover for right collector: 74003
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Step: 42
P31
P36
P38
Step: 41
Step
41a
Cover parts opening
Collector ventilation
opening
P38
P39
P40
P49
P31
P32
P33
P48
P38
P39
P40
P49
Important!
Always check that the opening on the
cover fits the ventilation opening of the
collector. See Step 41a.
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Step: 44
P39
P32
Step: 43
P32
P39
Important!
Check the engraved number on the cover.
Cover for left collector: 74001
Cover for centre collector: 74002
Cover for right collector: 74003
Mount the centre collector cover
and fit into the collector profile
as shown in Step 41 and 44.
Important!
Always check that the opening on the
cover fits the ventilation opening of the
collector. See Step 41a.
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Step: 46
P41
P41
Step: 45
P40
P33
P37
Important!
Check the engraved number on the cover.
Cover for left collector: 74001
Cover for centre collector: 74002
Cover for right collector: 74003
Mount the right collector
cover following the same
procedure as for the left
and centre cover
Important!
Always check that the opening on the
cover fits the ventilation opening of the
collector. See Step 41a.
Important!
Before fitting insulate pipes and
connections
Mount the collection strips
between the collectors.
Just plug them into the collector profiles as shown in Step
47.
You can use the connection
strips in both directions (there
is no upper or lower side).
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Step: 48
11
11
11
Align upper
perforation
with collectors
edge!
P41
P41
P41
Step: 47
P41
Place the connection
strips so that the upper
perforation on the lower
side is aligned with the
collectors edge.
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Step: 50
11
11
11
P41
P41
P41
Step: 49
11
11
11
P41
P41
P41
Bend the connection strip
along the perforations on
the lower side.
Bend the connection strip
along the perforations on
the upper side.
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Step: 52
12
12
13
13
Place the wooden wedges
on the upper side of the
collectors as shown in
Steps 53 and 54.
P42
P42
P43
P43
Step: 51
Additional
roof battens
Before the mounting of the
wooden wedges and the back
parts, mount additional roof
battens to stabilise the back
parts and the wooden wedges
as shown in Step 51.
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Step: 54
12
12
13
13
P42
P42
P43
P43
Step: 53
13
P42
P43
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Step: 56
6
1
P31
P36
Step: 55
5x50
mm
5x70
mm
Fix every wooden wedge
with 2 No. 5x50mm and 2
No. 5x70mm wood screws.
Cover the left front part
with soakers (Step 56 and
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Step: 58
14
6
1
P31
P36
P51
Step: 57
1
6
P36
P31
Fit the slate lateral part
into the left lateral part as
shown in Step 59 and
place it as shown in Step
60.
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Step: 60
14
6
P51
P36
Step: 59
Soaker
P51
P36
Fix the slate lateral part with a
nail on the roof batten.
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Step: 62
6
P36
Step: 61
14
Cover the slate lateral part
(Step 61 and 62).
6
P51
P36
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Step: 64
14
6
P51
P36
Step: 63
14
6
P51
P36
Repeat steps 58-62 until
you reach the top of the
lateral part (Step 66).
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Step: 66
Step: 65
6
P36
SOL202SIP – SOL808SIP - Slate integrated roof kit manual
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Step: 68
7
3
P33
P37
Step: 67
6
14
P51
P36
Mount the right side in the
same way as the left one.
If necessary to avoid a collision with the left back part,
cut the last slate lateral part
with a plate shear (Step 67).
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Step: 70
P44
P45
P46
P50
Step: 69
15
6
P44
P36
Fit the left back part to the collectors profile as shown in Step 70
and place it as shown in Step 71.
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Step: 72
15
6
3x
P44
P36
Step: 71
15
6
P36
P44
Fit the left back part with 3 No.
sealing screws.
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Step: 74
2x
16
15
11
P41
P44
P45
Step: 73
16
15
11
Fit the centre back part to the collectors profile as shown in Step 70.
In the case of a 2 collector installation please continue with Step 75.
P44
P45
P41
Fix the centre back part with 2
No. sealing screws.
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Step: 76
17
16
7
2x
P37
P46
P45
Step: 75
17
16
11
7
P41
P45
P46
P37
Fit the right back part with 3 No.
sealing screws.
Fit the right back part to the collectors profile as shown in Step 67
and place it as shown in Step 73.
SOL202SIP – SOL808SIP - Slate integrated roof kit manual
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Step: 78
17
7
+
P37
P46
Step: 77
15
Fix the left and the right back part
with a rivet (Step 77 and 78).
6
+
P36
P44
SOL202SIP – SOL808SIP - Slate integrated roof kit manual
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Step: 80
18
18
16
15
17
11
11
P41
P41
P47
P47
P44
P45
P46
Step: 79
18
18
17
16
15
11
11
Place the back part connections
on the back part as shown in Step
80.
P41
P41
P47
P47
P44
P45
P46
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Step: 82
Step: 81
4x
18
P47
Fix every back part connection
with 4 No. sealing screws.
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5 Operation & Maintenance
Connections should be double checked prior to commissioning of the system. Please
refer to the On Site Guide for guidance on how to commission and operate the solar
system.
Risk of scalding! Before carrying out any maintenance work on the system ensure that
it is safe to do so. The solar system must be decommissioned before work can be carried out. Refer to the On Site Guide for a maintenance schedule of the complete system.
Check for leaks at the collector connections and other connections in the system. Also
ensure pipe insulation is intact and in good condition.
Step: 83
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6 Spare Parts
Table 9: Spare Parts
Part No. Spare No. Description
P31 74021 left front part
P32 74022 centre front part
P33 74023 right frontpart
P34 74220 lateral fixation bracket
P35 74222 centre fixation bracket
P36 74211 left lateral part
P37 74213 right lateral part
P38 74001 left collector cover
P39 74002 centre collector cover
P40 74003 right collector cover
P41 74230 connection strip
P42 74090 wooden wedge 600 mm
P43 74091 wooden wedge 1200 mm
P44 74061_SL left back part
P45 74062 centre back part
P46 74063_SL right back part
P47 74070 back part connection
P48 74024 front part single collector
P49 74004 single collector cover
P50 74064_SL back part single collector
P51 74224 slate lateral part
R02894-1 R02894-1 manual
74357 bag of fittings
SOL202COL
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7 Decommissioning
Risk of scalding! Before carrying out any decommissioning work on the integrated roof
kit, please ensure the solar system has been decommissioned.
If the product is being recycled, local waste disposal laws must be adhered to.
8 Technical Data
Table 10: Collector technical data
Figure 5: Pressure loss collector for anti-freeze / water mixture (40% / 60%) at a thermal conduct-
ing temperature of 50° C.
Weight e mpty
33 kg
Dimensions
- length
1730mm
- width 1170mm
- height
83mm
Heat trans fer medium
SOLHT20
Max o p. pres. [bar] 10
Tilt angle
- min 20°
- max 75°
Collector a rray [m²] 2 4 6 8
Cu pipe [mm] 15 15 22 22
Wind / snow load [kN/m²] 1.9 1.9 1.9 1.9
SOL202SIP – SOL808SIP - Slate integrated roof kit manual
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