Lochinvar SCH Installation Manual

SCH-I-O Rev A

Installation & Operation

Manual

SCH Collectors

 WARNING:

This manual must only be used by a qualified heating installer/service technician. Read all instructions before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. LOCATION

Array Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Handling and Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What to Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3. ROOF ATTACHMENT INSTALLATION

Roof Attachment Types . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Roof Attachment Quantities for SCH Collectors . . . . . . . 11

Roof Attachment Spacing Distance . . . . . . . . . . . . . . . . . 12

Installation of Roof Attachment Types . . . . . . . . . . . . 13-27

4. COLLECTION INSTALLATION

Horizontal Bar Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Spacing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SCH Parallel Mounting Instructions . . . . . . . . . . . . . . 29-31

SCH Inclined / Non-South Facing Mounting Instructions 32-34

SCH Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 35

SCH Mounting Hardware + Hydraulic Connection Kits . . 36

5. HYDRAULIC CONNECTIONS

SCH Connections Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Hydraulic Expansion Kits . . . . . . . . . . . . . . . . . . . . . . 37-38

Pressure Drop Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6. SYSTEM STARTUP

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Filling, Flushing and Bleeding . . . . . . . . . . . . . . . . . . . . . 40

Clamp Ring Screw Connections . . . . . . . . . . . . . . . . . . . 41

Flat Seal Screw Connections . . . . . . . . . . . . . . . . . . . . . . 41

Operation, Multi-function Ball Valve & Check Valve . . . . 41

7. MAINTENANCE

Fluid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

System Design Considerations . . . . . . . . . . . . . . . . . . . . 42

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Solar Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Pump / Control Function . . . . . . . . . . . . . . . . . . . . . . . . . 43

Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

1 Introduction

SCH Collectors Installation & Operation Manual

The SCH collector is suitable for parallel installations and inclined installations on pitched and flat roofs as well as freestanding on the ground. It is available as a single-piece large collector in sizes ranging from 65 to 130 ft

with inlet and outlet connections of .86" in diameter. Suitable mounting systems are available for various types of roofing. The SCH collector is delivered in standard lengths of 9'-10" to 19'-7" and a height of 6'-7", resulting in gross surface areas between 65 and 130 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 SCH090 SCH110 SCH130 Quantity of Glass Panels 3 4 5 6 Gross area 65.66 ft Aperture surface area 58.45 ft Absorber surface area 59.85 ft External Dimensions (L x W)

6'-7" x 9'-10" 6'-7" x 13'-2" 6'-7" x 16'-4" 6'-7" x 19'-7"

87.19 ft

77.93 ft

79.76 ft

Weight Ratings 309 lbs. 411 lbs. 513 lbs. 614 lbs.

SCH mounting hardware + hydraulic connection kits

Part-number Description

Parallel installation:

SCA20001 Horizontal aluminum bar 10 ft 2 SCA20002 Horizontal aluminum bar 13 ft 2 SCA20003 Horizontal aluminum bar 16 ft 2 SCA20004 Horizontal aluminum bar 20 ft 2 SSK20004 End bracing kit 2222 SSK20005 Z-hook kit 2333

108.72 ft

97.95 ft

99.67 ft

Needed quantities for:

SCH065 SCH090 SCH110 SCH130

130.24 ft

116.90 ft

119.59 ft

Inclined (20°,40°,60°) installation:

SCA20001 Horizontal aluminum bar 10 ft 2 SCA20002 Horizontal aluminum bar 13 ft 2 SCA20003 Horizontal aluminum bar 16 ft 2 SCA20004 Horizontal aluminum bar 20 ft 2 SCA20005 Aluminum U-channel 10 ft 3 SCA20006 Aluminum U-channel 13 ft 3 SCA20007 Aluminum U-channel 16 ft 3 SCA20008 Aluminum U-channel 20 ft 3 SSK20001 A-frame 20° inclined 2334 SSK20002 A-frame 40° inclined 2334 SSK20003 A-frame 60° inclined 2334

Hydraulic connection kits: (1 array is max. 2 SCH’s!)

HYK20001 Hydr. conn. kit 2x 6.5' + plug + sensor well 1x per collector or array HYK20002 Hydr. conn. kit 1x 6.5'/1x 13' + plug + sensor well 1x per collector or array HYK20003 Serial hydr. exp. kit for stacked installation 1x per array HYK20004 Parallel hydr. exp. kit for side by side installation 1x per array HYK20005 Serial hydr. exp. kit for side by side installation 1x per array

Mechanical connection kits: (optional for installation!)

MCK20001 Mechanical conn. kit for side by side installation 1x per array MCK20002 Mechanical conn. kit for stacked installation 1x per array MCK20003 Cover for piping (for side by side installations) 1x per array

Gable bracing kits: (required for non-south facing installation!)

GBK20003 Bracing kit w/ diagonal support 1x per collector

1 Introduction

SCH Collectors Installation & Operation Manual

How it works...

1. Housing

Powder coated (RAL7016)aluminum frame structure with PU rigid foam and an aluminum rear wall.

2. Cover

Prismatic solar safety glass, .15" thick, for maximum light transmission.

3. Insulation

.76" heat resistant, special PU rigid foam and 1.57" mineral wool with high pressure resistance, emission free, non flammable.

4. Absorber

Full surface absorber, laser welded with highly-selective PVD coating (PVD = Physical Vapor Deposition), serpentine flow.

5. Collector seal

Aluminum profile system with double temperature and UV resistant silicone seals, emission free.

SCH Collector

6. Inlet connection

Copper pipes, .86" diameter.

7. Outlet connection

Copper pipes, .86" diameter.

8. Absorber coils

10 mm copper, serpentine arrangement.

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.

10. Sensor well

For measuring the collector outlet temperature directly in the fluid. The sensor well can be installed on the outlet connection as shown on the collector label. The sensor must be inserted up to the end of the sensor well.

11. Plug

This plug is used on the end collector of each array to complete the water flow path.

1 Introduction (continued)

SCH Collectors Installation & Operation Manual

Before getting started on your installation be sure to carefully read the preparation instructions in this section.

 WARNING

NOTICE

 CAUTION

Installer – Read all instructions, including this manual before installing. Perform steps in the order given.

Have your collector(s) serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

When calling or writing about the collector – Please have the collector model and serial number.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with the collector) does not apply to collectors improperly installed or improperly operated.

• You must comply with local regulations, laws and standards of the local governing authority.

• The frame must be capable of withstanding the local snow and wind loads and permit the correct anchoring of the collectors in accordance with all applicable local regulations.

• The load bearing capacity of the roofing and the frame shall be specially checked or analyzed by a structural engineer.

• The number of mounting brackets specified by the Lochinvar/TiSun manuals and parts sheets is based on an average collector load bearing per square foot. The maximum permissible 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.

 CAUTION

Lochinvar/TiSun Solar Thermal Collectors are not specifically designed for drain back installations. Consult the factory if drain back utilization is necessary.

• The mounting substructure must be capable of withstanding the local snow and wind loads and permit correct anchoring of the collectors.

• To avoid damage to the collectors and mounting frames from snow sliding off the roof, additional snow guards must be placed in sufficient numbers around the collectors and above the collectors.

• The collectors must be linked with a lightning arrester system and/or the building’s ground system by a licensed electrician.

• Hydraulic connection of the collectors must be performed according to Lochinvar/TiSun specifications.

• The collector connections must not be damaged, soiled or misaligned. Take care during transport, installation, and connection of the modules. Do not remove the header protection caps at the top and bottom connections of the 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.

• Always connect the collector outlet and inlet flow to each other diagonally, please follow the connection example (see FIG. 1-1 on page 6).

• Do not twist the headers when screwing the connections together. Hold threaded connection in the desired position and tighten clamping ring union nut to torque.

• Roof penetrations for solar piping must

be adequately sealed against water ingress.

• Use only the original sensor well supplied.

• Use only high temperature and glycol pipe sealing materials.

All piping should be properly insulated to avoid freezing and/or burn potential.

1 Introduction

SCH Collectors Installation & Operation Manual

NOTICE

• Check the materials for any damage sustained in transport and describe any damage in writing on the packing slip where necessary. This is important to process any needed freight or delivery damage claims.

• Carefully read through the relevant installation instructions before starting the installation and follow each step.

• Use only the original mounting components.

• Stainless steel screws may not be used again once they have been removed (because of the possibility of breaking).

• Any conversion or modification of the Lochinvar/TiSun product not expressly approved in writing by the manufacturer shall void the warranty.

• No liability can be accepted for damage resulting from failure to observe the installation instructions.

 WARNING

Figure 1-1 Connection Diagram

A properly sized expansion tank must be used to avoid damage to the Solar Thermal System.

If copper pipe is being used, all joints MUST BE brazed, no soldering allowed.

 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.

Only authorized solar companies familiar with our products may handle them.

There is a risk of injury when handling collectors and mounting accessories as these have sharp edges.

The collector becomes very hot in the sunlight. There is a risk of burn.

Comply with all safety regulations and applicable OSHA requirements.

Check the load bearing capacity and stability of the substructure onto which the collector is to be installed and will need to be accessed during the installation process.

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

Figure 2-2 Multiple Array Piping

PARALLEL SIDE BY SIDE

PARALLEL WITH BALANCING VALVES

(ON ROOF ONLY)

SERIES SIDE BY SIDE

2 Location

Installation positions

SCH Collectors Installation & Operation Manual

Figure 2-3 SCH Parallel Installations

min. 15° - max. 70°

Figure 2-5 SCH Freestanding Installations

Figure 2-4 SCH Inclined Installations

20°/40°/60°

min. 15° - max. 70°

NOTICE

For best performance, it is recommended that the collectors face true south.

It is not recommended for the collector field to deviate any further than 45° from true south.

min. 15° - max. 70°

NOTICE

Collector incline should be at least 15° and no more than 70° for best performance.

Avoid installation in shaded areas. Shaded areas will reduce the performance of the solar collectors.

2 Location (continued)

Handling and storing

 WARNING

 CAUTION

NOTICE

• Installation of LOCHINVAR/TiSun 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.

• Danger area has to be closed.

• Put ladders up properly and check stability.

• Check the under roof construction on the building before installation.

SCH Collectors Installation & Operation Manual

 WARNING

• 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.

• 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.

 WARNING

• Avoid rotating movements of the load through wind. Secure load before lifting.

What to avoid

 CAUTION

• Only move collectors on the given fixing loops.

NOTICE

Figure 2-6 Crane Transportation Connection Points and Positioning

< 30°

6.5 ft.

• Collectors are to be located such that eventual sliding of snow and ice does not endanger any person.

• See FIG. 2-6 for crane transportation connection points and positioning.

< 30°

6.5 ft.

< 30°

6.5 ft.

< 30°

8.5 ft.

SCH Collectors Installation & Operation Manual

3 Roof Attachment Installation

Roof attachment types

Table 3A Roof Fastenings - Parts

SOLAR ROOF MOUNTS

Part #

SRM20001

SRM20003

SRM20004

SRM20005

SRM20006 CLAMP, JOINT XX

Lochinvar

Name

BOLT,

DOUBLE

HANGER

ANCHOR,

RAFTER, STD

ROOF TILE

ANCHOR,

RAFTER, TALL

ROOF TILE

HOOK, FLAT

TILE

Installation Type

Parallel Inclined Free-

standing

XX X13

See

Page

Description

Stainless steel attachment for universal heavy duty installations, on parallel and inclined roofs and freestanding installations on sufficiently anchored bases.

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.

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.

Stainless steel attachment for parallel installations on plain tile, slate, and flat cement tiled roofs with pitches in excess of 30 degrees.

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.

SRM20007

SRM20008

SRM20009

SRM20010

SRM20012

SRM20013

SRM20014

SRM20015

PLATE,

FLANGE,

SHINGLE, STD.

PLATE,

FLANGE,

SHINGLE,

RAISED

BOLT,

ANCHOR,

CONCRETE W/

ADJ

BOLT,

ANCHOR,

CONCRETE

KIT, UNIV

CABLE

SECURING

ATTACHMENT,

ROOF CORR

METAL

ATTACHMENT,

WAVE ROOF SMXX

ATTACHMENT,

WAVE ROOF LGXX

XX X20

XX22

XX26

Galvanized steel attachment for parallel, inclined and freestanding installations on asphalt or elastomer roofs.

Galvanized steel attachment for inclined and freestanding installations on asphalt or elastomer roofs. Also recommended for flat roofs.

Galvanized steel attachment for inclined or freestanding installations with 2.75" height adjustment. For use in applications with no more than a 5 degree inclination.

Galvanized steel attachment for inclined or freestanding installations with no height adjustment. For use in applications with no more than a 5 degree inclination.

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.

Stainless steel attachment for parallel and inclined

installations on profiled and corrugated roofs.

Galvanized steel attachment for installations on

concrete corrugated roofs with 5 corrugations per meter. For parallel and inclined installations.

Galvanized steel attachment for installations on

concrete corrugated roofs with 8 corrugations per meter. For parallel and inclined installations.

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,

20013, 20014, 20015

area load up to

32 lb/sq-ft

SCH065 610610 SCH090 812812 SCH110 814814

Parallel installation

SCH130 10 18 10 18

Table 3C Inclined (20°, 40°, and 60°) Installations

SRM: 20001, 20003, 20004, 20007, 20008,

20009, 20010, 20013, 20014, 20015

area load up to 32 lb/

sq-ft

area load up to

64 lb/sq-ft

area load up to 64 lb/

sq-ft

SRM: 20005

area load up to

16 lb/sq-ft

SRM: 20006 + 20012

area load up to 64 lb/sq-ft

area load up to

32 lb/sq-ft

SCH065 610122

installation

SCH090 812143

Inclined (20, 40°, 60°)

SCH110 814183 SCH130 10 18 22 4

SCH Collectors Installation & Operation Manual

3 Roof Attachment Installation

Figure 3-1 Spacing Distance

a = 2 - 10 in.

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.

Note: For multiple collector installations reference the Collector Mounting Section of this manual for spacing between collectors.

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.

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.

 CAUTION

• 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.

• Beware of linear expansion in sheet metal that prevents a linear expansion and can cause lifting of the sheet.

Unpacking and checking parts

When unpacking the system, check the model names of the components of each system and check to be sure you have the correct number of parts (see FIG. 3-2).

Figure 3-2 Kit #SRM20001 - Double Hanger Bolt Kit Components

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).

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".

5. Install the hanger bolts into the pre-drilled holes until the threads are level with the roof’s surface.

Figure 3-3 Pre-Drill 9mm Holes Into Substructure

PRE-DRILL TWO (2) 9MM HOLES PERPENDICULAR TO THE ROOF (APPROX. 4 IN. DEEP)

INSTALL HANGER BOLT(S)

HANGER BOLT (M12) (2X)

WASHER (M12) (2X)

HANGER BOLT SEAL (2X)

HEX BOLT (M8) (1X)

WASHER (M8) (1X)

DOUBLE HANGER BOLT PLATE (1X)

HEX NUT W/FLANGE (M12) (6X)

SQUARE DISK (1X)

HEX NUT (M8) (1X)

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).

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).

9. Install the second hex nut with flange (flange side up) until the hex nut reaches the desired substructure height (FIG. 3-4B).

10. Slide the hanger bolt plate onto the flange of the hex nut installed in Step 9 (FIG.’s 3-4A and 3-4B).

11. Install the remaining hex nut with flange (flange side down) to the top of the double hanger bolt plate. Tighten and secure both hex nuts (top and bottom) to the double hanger bolt plate.

12. Make certain all double hanger bolt plates are facing the same direction.

SCH Collectors Installation & Operation Manual

3 Roof Attachment Installation

Figure 3-4A Install Double Hanger Bolt Components

HEX NUT W/FLANGE

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

Figure 3-5 Install Hex Bolt(s)

HEX BOLT

SQUARE DISK

DOUBLE HANGER BOLT PLATE

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)

+ 30 hidden pages