Bosch_Solar_Design_Guide_102009

Solar CollectorsDHW Tanks Pump Stations Controls and Accessories Design Guide Solar Thermal Systems Solar Pump 2 | Design Guide - Bosch Solar Thermal Systems | 3 Design Guide - Bosch Solar Thermal Systems Table of Contents 1 Principles 4 1.1 Introduction 4 1.2 Free solar energy 4 1.3 Energy supplied by solar collector system in relation to energy demand 5 2 Description of the solar system 6 3 Technical description of system components 7 3.1 Solar collectors 7 3.2 Solar storage tank 11 3.3 Solar controller 13 3.4 Bosch KS pump stations 16 3.5 Other system components 18 4 Notes regarding solar systems 21 4.1 General information 21 4.2 Regulations and guidelines for designing engineering a solar collector system 22 5 Sizing 23 5.1 Sizing principles 23 5.2 Sizing the collector array and solar storage tank 24 5.3 Space requirements for solar collectors 27 5.4 Hydraulic system engineering 31 5.5 Sizing of the diaphragm expansion vessel (DEV) 37 5.6 Sizing swimming pool water heating systems 40 6 Design/engineering information regarding the installation 42 6.1 Pipework, thermal insulation & collector r temperature sensor extension cable 42 6.2 Air vent valve 43 6.3 Roof mounting systems 45 6.4 Lightning protection and grounding of solar systems 58 7 Solar applications 59 7.1 Solar DHW system with electric backup element 60 7.2 Solar DHW system with gas tankless tankloading 61 7.3 Solar DHW system with gas tankless in line booster 62 7.4 Solar DHW system with gas tankless in line booster and recirc loop 63 7.5 Solar DHW system and swimming pool application with gas tankless in line booster 64 7.6 Solar commercial hot water system with gas tankless tankloading 65 8 System design recommendations 66 Contents 4 | Design Guide - Bosch Solar Thermal Systems 1 Principles 1.1 Introduction Solar thermal systems have become part of modern heating technology and reduce the consumption of fossil fuels. This protects the environment and lowers energy cost. This technical guide is designed to educate the homeowner, the installer, the engineer, and the architect on solar product offered by Bosch. 1.2 Free solar energy The energy that is provided by the sun can be used effectively in almost any part of North America. The ahhuaí íhsoíatíoh íeveí ííes betweeh 2.0 kWh[nȕ[day (634 BTU[ftȕ[day) ahd 7 kWh[nȕ[day (2,220 BTU[ftȕ[day). The "íhsoíatíoh nap" gíves you ah ídea of the average insolation that can be expected in your region (Figure 1). A solar thermal system uses the energy of the sun to heat domestic hot water (DHW). Solar Figure 1 Average insolation in North America It features descriptions of components, system sizing, and piping diagrams. The installations in this manual have been tried and tested by Bosch and were selected for their simplicity, energy savings, cost effectiveness, and comfort. systems for DHW heating are energy-saving and environmentally friendly. Frequently people are unaware of the astounding proportion of heating that technically advanced solar systems can provide today. A considerable proportion of solar energy can be used for heat generation using solar collector systems, saving valuable fuel, and fewer emissions reduce the burden on the environment and the earth’s climate. 1 Principles | 5 Design Guide - Bosch Solar Thermal Systems 1.3 Energy supplied by solar collector systems in relation to energy demand Solar collector systems for DHW heating Domestic hot water (DHW) heating is the most obvious application for solar collector systems. A relatively constant demand for hot water all year round is a good match for solar energy. Almost 100% of the energy demand for DHW heating during the summer can be covered by a solar system (Figure 2). Nevertheless, a conventional backup system must still be able to cover the DHW demand independently of solar heating. Long periods of bad weather may occur during which the convenience of hot water still has to be assured. 1 2 3 4 5 a b 6 7 8 9 10 11 12 M Q BTU (kWh) Figure 2 Energy provided by a solar collector system in relation to the annual energy demand for DHW heating. Legend (Figure 2) a Energy demand b Energy provided by the solar system M Month Q Heating energy Solar energy surplus (available for a swimming pool, for example) Utilized solar energy (solar coverage) Energy demand that needs to be provided by the backup system (reheating) 1 Principles 6 | Design Guide - Bosch Solar Thermal Systems 2 Description of the solar system The solar system consists of several components that were designed and selected to work together. Solar system components: · Coííectors · Líhe sets · Punp statíoh · Storage tahk · Cohtroííer · Backup heater Solar collectors contain an absorber that heats up when exposed to sunlight. The absorber contains pipes that are Ⱥííed wíth a Ȼuíd used to trahsport the soíar heat to the tahk where ít cah be stored for íater use. Wheh the Ȼuíd íh the collectors is warmer than the bottom of the storage tank, the controller will turn on the pump to transport hot Ȼuíd fron the coííectors to the tahk ahd repíace ít wíth coíd Ȼuíd returhíhg fron the tahk. The collectors, the pump station, and the tank are connected with supply and return piping that is insulated to minimize losses. The system is equipped with over temperature and over pressure devices, that prevent unsafe operating conditions. These safety devices are mechanical and work even during a power outage. As the system heats up or cools down, an expansion vessel (DEv) accouhts for expahsíoh ahd cohtractíoh of the Ȼuíd. Wheh the tahk ís satísȺed ahd cahhot accept ahy nore heat, the system will stop and go into stagnation. The collector temperature will rise quickly causing the water in the Ȼuíd to turh to stean ahd force aíí Ȼuíds out of the collectors. The expansion tank takes in the added volume of the steam. Once the tank can accept heat again and the collectors have cooled to a safe temperature, the steam will liquefy and the system will be ready to collect more solar heat. On days when more DHW is used than could be provided by the solar system, e.g. because guests are staying at the house or during a series of cloudy days with limited sunshine, a backup heater will provide added comfort. It is important that the backup heating system is capable of providing 100% of the demand to ensure comfort is never compromised. 2 Description of the solar system | 7 Design Guide - Bosch Solar Thermal Systems 3 Technical description of system components 3.1 Solar collectors 3.1.1 Bosch FKC·1 Ⱥat·pIate coIIector Selected features and characteristics · Exceííeht príce[perfornahce ratío · Cohsístehtíy hígh yíeíd through robust, highly selective black chromium coating · SRCC OG·100 certíȺed · Rapíd coííector cohhectíoh wíthout the heed for tools · Easy hahdííhg because of ííght weíght of 90 íbs (42 kg) · Heat trahsfer Ȼuíd has íohg·tern stabíííty due to harp absorber with extremely good stagnation characteristics · Ehergy·savíhg nahufacturíhg wíth recycíabíe materials V M 8 3 R 1 2 4 5 6 R V 7 R Solar return V Solar supply M Sensor well 1 Tempered glass 2 Absorber plate 3 Copper riser tubes 4 Mineral wool insulation 5 Galvanized steel back 6 Fiber-glass frame 7 Extruded plastic end cap 8 Header pipe cover ligurc3DcsigncfBcschllC·1sȽatplatcccllcctcr Component design and functions The housíhg of the Bosch FKC·1 soíar coííector cohsísts of a ííghtweíght, extreneíy strohg Ⱥber·gíass frane proȺíe. The back paheí ís nade fron 24 gauge (0.6 mm) galvanized sheet metal. The collector is covered with 1/8 inch (3.2 mm) thick single-pane tempered safety glass. The low-ferrous, structured castglass is coated, highly trahspareht (92% ííght trahsníssíoh) ahd has extreneíy good load-bearing capability. The 2-3/16 inch (55 mm) thick mineral wool provides extremely good thermal insulation and high efȺcíehcy. lt ís heat resístaht ahd hoh·outgassíhg. The absorber consists of individual strips with a highly selective black chromium coating. It is ultrasonically welded to the harp fan in order to provide an extremely good heat transfer. The Bosch FKC·1 has four pípe cohhectíohs for making simple, rapid hydraulic connections. The solar pípes are Ⱥtted usíhg spríhg cííps that requíre ho tooís. They are desíghed for tenperatures up to 370 °F (188 °C) and pressures of up to 87 psi (6 bar) in conjunction with the collector. 3 Technical description of system components 8 | Design Guide - Bosch Solar Thermal Systems Dimensions and speciȹcation for Bosch FKC·1 Ⱥat·pIate coIIectors 45- ½" R V R V 3-½" M 8 81- ½" 2 Bosch FKC-1s Bosch FKC-1w R Solar return V Solar supply M Measuring point (sensor well) R V 81-½" R 3-½" V M 45- ½" 8 ligurc4DimcnsicnscfBcschllC·1·s(vcrtical)andBcschllC·1w(hcrizcntal)Ƚat·platcccllcctcrs,dimcnsicns in inches Weight lbs (kg) 90 (41) 93 (42) Absorptivity 95% ± 2% Emissivity 12% ± 2% Nominal fow rate V gpm (l/h) 0.22 (50) Stagnation temperature °F(°C) 370 (188) Max. operating pressure (test pressure) psi (bar) 87 (6) Max. operating temperature °F(°C) 248 (120) Bosch FKC-1 fat-plate collector Type of installation Gross absorber surface area ft 2 (m 2 ) Aperture area (light entry area) ft 2 (m 2 ) Absorber contents gal (l) Bosch FKC-1s vertical 25.96 (2.37) 24.29 (2.26) 1/4 (0.86) horizontal 1/3 (1.26) ligurc5$pcciȼcaticnsfcrBcschllC·1Ƚat·platcccllcctcr 3 Technical description of system components | 9 Design Guide - Bosch Solar Thermal Systems 3.1.2 Bosch FKB·1 Ⱥat·pIate coIIector Selected features and characteristics · Affordabíe coííector nodeí wíth outstahdíhg performance · Hígh output through, seíectíve bíack íacquer coating · SRCC OG·100 certíȺed · Rapíd coííector cohhectíoh wíthout the heed for tools · Easy hahdííhg because of ííght weíght of 90 íbs (42 kg) · Heat trahsfer Ȼuíd has íohg·tern stabíííty due to harp absorber with extremely good stagnation characteristics · Ehergy·savíhg nahufacturíhg wíth recycíabíe materials R Solar return V Solar supply M Sensor well 1 Tempered glass 2 Absorber plate 3 Copper riser tubes 4 Mineral wool insulation 5 Galvanized steel back 6 Fiber-glass frame 7 Extruded plastic end cap 8 Header pipe cover ligurc6DcsigncfBcschllB·1sȽatplatcccllcctcr Component design and functions The housing of the Bosch FKB-1 solar collector cohsísts of a ííghtweíght, extreneíy strohg Ⱥber·gíass frane proȺíe. The back paheí ís nade fron 24 gauge (0.6 mm) galvanized sheet metal. The collector is covered with 1/8 inch (3.2 mm) thick single-pane tempered safety glass. The glass has a high light transmissivity (86%) and good load-bearing capability. A 2-3/16 inch (55 mm) thick mineral wool provides extremely good thermal insulation and high efȺcíehcy. lt ís heat resístaht ahd hoh·outgassíhg. The absorber consists of individual strips with a selective black lacquer coating. It is ultrasonically welded to the harp fan in order to provide an extremely good heat transfer. The Bosch FKB-1 has four pipe connections for making simple, rapid hydraulic connections. The solar pípes are Ⱥtted usíhg spríhg cííps that requíre ho tooís. They are desíghed for tenperatures up to 370 °F (188 °C) and pressures of up to 87 psi (6 bar) in conjunction with the collector. 3 Technical description of system components 10 | Design Guide - Bosch Solar Thermal Systems Dimensions and speciȹcation for Bosch FKB·1 Ⱥat·pIate coIIectors 45- ½" R V R V 3-½" M 8 81- ½" 2 Bosch FKB-1s R Solar return V Solar supply M Measuring point (sensor well) ligurc7DimcnsicnscfBcschllB·1·s(vcrtical)Ƚat·platcccllcctcr,dimcnsicns in inches Bosch FKB-1 fat-plate collector Type of installation Gross absorber surface area ft 2 (m 2 ) Aperture area (light entry area) ft 2 (m 2 ) Absorber contents gal (l) Weight lbs (kg) 90 (41) Absorptivity 86% ± 2% Emissivity 30% ± 2% Nominal fow rate V gpm (l/h) 0.22 (50) Stagnation temperature °F(°C) 370 (188) Max. operating pressure (test pressure) psi (bar) 87 (6) Max. operating temperature °F(°C) 248 (120) Bosch FKB-1s vertical 25.96 (2.37) 24.29 (2.26) 1/4 (0.86) ligurc8$pcciȼcaticnsfcrBcschllB·1Ƚat·platcccllcctcrs 3 Technical description of system components | 11 Design Guide - Bosch Solar Thermal Systems 3.2 Solar storage tank 3.2.1 Indirect double wall coil storage tank Available in 80 and 120 Gallon Models · Tenperature ahd pressure reííef vaíve íhcíuded · Coííector feed ahd returh Ⱥttíhgs íocated at front of tank for convenient installation · lsoíated tahk desígh for better heat retention · Hígh efȺcíehcy heatíhg eíeneht 4500W · Rheengías¹ tahk ííhíhg resísts corrosíoh ahd prolongs tank life · Heat exchahger. copper tubíhg wrapped around and secured to the tank. · Doubíe waíí, vehted desígh for posítíve leak detection · Coíd water íhíet bríhgs coíd water to tahk bottom to prevent mixing with heated water · Ahode rod equaíízes aggressíve water actíoh for prolonged tank life · Coíd water íhíet, hot water outíet, reííef vaíve and anode rod at top of tank for easy access and fast, economical installation · Autonatíc tenperature cohtroí · Over tenperature protector Figure 9 Indirect double wall coil storage tank 3 Technical description of system components 12 | Design Guide - Bosch Solar Thermal Systems Dimensions and speciȹcations of indirect singIe coil solar tank Description Roughing in dimenstions Energy information Type Gal. Cap. Model number Element wattage upper Height (inches) Diameter (inches) Approx. ship wt. (lbs) Approx. R-Factor 80 SOL-RET80 4500 W* 58-¾ 24-½ 222 R-17.3 120 SOL-RET120 4500 W* 62 28-½ 380 R-17.3 ligurc10$claraidclEtankdimcnsicnsandspcciȼcaticns * Heaters furnished with standard 240 volt AC, single phase non-simultaneous wiring and 4500 watt heating element. Special features · A specíaí 1[2" NPT opehíhg ís províded for íhstaííatíoh of a "probe type" thernostat.(Fígure 11) · Soíaraíde nodeís neet aíí curreht state requírenehts for solar storage tanks. · The tahks are Rheengías ííhed ahd are desíghed to operate up to 150 PSI. Note: To prevent corrosion, proper pH levels in transfer Ȼuíd nust be naíhtaíhed. Copper Coil Data (Type L Copper) · Maxínun pressure = 150 PSl · Maxínun tenperature = 185° F · Tube l.D. = 5[8" SolaraideHE Tank Capacity Coil Capacity (gallons) Length of Tubing Around Tank (feet) Approximate R-value of insulation 80 Gallons 2.2 120 R 17.3 120 Gallons 2.6 143 R 17.3 Figure 12 Copper coil data Pressure Drop Through CoiI (Feet of HȔO) Flow rate Head Loss (Feet) 80 Gallon 120 Gallon 1 GPM 1.3 1.6 2 GPM 4.8 5.7 3 GPM 10.0 12.0 Figure 13 Pressure drop through coil 1 Figure 11 Opening for probe type thermostat 1) probe type thermostat access cover 3 Technical description of system components | 13 Design Guide - Bosch Solar Thermal Systems 3.3 Solar controllers Temperature differential control lh "Autonatíc" node the soíar cohtroííer nohítors whether there ís sufȺcíeht íhsoíatíoh to heat the soíar storage tank. To do this, the controller compares the collector temperature using the collector sensor and the temperature in the lower area of the storage tank (tank sensor). If there is adequate insolation, i.e. the set temperature differential between the collector and the storage tank is exceeded, the solar circuit pump starts and the storage tank is heated. After a long period of Solar Pump Station Solar Pump Station Full Sunlight Limited Sunlight ligurc14luncticndiagramcfsclarDlWhcatingwithtcmpcraturcdiffcrcntialccntrcl&Ƚatplatcccllcctcrs (Left) - with system running (Right)·ccnvcnticnalrchcatingifthcrcisinsufȼcicntinsclaticn insolation and low DHW consumption, high temperatures occur in the storage tank. The solar circuit controller switches the solar circuit pump off when the maximum storage tank temperature has been reached. The maximum storage tank temperature can be set in the controller based on the individual requirements. The solar controller does not switch the pump off until the temperature differential has dropped below the minimum temperature. 3 Technical description of system components 14 | Design Guide - Bosch Solar Thermal Systems 3.3.1 TR 0301 U Differential Temperature Controller The standard delivery of the controller includes: · Ohe coííector tenperature sehsor Pt1000 type 4.9 ft (1.5n) sííícohe cabíe wíth bushíhg (Tenperature íínít 356 °F (+180 °C) · Ohe tahk tenperature sehsor Pt1000 type 0.9 ft (1.0 n) twísted síhgíe cohductor Ȼat surface sensors with compression cable lug (Temperature íínít 221 °F (+105 °C) An optional 3rd tank temperature sensor (top) Pt1000 type 9.8 ft (3.0 n) twísted síhgíe cohductor Ȼat surface sensors with compression cable lug (Temperature limit 221 °F (+105 °C) cah be íhstaííed for íhfornatíohaí purposes. Automatic Storage Tank Loading The TR0301 U controller constantly compares the temperatures between the collector (T1) and the lower area of the storage tank (T2) via temperature sensors. Once the sun heats the collector and there is a tenperature dífferehce of 16 °F (9 °C) betweeh the collector and the storage tank, the pump is switched on and the pump symbol shown rotating on the display. The punp trahsports the heat trahsfer Ȼuíd fron the storage tank to the collectors. There it is heated by the sun and transported back to the storage tank, where the heat is transferred to the domestic water. If the temperature difference between collector and storage tank falls below 8 °F (4.5 °C), the punp ís swítched off. The suh synboí ís no longer shown on the display. Automatic Stagnation If the lower area of the storage tank (T2) reaches the set maximum storage tank temperature (factory default 140 °F (60 °C)), chargíhg ís stopped. A tenperature of 6 °F (4 °C) beíow the naxínun storage tahk tenperature nust Ⱥrst be reached before charging can resume. Automatic Pump Protection During periods of high insolation, the temperature (T1) of the heat trahsfer Ȼuíd cah exceed 266 °F (130°C). In order to protect the pump from overheating, the system will resume operation as soon as the temperature drops beíow 261 °F (127°C). Vacation Function The vacation function is used to cool down a completely heated storage tank via the collector. The storage tank can heat up too much if no DHW is drawn over an extended period of time (e.g. vacation). Discharging the solar system over night prevents the solar system idling in stagnation for extended periods. Figure 15 Solar Controller TR0301U Figure 16 Display Legend 1 Temperature sensor symbols 2 Temperature and faults code display 3 Vacation function 4 Anti-freeze function 5 Seíect tenperature uhít °C[°F 6 Evacuated tube collector function 7 Setting maximum storage tank temperature 8 Actívated punp ahd Ȼuíd synboís íhdícate a system in operation 9 lhdícates naxínun storage tahk tenperature reached 10 Warning display if fault occurs 11 Indicates system stagnation 12 Shows sufȺcíeht heat for systen operatíoh Anti-freeze Function If the anti-freeze function is activated, the controller switches the pump on as soon as the collector tenperature faíís beíow +41 °F (+5 °C). The heat trahsfer Ȼuíd ís theh punped through the coííector ahd the system is prevented from freezing. If the collector reaches a tenperature of +45 °F (7 °C), the punp ís swítched off. 3 Technical description of system components | 15 Design Guide - Bosch Solar Thermal Systems 3.3.2 TR 0603mc U Differential Temperature Controller The TR 0603mc U is designed exclusively for the North America. The TR 0603mc U stores the system‘s operational data on a SD memory card, which can be used for data evaluation purposes. The 40-programmed systems and numerous additional functions allow universal use of the controller. The large display panel shows the animated control circuits, which allows you to view the operating conditions of each system. The TR 0603mc U has 6 inputs for recording temperature or puíse vaíues, as weíí as ah addítíohaí "Dírect Sehsor" íhput for conbíhed tenperature ahd Ȼow rate measurement. Pumps and switching valves are controlled by 3 outputs, sone of whích cah be RPM cohtroííed. Product Features · Ahínated LCD díspíay wíth backííght · Heatíhg returh íhcrease · Freeíy progrannabíe thernostat fuhctíoh · Tíner ahd hoííday (storage recooí) fuhctíohs · Heat quahtíty (puíse geherator [ Dírect Sehsor[ calculation) · Círcuíatíoh fuhctíoh · Back·up heatíhg fuhctíoh neasured íh kwh[BTU · Soííd fueí boííer back·up heatíhg · Tube coííector fuhctíoh · Ahtí·freeze fuhctíoh · lhtervaí fuhctíoh · Rapíd storage tahk íoadíhg · Reductíoh of systen staghatíoh phases · Ahtí·íegíoheíía fuhctíoh · Fauít díaghosís ahd fauít reportíhg output · Bypass swítchíhg · Data íoggíhg oh SD card · Seasohaí systens (íoadíhg of pooí [ storage tahk according to the time of the year) · Muítíííhguaí nehu havígatíoh Figure 15 Solar Controller TR0301U Technical Data Operating voltage 120 vAC, 60 Hz [optíohaí 240 vAC, 60 Hz} Max. owh consumption s 4 W Inputs 6 5 x temperature recording (Pt1000), 1 x temperature recording or pulse Additional input 1 x "Dírect Sehsor" (tenperature[Ȼow rate) Outputs 3 1 x relay switched output, max. 0.5 HP (120 V~) 2 x triac output for speed control, max. 0.17 HP (120 V~) Additional output 1 x (fault reporting output) Line cord 7‘, 18 AWG rated at 221 °F Number of pre- deȺhed hydrauííc schemes 40 Interfaces SD card, RS232, RS485 (TPC 1) Data logging SD card Permitted ambi- ent temperature 32 °F ... +113 °F (0 °C ... +45 °C) Display ahínated graphíc LCD wíth backííghtíhg Protection class IP 20/DIN 40050 Dimensions l x w x h 6.69 x 6.69 x 3.50 íhch (170 x 170 x 89 nn) 3 Technical description of system components 16 | Design Guide - Bosch Solar Thermal Systems 3.4 Bosch KS pump stations Features and characteristics · The Bosch pump station assembly consists of all required components such as the solar circulator, the gravity brake, the safety pressure relief valve, the pressure gauge, baíí vaíves íh the Ȼow ahd returh wíth íhtegrated thernoneter, ah adíustabíe Ȼow ííníter ahd thernaí protection. The Bosch KS pump station is designed for one solar storage tank. For two tanks two solar stations can be combined in one system. This arrangement provides two separate returh cohhectíohs wíth separate punps ahd Ȼow limiters. This enables the hydraulic balancing of two storage tanks with different pressure drop values. Another application of two pump stations in one system is the implementation of a solar system with two collector arrays in different orientation (east/west control). Here too it is important to have two separate returh cohhectíohs wíth separate punps ahd Ȼow ííníters. As previously described, hydraulic balancing of the two collector arrays with different pressure drop values is now feasible. Two safety assemblies (part of the standard delivery) and two diaphragm expansion vessels (DEV) are required for this arrangement. Two collector arrays with different orientation are controlled using two independent solar controllers. Conȹguration of the Bosch KS pump station The solar stations for collector arrays with up to 5 collectors are already equipped with an air separator. · The essehtíaí díaphragn expahsíoh vesseí (DEv) ís not part of the standard delivery of the Bosch KS pump station. It must be sized for each individual case. See chapter 5.5 Sizing of the Diaphragm Expansion vessel for details 1 2 2 3 4 5 6 7 6 8 2 9 1 2 10 V V R R Figure 17 Layout of the Bosch KS0105 pump station Legend V Supply from collector to storage tank R Return from storage tank to collector 1 Ball valve with thermometer and integrated gravity brake Posítíoh 0° = gravíty brake ready for operatíoh, ball valve open Posítíoh 45° = gravíty brake nahuaííy opeh Posítíoh 90° = baíí vaíve cíosed 2 Conpressíoh ríhg Ⱥttíhg (aíí Ȼow ahd returh connections) 3 Safety relief valve 4 Pressure gauge 5 Cohhectíoh for díaphragn expahsíoh vesseí 6 Fill & drain valve 7 Solar circuit pump 8 Flow volume indicator 9 Aír separator 10 Regulating/shut-off valve 3 Technical description of system components | 17 Design Guide - Bosch Solar Thermal Systems Dimensions and speciȹcation of Bosch KS pump station A C E B T S pump station K Bosch S pump station K Bosch Figure 18 Dimensions of the KS pump stations Pump station KS0105 Number of storage tanks 1 Casing dimensions Height H in (mm) 14" (355) Width W in (mm) 11-1/2" (290) Depth D in (mm) 9-1/4" (235) Detailed dimensions A in (mm) 5-1/8" (130) C in (mm) 3-1/8" (80) E in (mm) 2" (50) Copper pipe connection size (clamping ring ftting) 1/2" ID × 1 Expansion vessel connection ¾" Safety relief valve psi (bar) 87 (6) Circulation pump Type Grundfos Solar 15-58 Finished length in (mm) 5-⅛" (130) Electrical power supply V AC 120 Frequency Hz 60 Max. power consumption W 60 Max. current load A 0.25 Throughput limiter adjusting range gpm (l/min) ⅛- 1-½ (0.5–6) Weight lbs (kg) 16 (7.1) Supply/return KS0110 1 14" (355) 11-1/2" (290) 9-1/4" (235) 5-1/8" (130) 3-1/8" (80) 2" (50) 22 × 1 ¾" 87 (6) Grundfos Solar 5-⅛" (130) 120 60 125 0.54 ½- 4-¼ (2-16) 16 (7.1) KS0120 1 14" (355) 11-1/2" (290) 9-1/4" (235) 5-1/8" (130) 3-1/8" (80) 2" (50) 28 × 1 ¾" 87 (6) Grundfos UPS 5-⅛" (130) 120 60 195 0.85 2 - 7 (8-26) 21 (9.3) Max. recommended # of collectors 5 10 20 15-58 25-99 Flow range gpm Head range feet Motors Maximum fuid temperature °F (°C) Minimum fuid temperature °F (°C) Maximum working pressure psi 0 - 17.5 0 - 17.5 0 - 34 0 - 19 0 - 19 0 - 30 2 pole, single phase 2 pole, single phase 2 pole, single phase 230 (110) 36 (2) 230 (110) 36 (2) 230 (110) 36 (2) 145 145 145 ligurc19$pcciȼcaticn&dimcnsicnscfthcl$pumpstaticn 3 Technical description of system components 18 | Design Guide - Bosch Solar Thermal Systems 3.5 Other system components 3.5.1 Twin-Tube piping system Twin-Tube is a thermally insulated double tube for solar supply and return piping with UV protective jacket and integrated sensor lead. Space for a bending radius of at least 5 inches (125 mm) for routing the Twin-Tube 1/2 inch must be available on site (Figure 20). Twin-Tube 1/2 INCH Dimensions A inch (mm) 3" (73) B inch (mm) 2" (45) Pipe dimensions Diameter 2 × 1/2" ID inch Length ft. 50 Insulating material EPDM rubber Insulation thickness inch (mm) 2/3" (15) Temperature resistant up to ° F (°C) 374 (190) Protection flm PE, UV-resistant Sensor lead AWG18 (2 × 0.75 mm 2 ) ligurc21Twin·Tubcspcciȼcaticn 3.5.2 Lightning protection for the controller The collector temperature sensor in the lead collector can be subject to overvoltage during a thunderstorm because of its exposed location on the roof. This overvoltage can damage the sensor and the controls. The overvoltage protection is not a lightning rod. It is designed for situations where lightning strikes in the vicinity of the solar collectors. Safety diodes limit this overvoltage to a level that will not damage the controller. The junction box must be located within 10 ft. (3.5 m) of the FSK collector temperature sensor (Figure 22). A B Figure 20 Bending radius for Twin-Tube 1/2 inch R V Collectors Pump station FSK SP1 Twin-Tube V R DEV E Automatic all-metal air vent valve (accessory) FSK Collector temperature sensor (standard delivery of the controller) KS0105 pump station SP1 Lightning protection Figure 22 Overvoltage protection for controller example 3 Technical description of system components | 19 Design Guide - Bosch Solar Thermal Systems 3.5.3 Heat transfer Ⱥuid · Tyfocor L Heat trahsfer Ȼuíd ís used to trahsport soíar heat fron the collectors to the tank. Bosch uses Tyfocor L, a preníxed Ȼuíd of 45% propyíehe gíycoí ahd 55% water, ahd Tyfocor L "G", a preníxed Ȼuíd of 42% propylene glycol and 58% water. Both mixtures are clear, non-toxic, bio-degradable, and protect the system from freezing and corrosion. Tyfocor L "G" uses FDA íísted íhgredíehts ahd nust be used íh systens that requíre OG·300 certíȺcatíoh. Both Ȼuíds províde frost protectíoh dowh to ·22°F (·30°C) ahd up to +338°F (+170°C). Testing the heat transfer Ⱥuid Heat transfer media based on mixtures of propylene glycol and water have a long service life if the system is sized well for the application and properly maintained. The naíh íhȻuehces oh the servíce íífe of the soíar Ȼuíd are repeated overheating and over pressure. Ready-mixed heat transfer fuid pH value in the delivered condition min. pH Heat transfer fuid L 50/50 approx. 8 7 Figure 24 pH limits for checking ready-mixed heat transfer Ƚuid 0 50 -35°F (–37) 60 0 4 0 1 20 PP: glycol/% by vol. 30 32 (0) 14°F (–10) -4°F (–20) -22°F (–30) -58°F (–50) Solar fluid L / L "G" ∂ A °F (˚C) ligurc23lcvclcffrcstprctccticncfhcattransfcrȽuid subject to the glycol-water mixture. Legend (Figure 23) ∂ A Outside temperature Aging is also accelerated by oxygen (air-borne systems) and impurities such as copper or iron shavings introduced during installation. To check the heat trahsfer Ȼuíd oh síte, deterníhe the pH value and the antifreeze value. Suitable pH indicator strips and a refractometer (frost protection) are included in the Bosch solar service kit. 3 Technical description of system components 20 | Design Guide - Bosch Solar Thermal Systems 3.5.4 Thermostatically controlled domestic hot water mixer WARNING: Hot water can scald. Solar systems can easily reach water temperatures that can scald. Take suitable measures to provide protection against scalding. Anti-scald protection / tempering valve If the maximum storage tank temperature is set higher thah 122 °F (50 °C), take suítabíe neasures to províde protection against scalding. The following options are available: · Install a thermostatically controlled DHW mixing valve (tempering valve) downstream of the storage tank’s DHW connection. See Figure 25 for system integration of a thermostatically controlled DHW mixing valve (tempering) and a recirculation pump. 4 EK AW EZ 1 1 1 2 3 EK 5 7 6 MIX 8 8 Figure 25 DHW tempering valve installation diagram with optional DHW recirculation line Legend (Figure 25) AW DHW outlet EK Coíd water íhíet EZ DHW recirculation inlet (use is optional) MlX Míxed water 1 Check vaíve 2 DHW recirculation pump (optional) 3 Thermostatic mixing valve / tempering valve 4 Shut-off valve with check valve 5 DHW recirculation line 6 Faucet, shower, etc. 7 Coíd water suppíy 8 Shut-off valve 3 Technical description of system components | 21 Design Guide - Bosch Solar Thermal Systems 4 Notes regarding solar systems 4.1 General information Solar Pump Station Domestic Hot Water Solar Controller Cold Water Supply Symbols Service valves Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Expansion tank Well thermometer Circulator 1 2 3 4 5 6 7 Figure 26 Sample diagram in connection with the general information regarding solar systems Item System components General design 1 Collectors The size of the collector arrays must be determined independently of the hydraulic system. 2 Pipework with incline to the air vent (Optional) Installation of an air vent is not needed if a high head and high speed flling station is used for flling and charging the system. If an air vent is installed, position upright and at the highest point of the system, or at a secondary peak of the piping where air is expected to collect. 3 Connection lines Twin-Tube For ease of installation, use of the double copper tube Twin-Tube 1/2" is recommended, complete with its heat and UV protection jacket and integrated FSK collector sensor cable. If Twin-Tube cannot be used install standard L-type copper piping and sensor cable on site (e. g. AWG18 (2 × 0.75 mm), and insulate appropriately. 4 Pump station The Bosch KS0105 pump station contains all important hydraulic components for the solar circuit. The choice of pump stationis subject to the number of storage tanks, the number/arrangement of collectors or connections, and the collector array pressure drop. Figure 27 General information regarding solar systems. (continued on the next page) 4 Notes regarding solar systems 22 | Design Guide - Bosch Solar Thermal Systems Item System components General designinformation 5 Diaphragm expansion vessel Size the diaphragm expansion tank according to the system volume and the safety valve so that it can adequately compensate for the volume fuctuations in the system. With east/west systems an additional diaphragm expansion vessel is required for the 2nd collector array. A pre-cooling vessel is required if the DHW heating coverage is above 60% or in central heating systems. 6 DHW storage tank Determine the size of the storage tank independently of the hydraulic system. 7 Hot water tempering valve Reliable protection from excessively hot water temperatures ( risk of scalding! ) is provided by a thermostatically controlled hot water tempering valve (WWM). To prevent natural circulation, install the thermostatically controlled DHW mixing valve below the storage tank's DHW outlet. If this is not possible, provide a heat insulating loop or a check valve. 8 DHW water recirculation DHW recirculation (not shown above) causes signifcant standby losses. Using a poorly designed DHW recirculation system can reduce the net solar yield considerably. Run recirculation pump on a timer only a few times per hour during peak demand times. Figure 28 General information regarding solar systems 4.2 Regulations and guidelines for designing/engineering a solar system Installation and commissioning must be carried out by a licensed and experienced contractor. Take appropriate personal safety measures when carrying out any installation work on the roof. Observe all relevant accident prevention regulations! Apply all state-of-the-art technical standards to all work. Design the safety equipment in accordance with all applicable regulations. It is the installer’s responsibility to comply with the building and installation codes in effect and all regulations that apply to the operation of a solar hot water system. 4 Notes regarding solar systems | 23 Design Guide - Bosch Solar Thermal Systems 5 Sizing 5.1 Sizing principles 5.1.1 Solar DHW heating Proper sizing of a solar thermal system for DHW heating is crucial for performance and comfort, fuel savings, and a long service life. Verify each case individually as to whether it is possible to upgrade an existing DHW system with a solar thermal system. The conventional heat source must be able to provide 100% of the hot water in a building independently of the solar system. A system putting too much emphasis on fuel savings may not meet the homeowner’s approval if it does not provide DHW comfort during periods of bad weather. 5.1.2 Sizing with computer simulation For larger solar thermal systems and systems for process water heating Bosch recommends using computer simulation for proper sizing: · With six collectors or more, or · If the system differs greatly from the calculation conditions in the sizing diagrams Correct sízíhg essehtíaííy depehds oh the accuracy of the information on the actual DHW demand. The following values are important: · Daily DHW demand · Daííy proȺíe, DHW denahd · Weekíy proȺíe, DHW denahd · Seasohaí íhȻuehce oh the DHW denahd (e. g. canp síte) · Set DHW temperature · Existing DHW heating equipment (if an existing system is being extended) · Recirculation losses · Location · Orientation · Slope Coverage of 50% to 60% over the course of a whoíe year ís generally desirable for DHW heating systems for single family homes and two-family homes. Sizing for less than 50% is also realistic if the consumption data is unknown or unreliable. A coverage of less than 50% is generally appropriate in multifamily buildings. T-Sol is an extremely practical simulation software for calculating solar systems. Simulation programs require consumption values as well as the size of the collector array ahd the storage tahk. Cohsunptíoh íhfornatíoh should always be obtained, since values taken from literature are of little use. The collector array and the solar storage tank must therefore be pre-sized for the computer simulation. The required output result is obtained in stages. The T-Sol program a database of climate data such as tenperatures, ehergy íeveís, efȺcíehcíes ahd coverage, as well as appliance data. This information can be displayed on screen in many different ways and can be printed out for further analysis and to prepare a quotation. 4 Notes regarding solar systems 24 | Design Guide - Bosch Solar Thermal Systems 5.2 Sizing the collector array and solar heating storage tank 5.2.1 Systems for DHW heating in single family homes and two-family homes Number of collectors Empirical values from single family homes and two family homes can be used when a residential solar heating system for DHW heating is being sized. For larger systems and non-standard hot water demand, a T-Sol simulation (5.1.2 Sizing with computer simulation) is advisable. The foííowíhg factors íhȻuehce the optínun sízíhg of the collector array, the storage tank and the pumping station for solar collector systems for DHW heating: · Location · Roof slope (collector angle of inclination) · Roof orientation (south-facing collector) · DHW cohsunptíoh proȺíe Take the draw-off temperature in accordance with the existing or intended sanitary equipment into consideration. The typical number of occupants and the average consumption per person per day are essential for a reasonably accurate estimation. Information about particular draw-off habits and comfort requirements are ideal. Calculation principles Fígures 29 to 35 are based oh a sanpíe caícuíatíoh wíth the following system parameters: · Bosch FKC·1 Ȼat·píate coííectors · 1-3 collectors: SOL-RET80 80 gal storage tank; 4+ collectors: SOL-RET120 120 gal storage tank; · South-facing roof orientation · Roof incline 45° · Location Albany, NY · Draw temperature 113 °F Determining the number of collectors in accordance with fígure 29 resuíts íh ah ahhuaíízed soíar coverage of approx. 60% a b c 8 7 6 5 4 3 2 1 1 2 3 4 5 6 n P n Figure 29 Diagram for an approximate determination of the number of Bosch FKC-1 collectors for DHW heating (observe calculation principles!) Legend (Fígure 29) n Nunber of Coííectors n p Number of occupants DHW demand curves: a Low (< 10 gallons per person per day) b Average (13 gallons per person per day) c High (20 gallons per person per day) Example · Household with four occupants and a DHW demand of 50 gallons per day · Solar system for DHW heating · Accordíhg to Ⱥgure 29, curve b, two Bosch FKC·1 hígh·perfornahce Ȼat·píate coííectors are requíred. 5 Sizing | 25 Design Guide - Bosch Solar Thermal Systems lnȺuence of coIIector orientation and incIination on solar yield Optimum angIe of incIination for coIIectors Use of solar heat for Optimum angle of inclination of collectors DHW 30° – 45° Domestic hot water + swimming pool water 30° – 45° Figure 30 Angle of inclination of collectors subject to the use of solar system The optimum angle of inclination depends on the use of the solar system. For constant year-round use, the coííector ahgíe shouíd reȻect the íatítude of the íocatíoh. For better results during the winter months, use angles greater than the latitude. Angles shallower than the latitude are typically not recommended as they reduce performance in the winter and offer little performance increase during the summer months. In snowy climates shallow collector angles may lead to snow accumulation and further reduce performance. Angle of inclination Correction factors for collector orientation deviation from south Deviation to the west by South Deviation to the east by 90° 75° 60° 45° 30° 15° 0° –15° –30° –45° –60° –75° –90° 25° 1.19 1.14 1.10 1.07 1.04 1.03 1.03 1.04 1.06 1.09 1.13 1.17 1.22 Correction ranges: 1. 06–1. 10 1 . 11–1. 15 1. 16–1. 20 1. 00–1. 05 1. 21–1. 25 > 1. 25 Figure 31 Correction factors with south deviation of Bosch solar collectors for different angles of inclination Example · Parameters – Household with four occupants with DHW demand of 50 gallons per day – Location: Albany, NY (approx. 40° Latitude) – Angle of inclination 25° with rooftop installation of Bosch FKC·1 soíar coííectors – Deviation to the west by 60° Collector orientation Orientation of the solar collectors with the points on the conpass ahd the pítch have ah íhȻuehce oh the thernaí energy that can be harvested by a collector array. For maximum solar yield align the collectors at an angle of inclination close to the latitude of the site, and within 10° East or West of due South. If the collector array is mounted on a steep roof or a wall, the orientation of the collector array is identical to that of the roof or wall. If the collector array orientation deviates to the east or west, the rays of the sun will no longer strike the absorber area in the most effective way. This will reduce the performance of the collector array. According to Figure 31 there is a correction factor for every collector array deviation from due South, and subject to the degree of its pitch. The collector area that was determined under ideal conditions must be multiplied by this factor to achieve the same energy yield as is achieved with direct southern orientation. · Measure - 1.8 Bosch FKC·1 coííectors - 40° Latítude · 15° = 25° roof pítch - Correctíoh factor 1.10 - The caícuíatíoh resuíts íh. 1.8 × 1.10 = 2.0 To achieve the same energy yield as with direct southeríy oríehtatíoh, aííow for 2 Bosch FKC·1 soíar collectors. 5 Sizing 26 | Design Guide - Bosch Solar Thermal Systems Storage tank selection A suitable ratio between collector output (size of collector array) and storage tank capacity (storage tank volume) is heeded to nake a soíar heatíhg systen operate efȺcíehtíy. The size of the collector array is limited by the storage tank capacity (Figure 32). Rule of thumb A storage tank volume of twice the daily demand has proven to be adequate. Figure 32 shows standard values for selecting the DHW storage tank subject to the DHW demand per day depending on the number of occupahts. A storage tahk tenperature of 140 °F (60°C) ahd a draw·off tenperature 113 °F (45 °C) have beeh assumed. In a multi-storage tank system the stored volume of DHW should be able to cover twice the daily demand with a draw-off level of 85%. DHW storage tank Recommended daily DHW demand in gallons Recommended number of occupants Capacity Rec. no. 1) Collectors FKC-1 or FKB-1 with a DHW demand per person per day of with storage tank temperature of 140 °F (60 °C) and draw-of temperature of 113 °F (45 °C) 10 gallons Low 13 gallons Average 20 gallons High gallons SOL-RET80 up to 53/66 approx. 5–6 approx. 4-5 approx. 3 SOL-RET120 up to 66/80 approx. 6-8 approx. 5-6 approx. 3-4 120 3–4 80 2–3 Figure 32 Standard values for selecting DHW storage tank 1) Determining the number of collectors Daily heating/disinfection control Follow local codes and regulation for disinfection and prevention of Legionnaires’ disease outbreak. Collector area sizing Apply a daily consumption of approx. 1.8 - 2.0 gallons of DHW at 140 °F (60 °C) per ft² of coííector area for sízíhg the collector area in properties with a uniform cohsunptíoh proȺíe, such as íh nuítífanííy buíídíhgs. By way of sínpííȺcatíoh, the foííowíhg fornuía cah be used takíhg the specíȺed nargíhaí cohdítíohs íhto consideration: Marginal conditions for formula · Re-circulation cost: 340 BTU/hr per unit (100W/ unit) Old building: 480 BTU/hr per unit (140W/unit) · Pre-heat storage tank temperature max. 167 °F (75 °C), water trahsfer ehabíed · 26 gaí per uhít at 140 °F (100 í[uhít at 60 °C) n collector = 0.7 · n WE Figure 33 Formula for the required number of Bosch FKC-1 solar collectors in relation to the number of residential units (observe marginal conditions!) Calculating sizes n collector Nunber of Bosch FKC·1 soíar coííectors n WE Number of residential units 5 Sizing | 27 Design Guide - Bosch Solar Thermal Systems 5.3 Space requirements for solar collectors 5.3.1 Rooftop installation On pitched roofs Bosch solar collectors can be installed with a pitch of 25° to 65°. Installation on corrugated sheet and standing seam metal roofs is only permissible on roof pitches between 5° and 65°. Besides the area above the roof, the space required underneath the roof must also be taken into consideration. Dimensions A and B represent the area requirement for the selected number and layout of collectors. Dínehsíoh C represehts the níhínun dístahce fron the ridge. Dimension D represents the roof overhang, including the gable end thickness. Allow 20 inches to the right and/or left of the collector array for the connection lines (underneath the roof!). Allow 12 inches beneath the collector array (underneath the roof!) for routing the return connection line. Route the return line with a rise to the automatic air vent valve (if installed). Allow 16 inches above the collector array (beneath the roof!) for routíhg the Ȼow header (rísíhg) ahd the automatic air vent (if installed). B C D D A ≥ 12 in ≥ 20 in ≥ 20 in ≥ 16 in Figure 34 Space requirements on the rooftop 5 Sizing 28 | Design Guide - Bosch Solar Thermal Systems Area required for solar collector rooftop installation 2 3 4 5 6 7 8 9 A 1 X Y C B 10 2 3 4 5 6 7 8 9 1 10 B A Width of collector row B Height of collector row C Distance from roof ridge X Distance between collectors rows side by side Y Distance between collectors rows above each other Figure 35 Area required for collector arrays for rooftop installation Dimensions Collector array dimensions for Bosch fat-plate collectors Bosch FKC-1 and FKB-1 at rooftop installation FKC-1 and FKB-1 vertical FKC-1 horizontal A for 1 collector in 45-1/4” 81-1/2” for 2 collectors in 91-3/8” 164-3/16” for 3 collectors in 137-7/16” 246-1/2” for 4 collectors in 183-1/2” 329-1/8” for 5 collectors in 229-1/2” 411-3/8” B in 81-1/2” 45-1/4” C in 12" or 2 rows of tiles 12" or 2 rows of tiles X in 8” 8” Y subject to roof construction (batten spacing) subject to roof construction (batten spacing) ligurc36CcllcctcrarravdimcnsicnswithBcschȽat·platc collectors for rooftop installation 5 Sizing | 29 Design Guide - Bosch Solar Thermal Systems 5.3.2 Flat roof installation Flat roof installation is possible with vertical and horizontal collectors. The area required for the collectors correspohds to the íhstaííatíoh area for the Ȼat roof supports used plus a space for pipework routing. This space should be at least 20 inches (50 cm) to the left and ríght of the array. Maíhtaíh a níhínun dístahce of 30 inches (100 cm) from the roof edge. In locations with snowfall, consider that snow will slide off the collectors and may accumulate at their base. In areas with large amounts of snowfall consider measures for snow removal to minimize service interruptions. A B Figure 37 Flat roof stand installation dimensions on the cxamplccfBcschllC·1vcrticalȽat·platc collectors (dimension A - Figure 36 and dimension B - Figure 37) Number of collectors Collector row dimensions FKC-1 and FKB-1 vertical FKC-1 horizontal A A in in 2 92-1/8” 164-1/2” 3 138-3/16” 247-1/4” 4 184-1/4” 330” 5 230-5/16” 412-5/8” ligurc38CcllcctcrrcwdimcnsticnswhcnusingȽat roof supports Angle of inclination FKC-1 and FKB-1 vertical FKC-1 horizontal B B in in 25° 72-7/16” 41-3/4” 30° 68-7/8” 40-3/16” 35° 66-1/8” 37-3/16 40° 62-3/16” 35-13/16” 45° 58-1/4” 33-7/16” 50° 58-1/4” 33-7/16” 55° 58-1/4” 33-7/16” 60° 58-1/4” 33-7/16” Collector row dimensions ligurc39CcllcctcrrcwdimcnsicnswhcnusingȽatrccf supports. 5 Sizing 30 | Design Guide - Bosch Solar Thermal Systems 5.3.3 Space requirements for wall mounting Bosch Ⱥat·pIate coIIectors Ohíy Bosch FKC·1 horízohtaí Ȼat·píate coííectors are suitable for wall mounting, and only for an installation height of up to 65 ft above ground. The wall must have adequate loadbearing capacity! The space requirement on the wall for the collector rows depends on the number of collectors. In addition to the width of the collector array, allow at least 20 inches to the left and right (dimension A , Figure 40) for routing the pipework. The space between the collector row and the edge of the wall must be at least 3ft. (1.0m). A 3 3 ½ Figure 40 Installation dimensions of wall mounting kits fcrBcschllC·1hcrizcntalȽat·platcccllcctcrs, dimensions in inches (dimension A - Figure 42) Number of collectors Collector row dimensions for Bosch FKC-1 horizontal A in 2 164-1/8” 3 246-1/2” 4 329-1/8” 5 411-3/8” Figure 41 Collector row dimensions when using wall mounting supports Minimum row spacing The wall mounting kit is particularly suitable for buildings with non-ideal roof orientation, or where shading of windows and doors is desired. This allows taking advantage of the sun while creating an architectural feature. Coííectors cah be nouhted to províde ídeaí shade for windows and keep rooms nice and cool. In winter, when the sun’s path is lower, solar gain can provide an additional source of energy. Several rows of collectors arranged above of each other must be kept at least 145 inches apart to prevent the collectors from casting shadows on each other (Figure 41). 1 4 5 Figure 42 Shade-free spacing for several rows of wall installation kits for horizontal Ƚat·platcccllcctcrsarrangcdabcvccach other. Dimensions in inches Snow and ice accumulating on the collectors may give way and slide off suddenly. Take provisions that the installation does not pose a risk to property and cause personal injury from falling snow and ice. 5 Sizing | 31 Design Guide - Bosch Solar Thermal Systems 5.4 Hydraulic system engineering 5.4.1 Hydraulic circuit Collector array A collector array must consist of the same type of collectors and have the same orientation (all vertical or all horízohtaí). Thís ís hecessary, síhce the Ȼow dístríbutíoh would otherwise not be uniform. A maximum of ten Bosch FKC·1 or FKB·1 Ȼat·píate coííectors nay be íhstaííed íh a row and hydraulically connected in parallel if the supply and return connections are on alternate sides. In small systems it is preferable to connect collectors in series. Cohhectíhg the coííectors íh paraííeí ís better íh íarger systens. Thís aííows a nore uhíforn voíune Ȼow distribution of the entire array. Connection in series Connection in parallel Row(s) Max. number of collectors per row Row(s) Max. number of collectors per row 1 10 1 With supply and return on opposite sides max. 10 collectors per row 2 5 2 3 3 3 4 Never connect more than three rows in series! 4 … … n Figure 43 Collector array layout options Connection in series The hydraulic connection of collector rows in series is accomplished quickly because of the simple connection desígh. Cohhectíoh íh seríes ís the preferred way to achíeve a uhíforn voíune Ȼow dístríbutíoh. If there are several arrays (rows) in a system, the number of collectors per row may not differ by more than one. The naxínun hunber of Ȼat·píate coííectors cohhected íh series is limited to 10 collectors and 3 rows (Figure 43). The hydraulic connection is shown in the following diagram in the example of a rooftop installation. Additional automatic air vent valves may be required if such valves cannot be installed at the highest point (i.e. Ȼat roof íhstaííatíoh). Collector array with dormer The following hydraulic scheme represents one option for solving the challenge posed by dormers. It is important that the maximum number of collectors in one row in series is not exceeded. V E FSK R E Dormer Bosch FKC-1 and FKB-1 Figure 44 Hydraulic connection of collector arrays that are interrupted by a dormer 5 Sizing 32 | Design Guide - Bosch Solar Thermal Systems 5.4.2 Flow rate in the collector array The honíhaí Ȼow rate for ehgíheeríhg snaíí ahd nedíun· sized systems is 0.22 gpm (50l/h) per collector, resulting íh a totaí systen Ȼow rate per fornuía (Fígure 45). A Ȼow rate 10% to 15% íower (at fuíí punp speed) does hot usuaííy íead to síghíȺcaht yíeíd reductíohs. However, avoíd hígher Ȼow rates to níhíníze the anouht of power required by the solar circuit pump. 5.4.3 Pressure drop calculation in collector array Collector row pressure drop The pressure drop of a collector row increases with the number of collectors. The pressure drop for a row including accessories, subject to the number of collectors per row, can be found in Figure 46. at a flow rate per collector (nominal flow rate 0.22 gpm) Pressure drop for a row consisting of n collectors Bosch FKC-1 and FKB-1 vertical Bosch FKC-1 horizontal Figure 46 Pressure drop values for collector rows with Bosch FKC-1 including AAV and connection kit,prcssurcdrcpvalucsapplvtcsclarȽuidl at an average temperature of 122°F (50°C) 1) Flow rate per collector, connected in two row 2) Flow rate per collector, connected in three rows - Non-permitted VA = Vl,c nK = 022p nK ligurc45lcrmulafcrtctalsvstcmȽcwratc Calculating sizes ş Vƴ Totaí systen Ȼow rate íh gpn ` Vk, Nom Nominal flow rate of collector in gpm nk Number of collectors The pressure drop vaíues for the Bosch FKC·1 ahd FKB·1 coííectors for a soíar Ȼuíd níxture cohsístíhg of 50% gíycoí ahd 50% water at a neah tenperature of 122°F (50°C) are specíȺed íh Fígure 46. 5 Sizing | 33 Design Guide - Bosch Solar Thermal Systems Rows of collectors connected in series The pressure drop of the array results from the sum of all pipework plus each row of collectors. The pressure drop of rows of collectors connected in series is cumulative. p Array Δ p Row Δ n Row ⋅ Figure 47 Formula for pressure drop of a collector array with rows of collectors in series As far as Figure 48 is concerned, take into cohsíderatíoh that the actuaí Ȼow rate ís caícuíated from the individual collectors connected in series, the hunber of rows, ahd the honíhaí coííector Ȼow rate (0.22 gpm): V K V K,Nom n Row ⋅ 0.22 gpm n Row ⋅ ligurc48lcrmulafcrȽcwratcthrcughaccllcctcrwith rows of collectors connected in series Calculation parameters (Figure 47 and 48) /Ǥ Array Pressure drop for coííector array íh íh. W.C. /Ǥ Row Pressure drop for ohe coííector row íh íh. W.C. n Row Number of collector rows Vk Flow rate through the individual collectors in gpm Vk, Nom Nominal flow rate of collector in gpm Example · Parameters - Cohhectíoh íh seríes of 2 coííector rows, each wíth 5 Bosch FKC·1 or FKB·1 soíar coííectors · Wanted – Pressure drop of collector system · Caícuíatíoh – Flow rate through one collector: V k = v k, Nom · n V k = 0.22 gpn · n Row = 0.22 gpn · 2 = 0.44 gpn – Read from Figure 50: 13.85 in. H 2 O per collector row – Pressure drop of array: /Ǥ Array = /Ǥ Row· n Row = 13.85 in. H ² O · 2 = 27.2 íh H ² O The pressure drop of the collector array is 27.2 in. H 2 O. R V E FSK Figure 49 Connection in series of two collector rows 5 Sizing 34 | Design Guide - Bosch Solar Thermal Systems Collector rows connected in parallel The pressure drop for the array results from the total of the pipework pressure drop values up to a collector row and the pressure drop of an individual collector row. p Array Δ p Row Δ Figure 50 Formula for the pressure drop of a collector array with rows of collectors connected in parrallel Unlike the situation when connecting in series, the actuaí Ȼow rate vía the íhdívíduaí coííectors correspohds to the honíhaí coííector Ȼow rate of 0.22 gpn (50 l/h). V K V K,Nom = ligurc51lcrmulafcrthcȽcwratcthrcughaccllcctcr with rows of collectors connected in parrallel Calculation parameters (Figure 50 and 51) /Ǥ Array Pressure drop for coííector array íh. W.C. /Ǥ Row Pressure drop for ohe coííector row íh. W.C. Vk Flow rate through the individual collectors in gpm Vk, Nom Nominal flow rate of collector in gpm Example · Parameters - Cohhectíoh íh paraííeí of 2 coííector rows, each with 5 solar collectors · Wanted – Pressure drop of overall collector array · Caícuíatíoh – Flow rate through one collector: V k = V k, Nom ·n = 0.22 gpn – Read from Figure 50: 4.45 in. H 2 O per collector row – Pressure drop of array: /Ǥ Array = /Ǥ Row = 4.45 íh H 2 O The pressure drop of the collector array is 4.45 in. H 2 O R V E FSK E Figure 52 Two collector rows connected in parallel using reverse-return piping 5 Sizing | 35 Design Guide - Bosch Solar Thermal Systems 5.4.4 Pressure drop of pipework in the solar circuit Calculating the pipework The Ȼow veíocíty íh the pípework shouíd be íh excess of 1.3 ft/sec to allow air remaining in the heat transfer medium to be transported to the next air separator. Flow noise can occur from velocities of 3 ft/sec and higher. Take Number of collectors Flow rate Flow velocity v and pressure dropR in copper pipes with pipe dimensions of gpm 2 0.44 3 0.66 4 0.88 5 1.10 R in H 2 O/ft 0.11 0.17 0.42 0.61 v ft/s 0.69 1.00 1.38 1.70 1/2 inch Figure 53 Flow velocity and pressure drop per ft of straight copper pipe for a 50/50 glycol:water mix at 122°F (50°C) 5.4.5 Pressure drop of the selected solar storage tank The pressure drop of the solar storage tank depends on the hunber of coííectors ahd the Ȼow rate. The íhdírect coils of the solar storage tank have various pressure drop characteristics because of their differing dimensions. Use Number of collectors Flow rate Pressure drop in solar indirect coils of the storage tank SOL-RET80 gpm in feet of head 2 0.44 0.6' 0.8' 3 0.66 0.8' 1.1' 4 0.88 1.2' 1.4' 5 1.1 1.3' 1.6' SOL-RET120 in feet of head Figure 54 Pressure drop values of solar storage tanks for a 50/50 glycol:water mixture at 122°F (50°C) individual resistance values (caused by bends, for example) into consideration in the pressure drop calculation by adding 30% to 50% to the pressure drop of the straight pipework. Figure 54 to estimate the pressure drop. The pressure drop in the table applies to a 50/50 glycol:water mixture at a tenperature of 122 °F (50 °C). 5 Sizing 36 | Design Guide - Bosch Solar Thermal Systems 5.4.6 Bosch KS0105 pump station The pump station needs to overcome the following pressure drops: · Pressure drop in the collector array · Pipework pressure drop · Pressure drop in the solar storage tank · Addítíohaí pressure drop due to heat neter, vaíves or other Ⱥttíhgs 0 40 80 120 160 200 0 1 2 3 4 5 6 7 V/gpm 0 5 10 20 30 25 35 KS0105 n FKC-1/FKB-1 0 2 4 8 10 14 12 16 n CPC12 15 6 in W.C. ligurc55PrcssurcrangcscfthcBcschl$0105pumpstaticnssubjccttcthcȽcwratcandnumbcrcfccllcctcrs Ƚcwlimitcrdisplavrangchighlightcdinbluc 5 Sizing | 37 Design Guide - Bosch Solar Thermal Systems 5.5 Sizing of the diaphragm expansion vessel (DEV) 5.5.1 System volume calculation The volume of a solar system with the Bosch KS0105 pump statíoh ís síghíȺcaht for sízíhg the expahsíoh vesseí ahd deterníhíhg the voíune of soíar Ȼuíd. The foííowíhg fornuía appííes to the Ⱥíííhg voíune of the solar system with a Bosch KS0105 pump station: V A V K n K V WT V KS V R + + + = ligurc56lcrmulafcrȼllingvclumccfsclarhcating systems with Bosch KS0105 pump station Calculating sizes V A System filling volume Vk Volume of one collector n k Number of collectors V WT Solar indirect coil volume Vks Volume of a Bosch KS0105 pump station (approx. 1/4 gal (1 l)) VR Pipework volume Pipe dimension Ø × wall thickness Specifc line volume in gallons per foot (l/ft) 1/2" 0.0121 (0.0450) 3/4" 0.0251 (0.0950) 1" 0.0429 (01624) ligurc57$pcciȼcȼllingvclumccfsclcctcdpipcwcrk Solar collectors Collector content gallons (liters) Type Version Flat-plate collector FKC-1 vertical 0.23 (0.86) horizontal 0.33 (1.25) Flat-plate collector FKB-1 0.23 (0.86) vertical Figure 58 Filling volume of Bosch solar collectors 5 Sizing 38 | Design Guide - Bosch Solar Thermal Systems 5.5.2 Diaphragm expansion vessel for solar systems Calculation principles Precharge Adjust the precharge of the diaphragm expansion vesseí (DEv) príor to Ⱥíííhg the soíar systen. The required system precharge is calculated using the following formula: p V 0.442 h stat 5.8psi + = Figure 59 Formula for inlet pressure of a diaphragm expansion vessel Calculation parameters (Figure 59) and picture legend (Figure 60) Ǥ V DEV inlet pressure in bar h stat Static height in ft between center of DEV and highest point of system The minimum precharge is 17.4 psi (1.2 bar). Filling pressure The expansion vessel creates an equilibrium between the Ȼuíd pressure ahd the gas pressure. The equíííbríun (Vv Figure 64) is set with the system cold and monitored via the pressure gauge after bleeding the air from the system. The system pressure should be dialed in at 5 psi above the DEV preset pressure. A controlled evaporation tenperature of 250 °F (120 °C) ís therefore reached íh the event of stagnation. The Ⱥíííhg pressure ís caícuíated usíhg the foííowíhg formula: p 0 p V 5psi + = ligurc61lcrmulafcrȼllingprcssurccfadiaphragm expansion vessel Calculation parameters (Figure 61) and picture legend (Figure 62) Ǥ o DEV filling pressure in psi Ǥ V DEV precharge pressure in psi V v Menbrahe A devíatíoh fron the optínun precharge pressure or Ⱥíííhg pressure always leads to a reduction in available volume. This can cause system malfunctions, like early stagnation, or Ȼuíd spííís fron the reííef vaíve. p V Figure 60 In a precharged diaphragm expansion vessel that is disconnected from the system the mcmbrancwillȼllthccntircspacc p 0 V V Figure 62 Filling pressure of a diaphragm expansion vessel 5 Sizing | 39 Design Guide - Bosch Solar Thermal Systems Operating pressure At the naxínun coííector tenperature, the Ⱥíííhg gas ís conpressed to the Ⱥhaí systen pressure by takíhg up additional expansion volume (Figure 64). The Ⱥhaí pressure of the soíar systen ahd the pressure rating and the required size of the DEV are determined by the safety vaíve respohse pressure. The Ⱥhaí pressure ís determined using the following formula: p e p SV 3psi ≤ for p SV 44psi p e 0.9 p SV ≤ for p SV 44psi > − ≤ ligurc63lcrmulafcrȼnalprcssurccfadiaphragm expansion vessel subject to the safety valve response pressure Calculation parameters (Figure 63) and picture legend (Figure 64) Ǥ e DEV final pressure in psi Ǥ sV Safety valve response pressure in psi V e Expansion volume V v Hydraulic seal p e V V + V e Figure 64 Final pressure of diaphragm expansion vessel Intrinsic safety of a solar system A solar system is considered to be intrinsically safe if the DEV can absorb the volume change as a result of solar Ȼuíd evaporatíoh íh the coííector ahd the cohhectíhg ííhes (stagnation). If a solar system is not intrinsically safe, the safety valve responds during stagnation resulting in loss of Ȼuíd ahd pressure. Afterwards the soíar systen has to be re-started and must be properly balanced to avoid future service interruptions.. A DEV is sized on the basis of the following assumptions and formula: Calculation parameters (Figure 65 and 66) V n,min Míhínun D voíune íh gaííohs V A System filling volume in gallons n Expansion coefficient (= 7.3% wíth / = 180°F (100°C) V D Evaporation volume in gallons Ǥ e DEV outlet pressure in psi Ǥ o DEV filling pressure in psi n k Number of collectors V k Volume of collectors V n min , V A n V D + ( ) p e 14.7 + ( ) p e p 0 − ( ) ---------------------- = Figure 65 Formula for minimum DEV volume V D n K V K = Figure 66 Formula for evaporation volume 5 Sizing 40 | Design Guide - Bosch Solar Thermal Systems The weather conditions and the swimming pool heat loss íhto the grouhd have a cohsíderabíe íhȻuehce oh sízíhg. For that reason, sizing a solar heating system for heating swimming pool water can only ever be approximate. Basically, the sizing has to be oriented to the area of the pool. The water cannot be guaranteed to be at a certain temperature over several months. If the solar swimming pool water heating system is combined with DHW heating, we recommend the use of a dual-mode solar heating storage tank with a large solar indirect coil and limited storage tank heating up to 140 °F. Standard values for indoor swimming pools with covers Cohdítíohs for stahdard íhdoor swínníhg pooí vaíues · Pool basin covered when not in used (insulation) · Set pool water temperature 75 °F If the required set water temperature is higher than 75 °F, the number of required collectors increases by the correction factor listed below Range Reference size Sizing with solar collectors FKC-1 Pool surface Pool surface in ft² 1 collector for every 50 ft² Correction factor for pool water temperature Deviation above 75 °F pool water temperature 1.3 additional collectors for every +1 °F above pool water temp of 75 °F Example · Parameters – Indoor swimming pool, covered - Pooí surface 350 ft² – Pool water temperature 76 °F · Wanted - Nunber of FKC·1 soíar coííectors for soíar swimming pool water heating · Read above table - 5 FKC·1 soíar coííectors for pooí area of 350 ft² - 1 FKC·1 soíar coííector as correctíoh for +1 °F above 75 °F pool water temperature Síx FKC·1 soíar coííectors are requíred for soíar swínníhg pool water heating. 5.6 Sizing swimming pool water heating systems 5 Sizing | 41 Design Guide - Bosch Solar Thermal Systems Standard values for outdoor swimming pools The standard values only apply if the swimming pool is insulated and embedded in the ground in a dry condition. First insulate the pool if the swimming pool is at the level of groundwater without insulation. Then carry out a heat demand calculation. Covered outdoor swimming pool (or indoor swimming pool without insulation) A ratio of 1:2 applies as standard value. This means that the area of a coííector array wíth the FKC·1 nust be haíf the size of the pool surface area. Outdoor swimming pooI without insuIation In this case the standard value ratio is 1:1. This means that the area of a coííector array conprísíhg FKC·1 collectors must be the same size as the pool surface. If the solar heating system is intended for an outdoor swimming pool, DHW heating and/or central heating backup, add the required collector areas for the swimming pool water and DHW. Do not add the collector areas for central heating. The solar heating system heats the outdoor swimming pool in summer and central 5 Sizing 42 | Design Guide - Bosch Solar Thermal Systems 6 Design/engineering information regarding installation 6.1 Pipework, thermal insulation and collector temperature sensor extension cable Glycol and temperature-resistant sealing Aíí conpohehts of a soíar systen (íhcíudíhg Ȼexíbíe gaskets for valve seats, diaphragms in expansion vessels etc.) must be made from glycol-resistant materials and carefully sealed, since water:glycol mixtures have a greater tehdehcy to íeak thah pure water. Araníde Ⱥber seaís have proven to be effective. Graphited cord is suitable for sealing glands. Hemp seals must also be coated with temperature-resistant and glycol-resistant thread paste. Nísseh products "Neo Fernít uhíversaí" or "Fernítoí" cah be used as thread paste (follow the manufacturer’s instructions). The soíar hose ferruíes oh the Bosch FKC·1 ahd FKB·1 collectors provide an easy and reliable seal for collector cohhectíohs. Cohhectíhg kíts for 1[2 íhch Twíh·Tube are available for providing a reliable connection to the Twin- Tube double tube. Pipework routing All connections in the solar circuit that do not have Bosch- suppííed conpressíoh Ⱥttíhgs nust be soídered or brazed. Aíterhatíveíy, conpressíoh Ⱥttíhgs or press Ⱥttíhgs cah be used, provided that they are suitable for use with a water:glycol mixture and respectively high temperatures of up to 400 °F (205 °C). Aíí pípework nust be routed wíth a rise towards the collector array or the air vent valve, if installed. Heat expansion must be taken into consideration when routing the pipework. Pipe diameter inches Twin-Tube (double tube) insulation thickness inches Aerofex SSH pipe diameter × insulation thickness inches Aerofex HT pipe diameter × insulation thickness inches Mineral wool insulation thickness (indoor application only) inches 1/2 1/2" – 1/2 x 1" 3/4" 5/8 – 5/8 x 1" 5/8 x 1" 3/4" 3/4 1/2" 1 x 1" 1 x 1" 3/4" 1 – 1 x 1" 1 x 1" 3/4" 1-1/4 – 1-1/4 x 1-1/2" 1 x 1-1/2" 1-3/16" 1-1/2 – 1-1/2 x 1-1/2" 1-1/2 x 1-1/2" 1-3/16" Figure 67 Thickness of thermal insulation for solar system connection lines. Collector temperature sensor extension lead When routing the pipework, also route a two-core lead (up to 164 ft length 18 AWG) for the collector sensor alongside. An appropriate lead is provided in the insulation of the Bosch Twin-Tube. Provide a shield for the collector The pipes must be routed with provisions for expansion (bends, sliding clamps, compensators) to prevent damage and leaks. Plastic pipework, PEX, or galvanized components are not suitable for solar systems. Thermal insulation Cohhectíoh ííhes nay be routed íh uhused Ȼues, aír ducts and wall cavities (in new buildings). Open ducts must be properly sealed to prevent heat loss caused by rising air (convection). Follow building codes when pehetratíhg Ȼoors. The thermal insulation of the connection lines must be designed for the operating temperature of the solar system. Therefore use appropriate high temperature-resistant insulating materials such as íhsuíatíhg hoses nade fron EPDM rubber. Thernaí insulation exposed to the elements on the roof must be UV, weather and temperature resistant. Figure 67 shows standard values for the insulating thíckhess oh pípework íh soíar systens. Míheraí wooí ís not suitable for outdoor applications because it absorbs water and then fails to provide thermal insulation. temperature sensor extension lead, if it is routed next to a 120 V cable. Install the FSK collector temperature sensor in the sensor well of the top supply header of the Bosch FKC·1 ahd FKB·1 coííectors. 6 Design/engineering information regarding installation | 43 Design Guide - Bosch Solar Thermal Systems 6.2 Air vent valve 6.2.1 Automatic air vent valve Uhíess a hígh voíune ahd hígh pressure Ⱥíííhg statíoh wíth aír separator ís beíhg used, soíar systens wíth Ȼat· plate collectors are vented via quick-acting air vent valves at the híghest poíht of the systen. After Ⱥíííhg has beeh completed, this valve must be closed and remain closed to preveht steaníhg soíar Ȼuíd fron escapíhg fron the system in the event of stagnation. Provide an air vent valve at the highest point of the system (detail E, Figure 68) and, for every change of direction, with a new rise (e.g. in dormers, Figure 44). If there are several rows of collectors, provide an air vent valve for each row (Fígure 69), uhíess the systen cah be vehted above the top row (Figure 70). Use only automatic all- metal air valves. Never use aír veht vaíves wíth píastíc Ȼoats íh soíar heating systems because of the high temperatures that occur. lf there ís íhsufȺcíeht roon for ah autonatíc aíí· metal air vent valve with an upstream ball valve, install a manual air vent valve. R V E FSK E Bosch FKC-1 and FKB-1 Figure 68 Hydraulic diagram with air vent valve at the highest point of system R V E E Figure 69 Hydraulic diagram with air vent valve for each ccllcctcrrcwcnthccxamplccfȽatrccf installation (connection in series) R V E Figure 70 Hydraulic diagram with air vent valve above the top row on the example of rooftop installation (connection in series) 6 Design/engineering information regarding installation 44 | Design Guide - Bosch Solar Thermal Systems 6.2.2 Filling station and air separator The quíckest ahd nost efȺcíeht way to Ⱥíí Bosch soíar systens ís by usíhg the Bosch Ⱥíííhg statíoh (Fígure 71), resulting in most air being pushed out of the system during the Ⱥíííhg procedure. Ah aír veht vaíve oh the roof ís hot needed in this case. BeheȺts of the systen are. · Reduced installation effort because no air vent valves are needed on the roof · Easy ahd quíck conníssíohíhg, í.e. Ⱥíííhg ahd deaeration in one step , followed by pressurization. · EfȺcíehtíy vehted systen · Low-maintenance operation If the collector array consists of several rows connected in parallel, provide each individual row with a shut-off valve íh the suppíy pípe. Each row ís Ⱥííed ahd vehted íhdívíduaííy duríhg the Ⱥíííhg procedure. 1 2 A 1 Pressure hose 5 ft 2 Return hose 6 ft No air vent valve needed ligurc72$vstcmdcsign,dctailA:lillingprcccdurcwith pump ligurc71Bcschsclarȼllingstaticn 6 Design/engineering information regarding installation | 45 Design Guide - Bosch Solar Thermal Systems 6.3 Roof mounting systems 6.3.1 Permissible standard snow loads and building heights The following table contains the permissible standard snow loads and building heights for the different installation options. This information is most useful during the planning phase of a solar thermal project. Rooftop installation Vertical/horizontal Flat roof installation Vertical/horizontal Wall mounting 45–60 Horizontal Roof cover/wall Tiles, plain tiles, slate, shingle, corrugated sheets, sheet steel, bitumen – load-bearing Permissible roof pitch 25°–65°, 5°–65° (corrugated sheets, sheet steel roof) 0° (with slightly sloping roofs of up to 25°, protection from sliding of or on-site attachment) – Permissible building heights (wind loads) of up to 65 ft- at wind speeds of up to 80 mph Without accessories Without accessories (observe securing fat roof supports!) Without accessories Permissible building heights (wind loads) of up to 300 ft - at wind speeds of up to 94 mph Only vertical collectors with rooftop installation kit With fat roof support kit (observe fat roof support fxing!) Not permissible Standard snow loads 0–2 5 lbs/ft² Without accessories Without accessories Without accessories Standard snow loads > 25 lbs/ft² Only vertical collectors with rooftop installation kit up to 35 lbs/ft² Without fat roof support kit up to 43 lbs/ft² Not permissible Figure 73 Permissible standard snow loads and building heights 6 Design/engineering information regarding installation 46 | Design Guide - Bosch Solar Thermal Systems 6.3.2 Rooftop installation The collectors are secured directly to the roof at the same pitch of the roof itself. The rooftop íhstaííatíoh kít for Bosch FKC·1 ahd FKB·1 Ȼat·píate coííectors cohsísts of a stahdard kít for the Ⱥrst coííector íh a row ahd ah extehsíoh kít for each additional collector in the same row (Figure 74). Use the rooftop installation extension kit only in conjunction with a standard kit. In place of the single-side collector clamps (item 1 Figure 75) the extension kit contains so-called double-sided collector clamps (item 5 Figure 75) and cohhectors for deȺhíhg the correct spacíhg ahd securíhg two adíaceht Bosch FKC·1 or FKB·1 Ȼat·píate coííectors. 2 - 3 - 1 / 4 " ( 5 0 – 8 0 m m ) 11-1/4" (285 mm) 1 / 3 " ( 9 m m ) 1-1/4" (33 mm) 1 - 1 / 2 " ( 3 5 m m ) 1/3" (9mm) 16" (407 mm) 1 - 1 / 2 - 2 - 1 / 4 " ( 3 8 – 5 9 m m ) 1- 1/2" ( 40 mm) DIA 1/3" (9mm) 11- 3/4" ( 300 mm) 1 - 1 / 4 " ( 3 5 m m ) 2 - 3 / 4 " ( 7 0 m m ) 2 - 1 / 2 " ( 6 2 m m ) 4 " ( 1 0 m m ) 1 / 3 " ( 8 m m ) 6- 1/2" ( 165 mm) 12" ( 304 mm) 2- 1/3" ( 61 mm) 2- 1/2" ( 65 mm) 201/2" ( 65 mm) 1 / 3 " ( 8 m m ) 7" (180 mm) 2-1/4" (55 mm) M 1 2 3" (75 mm) For information on attachment systems for standing seam steel or alumimum roofs, please contact Bosch. Roof connection for tile and plain tile covers Roof connection for slate and shingle covers Roof connection for corrugated sheet roof r o h c n a r e t f a R k o o h f o o R Roof hook Figure 74 Roof connection versions for different roof covers (dimensions in inches (mm)) Roof connections for different roof covers The proȺíe raíís ahd coííector tehsíohers of the varíous rooftop installation kits are identical for all roof connections. The various installation kits for tile and plain tile, slate and shingle cover as well as for corrugated sheet and sheet steel roofs only differ with regard to the type of roof hook (Figure 74) or special attachment materials used (Figure 75). 6 Design/engineering information regarding installation | 47 Design Guide - Bosch Solar Thermal Systems Roof connection for tiled roofs Figure 75 shows an example for a rooftop installation on a tile roof. On roofs with simple battens, the roof jacks are fastened to the sheathing (Figure 76). This is done by turning the lower part of the roof jack over. If additional height compensation is needed, the lower section of the roof jack can be shimmed up. On roofs with counter battens, the roof jacks (Figure 74) are hooked over the existing roof battens (Figure 76) and fastened to the proȺíe raíís. When considering installation on a tile roof, check whether the dínehsíohs specíȺed íh Fígure 75, detaíí A, can be met. Use the roof jacks supplied, if they · Ⱥt íhto the vaííey of the roof tííe ahd · extehd over the roof tííe píus roof batteh. The tile cover should not exceed 5 inches. Where hecessary, íhcíude a rooȺhg cohtractor íh the píahhíhg ahd íhstaííatíoh process. Care nust be takeh that the hooks are only mounted on parts of the roof that are capable of providing the necessary support under all foreseeable conditions. Legend (Figure 75) 1 Single-sided collector tensioner (only in the standard kit) 2 Roof jack, adjustable 3 ProȺíe raíí 4 Coííector hook (2x per coííector) 5 Double-sided collector clamp (only in the extension kit) 6 Cohhector (ohíy íh the extehsíoh kít) 7 Sheathing Legend (Figure 76) 1 Hex nut 2 Serrated washer 3 Roof batten 4 Roof jack, lower part Legend (Figure 77) 1 Hexagon nut 2 Serrated washer 3 Wood screws 4 Roof jack, lower part 5 Sheathing 7 A 1-1/3" (35mm) 2 - 3 - 1 3 " B 5 mm Allen wrench 6 4 3 2 1 ( 5 0 - 8 6 m m ) Figure 75 Rooftop installation standard kit and extension kit (highlighted in blue) for one BcschllC·1andllB·1Ƚat·platcccllcctcr (detail A: dimensions in inches (mm)) 1 2 3 4 Figure 76 Installed roof jack 1 2 4 3 5 Figure 77 Roof jack fastened to the sheeting 6 Design/engineering information regarding installation 48 | Design Guide - Bosch Solar Thermal Systems Plain tile roof connection Figure 78 shows attaching the roof jack (item 2) to a plain tile roof. Trim and attach the plain tiles on site. The horízohtaí proȺíe raíís are fastehed to the roof íack the same way as with regular tiles (Figure 75). Cohsuít a rooȺhg cohtractor for rooftop íhstaííatíoh on plain tiles, if needed. Legend (Figure 78) 1 Plain tiles (cut along the dotted line) 2 Roof hook, lower part fastened to sheathing Roof connection with slate or shingle Roof jack installations on slate or shingle roofs shouíd be carríed out by a rooȺhg cohtractor. Fígure 79 shows ah exanpíe of ah íhstaííatíoh of the roof íacks (íten 5 Fígure 79) oh a síate or shíhgíe roof. Gaskets, cauíkíhg ahd Ȼashíhg to be províded oh síte. The horízohtaí proȺíe raíís are to be fastehed to the roof íacks in the same way as on a tile roof (Figure 75). Legend (Figure 79) 1 Flashing top (on site) 2 Flashing bottom (on site) 3 Overlapping shingle or slate 4 Gasket or caulking (on site) 5 Roof jack 6 Screw (provided) 1 2 Figure 78 Roof jack attached on a plain tile roof 1 2 6 4 5 4 3 Figure 79 Special roof jack with waterproof cover (optional) for attaching a rooftop installation kitfcrȽat·platcccllcctcrstcaslatccr shingle roof 6 Design/engineering information regarding the installation | 49 Design Guide - Bosch Solar Thermal Systems Roof connection in situations with added insulation on rafters Figure 80 shows a scenario with insulation on rafters using the roof hooks. In order to establish an adequate base to attach the roof hooks to, the rooȺhg cohtractor secures wooden boards with a minimum cross-section of 1 x 8 inches to the rafters. The force generated by the roof hook must be transferred by this board to the loadbearing rafters. Wíth ah assuned naxínun show íoad of 42 íbs[ft² (wíthout accessoríes) or 65 íbs[ft² (wíth accessoríes), the design must be able to safely bear the following loads: · Force parallel to the roof surface: F sx = 180 íbf · Force perpendicular to the roof surface: Fsy = 400 íbf The horízohtaí proȺíe raíís nust be fastehed to the special roof jacks in the same way as they are with a tile roof (Figure 75). Legend (Figure 80) 1 Roof tile 2 Roof jack 3 Insulation on rafters 4 Rafter 5 Adequate screw for load (provided on site) 6 Board (at least 1 x 8 inches) Fsx Load parallel to the roof surface Fsy Load perpendicular to the roof surface Attachment on corrugated sheet roofs Installation on a corrugated sheet roof is only possible if the headless screws can be fastened at least 1½ inches into a structural element with adequate load- bearing capacity (Figure 81). The corrugated sheet roof connection kit contains headless screws including retaining brackets and gaskets that are used instead of the roof jacks in the rooftop installation kit. Fígure 83 shows how the proȺíe raíís are attached to the retaining brackets of the screws. Legend (Figure 81) 1 M8 × 16 Aííeh screws 2 ProȺíe raíí 3 Retaining bracket 4 Hex nut 5 Gasket F s y F s x 1 5 2 3 4 6 = 8 " (2 0 0 m m ) 1 5 2 3 4 6 > = 1 " (2 8 m m ) Figure 80 Example of on-site attachment of additional boards on top of insulation on rafters. Design may vary based on conditions. Use of a rccȼngccntractcrhighlvrcccmmcndcd. < 2 - 1 / 2 " ( 6 0 m m ) 4 " ( 1 0 5 m m ) > 1 - 1 / 2 " ( 4 0 m m ) 3 4 5 1 2 3 ligurc81Examplccfprcȼlcrailattachmcntwithrccftcp installation on a corrugated sheet roof. Use cfarccȼngccntractcrishighlvrcccmmcndcd 6 Design/engineering information regarding the installation 50 | Design Guide - Bosch Solar Thermal Systems Installation on standing seam steel or aluminum roofs Cohtact our soíar suppííer or Bosch Soíar for specíaí attachment clamps for standing seam metal roofs. http://www.boschsolar.com/ Connection on Ⱥat seam metaI roofs Figure 88 shows a mounting option for metal roofs without standing seams. It is recommended to consult a rooȺhg cohtractor as the roof's nenbrahe has to be penetrated. Secure a sleeve similar to the one shown in Figure 82 to the roof on site and use appropriate measures to waterproof the pehetratíoh. Choose the hunber of síeeves per collector based on their load rating, but at least four. Sleeves can also be soldered or brazed to the roof. The M12 × 180 screws are fastehed to the substructure (rafter or load-bearing beam, at least 2 x 2 inches) through the sleeve. Legend (Figure 82) 1 ProȺíe raíí 2 M8 × 16 Aííeh screws 3 Retaining bracket 4 M12 screw 5 Sleeve 6 Sheet metal roof 7 Load bearing sub-structure (minimum 2 x 2 inches) Cohsuít a rooȺhg cohtractor to ehsure a weather proof installation and avoid water damage to the building. Snow Ioad proȹIe]additionaI raiI Install a snow guard and an additional rail (accessories) on buildings between 65 ft and 300 ft in heíght ahd íh regíohs wíth show íoads of 42 íbs[ft² to 65 íbs[ft² . These províde better dístríbutíoh of the hígher loads on the roof. Figure 83 shows the installation of a snow guard and an additional rail on the example of tile cover. Both accessoríes cah aíso be Ⱥtted to íhstaííatíoh systens for other roof types. Legend (Figure 83) 1 ProȺíe raíís types (rooftop íhstaííatíoh kít) 2 Additional rails (including collector tensioner) 3 Additional roof connection (snow guard standard delivery) 4 vertícaí proȺíe raíís (show guard stahdard deíívery) < 2 - 3 / 8 ” 4 - 1 / 8 ” > 1 - 1 / 2 ” 3 4 5 7 6 7 5 4 3 6 1 2 1-1/2” Figure 82 On-site attachment of sleeves for watertight mounting of screws for installation on sheet metal roofs (dimensions in inches) 3 4 2 1 1 Figure 83 Rooftop installation kit with snow guard and additional rail 6 Design/engineering information regarding the installation | 51 Design Guide - Bosch Solar Thermal Systems Hydraulic connections The rooftop connection kits are used to make the hydraulic collector connections (Figure 84). It is recommended to penetrate the roof close to the collector connection, and avoid long pipe runs above the roof. For asphalt shingle roofs use standard plumber’s rubber pípe Ȼashíhg. lt ís reconnehded to cohsuít a rooȺhg cohtractor for specíȺcs ahd to avoíd water danage to the buíídíhg. Roof outlets are required for supply and return, since the collector connections are above roof level. On tile roofs a "vehtííatíoh tííe" (Fígure 85) cah be used as a roof outíet for the supply and return lines. If the site allows, and an air vent is needed (-> 6.2), mount the air vent in the attic. Ensure still that it marks the highest point of all piping, and is mounted perfectly vertical to ensure proper operatíoh of the íhterhaí Ȼoat. The suppíy ííhe ís routed through the rooȺhg skíh wíth ah íhcííhe to the aír veht valve, if required, via the upper ventilation tile. The lead from the collector temperature sensor also runs through this tile. Route the return line to the pump station. A píunber's rubber pípe Ȼashíhg or vehtííatíoh tííe cah be used for this if the return line runs in the attic (Figure 85). An additional air vent valve is not usually required, in spite of the change of direction at the penetration. lhvoíve a rooȺhg cohtractor íh the píahhíhg to preveht damage to the building. Legend (Figure 84) 1 Cohhectíhg ííhe 39 íhches 2 Dummy plug 3 Spring clips 4 Hose coupling with R 3/4 inch connection or 5/8 inch locking ring Legend (Figure 85) 1 Supply line 2 Return line 3 Sensor lead 4 Ventilation tile 5 Air vent valve Static requirements The rooftop installation kit is exclusively designed for the secure mounting of solar collectors. Never attach other rooftop equipment such as antennae to the collectors or collector mounting kits. The roof and the substructure must have an adequate load-bearing capacity. A load of about 100 1 3 4 2 3 3 2 3 1 4 3 3 Figure 84 FKC-1 and FKB-1 rooftop connection kit 1 2 3 4 4 5 Figure 85 Ventilation tile example íbs cah be expected for each Bosch FKC·1 or FKB·1 Ȼat· píate coííector. Aíso take the specíȺc regíohaí íoads resulting from wind, snow and other factors into account. The values in Figure 86 are standard snow loads and building heights for rooftop installation. 6 Design/engineering information regarding the installation 52 | Design Guide - Bosch Solar Thermal Systems Rooftop installation system component selection aid Include appropriate connection materials in the design based on the number of collectors and their hydraulic connections. Total number of collectors 2 3 4 5 Number of rows 1 2 1 2 3 1 2 1 2 Number of collectors per row 2 1 3 2 1 1 4 2 5 3 2 FKB-1 and FKC-1 portait Standard kit 1) Tiles Plain tiles 1 2 1 2 3 1 2 1 2 Slate andasphalt shingle Corrugated sheet Sheet metal roof Extension kit 1) Tiles Plain tiles 1 – 2 1 – 3 2 4 3 Slate andasphalt shingle Corrugated sheet sheet metal roof Additional kit Standard kit 2) Tiles Plain tiles 1 2 1 2 3 1 2 1 2 Slate andasphalt shingle Corrugated sheet Sheet metal roof Additional kit Extension kit 2) Tiles Plain tiles 1 – 2 1 – 3 2 4 3 Slate andasphalt shingle Corrugated sheet Sheet metal roof FKC-1 landscape Standard kit 1) Tiles Plain tiles 1 2 1 2 3 1 2 1 2 Slate andasphalt shingle Corrugated sheet Sheet metal roof Extension kit 1) Tiles Plain tiles 1 – 2 1 – 3 2 4 3 Slate andasphalt shingle Corrugated sheet Sheet metal roof Figure 86 Installation materials for rooftop installation systems 1) Cohsístíhg of íhstaííatíoh kít ahd roof cohhectíoh 2) Cohsístíhg of show guard ahd addítíohaí horízohtaí raíí, requíred for show íoads of 42 íbs[ft² to 65 íbs[ft² or buíídíhg heíghts of 65 ft to 300 ft 6 Design/engineering information regarding the installation | 53 Design Guide - Bosch Solar Thermal Systems 6.3.3 Flat roof installation Flat roof installation is intended for level roof surfaces, or where the collectors are to be positioned at an angle steeper than the pitch of the roof (Figure 87). The Ȼat roof íhstaííatíoh kít for Bosch FKC·1 ahd FKB·1 Ȼat·píate coííectors cohsísts of a stahdard kít for the Ⱥrst coííector íh a row ahd ah extehsíoh kít for each addítíohaí coííector íh the sane row (Fígure 95). Accessories are required for buildings more than 65 ft hígh, or wíth show íoads of > 42 íbs[ft² (Fígure 73). The ahgíe of íhcííhatíoh of the Ȼat roof support cah be adjusted in steps of 5° as follows: · vertícaí Ȼat roof support. 30° to 60° (25° by trimming the telescopic rail) · Horízohtaí Ȼat roof support. 35° to 60° (25° or 30° by trimming the telescopic rail) The Ȼat roof supports cah be íhstaííed to the roof by means of weighting (ballast) or by attaching them to the roof substructure. On·site mounting The Ȼat roof supports cah by nouhted ohto oh·síte substructures consisting of I-beams, for example (Fígure 89). For thís, predríííed hoíes are íh the botton proȺíe raíís of the Ȼat roof supports. The oh·síte substructure must be designed such that the wind force acting upon the collectors can be absorbed. The support spacíhg dínehsíohs cah be fouhd íh Ⱥgures 97 to 99. The posítíohs of the hoíes for attachíhg the Ȼat roof supports to the oh·síte substructure cah be fouhd íh Ⱥgure 100. For buildings more than 65 ft in height or with snow íoads of 42 íbs[ft² to 80 íbs[ft², each stahdard kít for vertícaí coííectors nust be Ⱥtted wíth ah addítíohaí raíí (standard kit addition) and each extension kit must be Ⱥtted wíth ah addítíohaí raíí ahd ah addítíohaí support (extehsíoh kít addítíoh). Wíth horízohtaí coííectors, Ⱥt aíí installation kits with an additional rail (standard kit and extension kit addition). 30˚ 45˚ 30˚ 15˚ 15˚ 45˚ 1 2 ligurc87ExamplcscfactualȽat·platcccllcctcranglc cfinclinaticnwhcnusingȽatrccfsuppcrts cnaȽatrccfwithashallcwpitch(<25°) ltcm1:pitch,ltcm2:ccllcctcranglccf inclination Figure 88 Flat roof support standard kit and extension kit(bluc)fcrcncllC·1·scrllB·1·sȽat collector 22-3/16 22-3/16 (13-7/8) (13-7/8) ligurc89llatrccfsuppcrtȼxcdcnsitcwithbasc anchoring to a substructure consisting of l·bcamsuppcrts(dimcnsicnsininchcs), valucinbrackctsfcrhcrizcntalvcrsicn, center contact surface (blue) only required for buildings above 65ft in height. 6 Design/engineering information regarding the installation 54 | Design Guide - Bosch Solar Thermal Systems 38-1/2” 46” 38-1/2” Figure 90 Collector support spacing in standard version with Ƚatrccfsuppcrtsfcrvcrticalccllcctcrs FKC-1 and FKB-1 (dimensions in inches) 38-1/2” 38-1/2” 38-1/2” ” 2 / 1 - 7 ” 2 / 1 - 7 Figure 91 Collector support spacing in standard version whcnusingadditicnalsuppcrtswithȽatrccf supports for vertical collectors FKC-1 and FKB-1 (dimensions in inches) 71-5/8 ” 71-5/8 ” 10-11/16” ligurc92DistanccbctwccnccllcctcrsuppcrtswithȽatrccf supports for horizontal FKC-1 collectors (dimensions in inches) 6 Design/engineering information regarding the installation | 55 Design Guide - Bosch Solar Thermal Systems Securing by means of ballast trays Four baííast trays are requíred for each Ȼat roof support when the collectors are weighed down (dimensions: 37·3[8" x 13·3[4" x 2") · these are hooked íhto the Ȼat roof support (Fígure 93) ahd nust be Ⱥííed wíth cohcrete brícks, graveí or the ííke. See Fígure 96 for the requíred baííast weíght (naxínun 700 íbs wíth graveí Ⱥíííhg) subject to the height of the building. With a building up to 65 ft high and snow loads of up to 42 íbs[ft², ohe addítíohaí support ís requíred for the 4th, 7th and 10th collector in a row when ballast trays are used in conjunction with vertical collectors. The installation kit includes one additional support when horizontal collectors are used. The additional supports are required for hooking in the trays. For buildings higher than 65 ft or with snow loads of 42 íbs[ft² to 80 íbs[ft², each stahdard kít nust íhcíude ah additional rail (standard kit addition) and each extension kit for vertical collectors must include an additional support and an additional rail (extension kit addition). With horizontal collectors, all installation kits must be equipped with an additional rail (standard kit and extension kit addition). Erect the entire structure on protective building mats to protect the roof membrane. Ensure that the roof and building can support the weight of the collectors and ballast. Hydraulic connections The Ȼat roof cohhectíoh kíts are used to nake the hydrauííc coííector cohhectíohs íh Ȼat roof íhstaííatíoh (Fíg. 87). Route the supply line parallel to the collector to prevent damage to the connection due to the movement of the collector in the wind. Static requirements Follow Figure 73 snow loads and building heights. Legend (Figure 94) 1 Bracket with R 3/4 inch connection on the system-side or 5/8 inch locking ring 2 Stop washer 3 Nut G1 4 Dummy plug 5 Spring clips Legend (Figure 95) 1 Pipe clamp (on site) 2 M8 thread to attach hose cíanp for routíhg pípe alongside the collector 3 Bracket (connection kit standard delivery) 4 Supply line Figure 93 Flat roof support with ballast trays and additional guy ropes 4 3 2 1 4 3 2 1 5 5 ligurc94llC·1Ƚatrccfccnnccticnkit 4 2 1 3 Figure 95 Collector supply line routing 6 Design/engineering information regarding the installation 56 | Design Guide - Bosch Solar Thermal Systems Flat roof support weights To deterníhe the roof íoads, the foííowíhg weíghts for Ȼat roof íhstaííatíoh kíts, use the. · Standard kit, vertical: 27 lbs · Stahdard kít, horízohtaí. 19 íbs · Extension kit, vertical: 16 lbs · Extehsíoh kít, horízohtaí. 19 íbs FIat roof support ȹxing (coIIector stabiIization) Beíow tabíe ís for referehce ohíy. Requíred support varíes fron síte to síte ahd shouíd be veríȺed by a professíohaí ehgíheeríhg Ⱥrn. Building height Wind velocity Base anchoring Ballast Guy rope Protection against tilting Protection against slippage Number and type of screws 1) Weight (e.g. concrete bricks) Weight (e.g. concrete bricks) Max. tensile strength per rope ft mph lbs lbs lbf 0-25 60 2x M8/8.8 595 400 360 25-65 80 2x M8/8.8 990 700 560 65-300 90 3x M8/8.8 2) 990 740 ligurc96CpticnsfcrsccuringȽatrccfsuppcrtsfcrcachccllcctcrtcprcvcnttiltingcrslidingfrcmwind. 1) Per collector support 2) Not permitted Flat roof installation; component selection aid Cohsíder appropríate attachneht nateríaís íh the desígh based oh the hunber of coííectors ahd theír hydrauííc connections. Total number of collectors 2 3 4 5 Number of rows 1 2 1 2 3 1 2 1 2 Number of collectors per row 2 1 3 2 1 1 4 2 5 3 2 Installation kits with ballast tray 1) FKC-1 and FKB-1 vertical Standard kit 1 2 1 2 3 1 2 1 2 Extension kit 1 – 2 1 – 3 2 4 3 Additional support 2) – – – – – 1 – 1 – Standard kit addition 3) 1 2 1 2 3 1 2 1 2 Addition to extension kit 3) 1 – 2 1 – 3 2 4 3 FKC-1 horizontal Standard kit 1 2 1 2 3 1 2 1 2 Extension kit 1 – 2 1 – 3 2 4 3 Standard kit addition 3) 1 2 1 2 3 1 2 1 2 Addition to extension kit 3) 1 – 2 1 – 3 2 4 3 Installation kits for on-site attachment FKC-1 and FKB-1 vertical Standard kit 1 2 1 2 3 1 2 1 2 Extension kit 1 – 2 1 – 3 2 4 3 Standard kit addition 3) 1 2 1 2 3 1 2 1 2 Addition to extension kit 3) 1 – 2 1 – 3 2 4 3 FKC-1 horizontal Standard kit 1 2 1 2 3 1 2 1 2 Extension kit 1 – 2 1 – 3 2 4 3 Standard kit addition 3) 1 2 1 2 3 1 2 1 2 Addition to extension kit 3) 1 – 2 1 – 3 2 4 3 ligurc97lixingmatcrialsfcrȽatrccfinstallaticnsvstcm 1) The standard installation and extension kits contain one set of ballast troughs each 2) Not required if the additional extension kit is selected 3) Required in addition to the standard and extension kit with snow loads in excess of 42 lbs/ft² or building height exceeding 65ft 6 Design/engineering information regarding the installation | 57 Design Guide - Bosch Solar Thermal Systems 6.3.4 Wall installation Waíí íhstaííatíoh ís ohíy suítabíe for horízohtaí Bosch FKC·1 Ȼat píate coííectors, ahd ohíy for waíís up to ah íhstaííatíoh height of 65 ft. Waíí nouhtíhg requíres horízohtaí Ȼat roof supports. The Ⱥrst coííector íh the row ís íhstaííed usíhg a waíí support standard kit. Every additional collector in the same row is installed using a wall support extension kit. These kits íhcíude three supports (Fígure 99). The pítch of the collectors on the wall may only be set to between 45° and 60° reíatíve to the horízohtaí (Fígure 98). On·site attachment Secure the collector supports on site to structural elements of a wall capable of bearing the load of the collector array in addition to possible snow and wind loads usíhg a níhínun of three boíts per support (Fígure 99). 38-1/2" 38-1/2" 5-5/16" 38-1/2" 38-1/2" 0 . 3 5 3 0 . 3 5 3 Figure 99 Wall mounting with wall support standard kit and wallsuppcrtcxtcnsicnkit(bluc),dimcnsicnsin inches Snow and ice accumulating on the collectors may give way and slide off suddenly. Take provisions that the installation does not pose a risk to property and cause personal injury from falling snow and ice. Component selection aid for wall mounting system for Bosch FKC-1 horizontal Total number of collectors 2 3 4 5 Number of rows 1 2 1 2 3 1 2 1 2 Number of collectors per row 2 1 3 2 1 1 4 2 5 3 2 Installation kits FKC-1-w Standard kit for wall mounting 1 2 1 2 3 1 2 1 2 Extension kit for wall mounting 1 – 2 1 – 3 2 4 3 Figure 100 Fixing materials for wall mounting system for Bosch FKC-1 horizontal Static requirements The values in Figure 73 are the permissible standard snow loads and building heights. 45˚ 45˚ 30˚ 60˚ 1 2 Figure 98 Max. permitted collector pitch on a wall 1: pitch (absolute angle relative to the horizontal) 2: collector angle of inclination 6 Design/engineering information regarding the installation 58 | Design Guide - Bosch Solar Thermal Systems 6.4 Lightning protection and grounding of solar systems Requirements for lighting protection Follow the national and local building codes on the installation on lightning arrestors. In the absence of such regulations for the building in question, it is the building owner’s responsibility to decide after consulting with professionals if a lightning protection system should be installed. Take into account that the collector array may be adding height to the building, and that the metal rails may increase the likelihood of a lightning strike. Lightning protection is typically required for buildings that · measure more than 65 ft in height · are síghíȺcahtíy hígher thah the surrouhdíhg buildings or horizontal In buildings open to the public (schools, government, ofȺce buíídíhgs, etc.) the ííghthíhg protectíoh requírenehts should be discussed with an expert and/or the building operator. This discussion should take place in the planning phase of the solar system. In residential installations solar systems are typically not síghíȺcahtíy hígher thah the roof ítseíf, ahd the probabíííty of a dírect ííghthíhg stríke does hot síghíȺcahtíy íhcrease from the addition of a solar thermal system. Grounding of the solar system Irrespectively of whether a lightning protection system is present, the supply and return of a solar system must always be grounded with a copper cable (minimum AWG 9) to the buíídíhg's grouhdíhg rod. If a lightning protection system is present, determine whether the collector array and the piping are protected by this system. If in question, consult a specialist electrical contractor. 6 Design/engineering information regarding the installation | 59 Design Guide - Bosch Solar Thermal Systems 7 Solar applications The following drawings are conceptual in nature and may not necessarily display all design, installation, and design considerations. Additional safety and/or auxillary equipment may be needed or required by code. These drawíhgs are for referehce ohíy for ofȺcíaís, systen designers, and licensed installers. It is expected that installers and system designers have adequate knowledge of industry practice for the equipement, procedures and applications. The following drawings are not to scale. 7.1 Solar DHW system with electric backup element__________________________________________pg. 60 7.2 Solar DHW system with gas tankless tankloading______________________________________pg. 61 7.3 Solar DHW system with gas tankless in line booster___________________________________pg. 62 7.4 Solar DHW system with gas tankless in line booster and recirc loop__________________pg. 63 7.5 Solar DHW system and swimming pool application with gas tankless in line booster__pg. 64 7.6 Solar commercial hot water system with gas tankless tankloading_____________________________pg. 65 7 Solar applications 60 | Design Guide - Bosch Solar Thermal Systems 7.1 Solar DHW system with electric backup element Electric element keeps comfort zone at top of the tank at tenperature. Requíres 240vAC síhgíe phase. System can be combined with third party solar PV system for generation of electricity used for electric element, pumps, and other loads. Symbols Service valves Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Expansion tank Well thermometer Circulator Solar Pump Station Domestic Hot Water Solar Controller Cold Water Supply Electric Element Thermostatic valve Setpoint 120°F Collector sensor Tank sensor 7 Solar applications | 61 Design Guide - Bosch Solar Thermal Systems 7.2 Solar DHW system with gas tankless tankloading Tankless water heater keeps comfort zone at top of tank at temperature. Use Ȼow·actívated Bosch GWH715ES or Bosch GWHC800ES wíth aquastat that actívates the círcuíator. Bosch GWH345ESR or GWH450ESR requires optional 12kOhm tank sensor, and the circulator wires directly to the water heater. See appliance manual for details and wiring diagram. Use of a timer is recommended to interrupt reheating during night time. Solar Pump Station Domestic Hot Water Solar Controller Cold Water Supply Symbols Service valves Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Expansion tank Well thermometer Circulator Thermostatic valve Setpoint 120°F 345/450 ESR, 715ES or C800ES gas tankless water heater Collector sensor Aquastat or tank sensor Tank sensor Aquastat / Water Heater setpoints Modeí Nunber Aquastat setpoint Water heater setpoint GWH C 920 ESC s140°F 14°F above Aquastat setpoint GWH C 920 ES s126°F* 140°F GWH 715 ES s126°F* 140°F GWH C 800 ES s126°F* 140°F * If local codes require higher setpoint or to increase the recovery capacity of the water heater, contact Bosch Thermotechnology. 7 Solar applications 62 | Design Guide - Bosch Solar Thermal Systems 7.3 Solar DHW system with gas tankless in line booster The tankless water heater only runs when solar water needs a boost. Buffer tank provides small amounts of DHW instantly and increases comfort by smoothing out DHW temperature. Recommended appliances: Bosch GWH715 or GWHC800. Thermostatic valve 1 ensures that warm solar water bypasses the water heater and directs cooler water through the appliance when reheating is needed. Thermostatic valve 2 acts as a tempering valve that brings potentially hot water temperatures down to a level that is safe for the inhabitants. Water supply Hot Cold Solar Pump Station Domestic hot water Thermostatic valve 1 Thermostatic valve 2 Ariston GL6+ or GL8ti mini tank Symbols Service valves Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Expansion tank Well thermometer Circulator Solar Controller Collector sensor Tank sensor System parameters: · Hoheyweíí AM101 Thernostatíc vaíves requíred for proper operation; · Renove check vaíves fron Thernostatíc vaíve 1 as ít ís used as a diverter valve; · Thernostatíc vaíve 2 ís a tenperíhg vaíve, · Reconnehded setpoíht 120°F for both vaíves, · Set tahkíess water heater tenperature to 140° F · Arístoh níhí tahk wííí províde íhcreased tenperature stability and quicker hot water delivery. (recommended but not required) 7 Solar applications | 63 Design Guide - Bosch Solar Thermal Systems 7.4 Solar DHW system with gas tankless in line booster and recirc loop Identical to system 7.4, but with domestic recirculation added. The tankless water heater only runs when solar water needs a boost. Buffer tank provides small amounts of DHW instantly and increases comfort by smoothing out DHW temperature. Recommended appliances: Bosch GWH715 or GWHC800. Thermostatic valve 1 ensures that warm solar water bypasses the water heater and directs cooler water through the appliance when reheating is needed. Thermostatic valve 2 acts as a tempering valve that brings potentially hot water temperatures down to a level that is safe for the inhabitants. Do not run the recirculation pump continuously, as it would drain the solar tank. Instead it is recommended to use a timer for the recirculation pump at 3 to 6 runs per hour. Each run must be long enough for hot water to reach the farthest tap. The timer should also limit recirculation pump operation to the time of day when occupants are home and likely to use hot water. Water supply Hot Cold Solar Pump Station Domestic hot water Thermostatic valve 1 Thermostatic valve 2 Ariston GL6+ or GL8ti mini tank Solar Controller Collector sensor Tank sensor Symbols Service valves Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Expansion tank Well thermometer Circulator Flow check valve System parameters: · Hoheyweíí AM101 Thernostatíc vaíves requíred for proper operation; · Renove check vaíves fron Thernostatíc vaíve 1 as ít ís used as a diverter valve; · Thernostatíc vaíve 2 ís a tenperíhg vaíve, · Reconnehded setpoíht 120°F for both vaíves, · Set tahkíess water heater tenperature to 140° F · Arístoh níhí tahk wííí províde íhcreased tenperature stability and quicker hot water delivery. (recommended but not required) · Choose síze of the Arístoh níhí tahk to natch the voíune of the recirculation loop 7 Solar applications 64 | Design Guide - Bosch Solar Thermal Systems 7.5 Solar DHW system and swimming pool application with gas tankless in line booster The tankless water heater only runs when solar water needs a boost. Buffer tank provides small amounts of DHW instantly and increases comfort by smoothing out DHW temperature. Recommended appliances: Bosch GWH715 or GWHC800. Thermostatic valve 1 ensures that warm solar water bypasses the water heater and directs cooler water through the appliance when reheating is needed. Thermostatic valve 2 acts as a tempering valve that brings potentially hot water temperatures down to a level that is safe for the inhabitants. Once the DHW target temperature is met, the diverter valve is activated opening the port to the pool heating exchanger. Symbols Service valves Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Expansion tank Well thermo- meter Circulator Water supply Hot Cold Solar Pump Station Domestic hot water Thermostatic valve 1 Thermostatic valve 2 Ariston GL6+ or GL8ti mini tank Solar Controller Collector sensor Tank sensor POOL Heat exchanger Drain valve Temperature sensor The swimming pool pump is switched on as soon as the switch-on temperature difference between the external heat exchanger and the swimming pool is reached. When the switch-off temperature difference between the external heat exchanger and the swimming pool is reached, the swimming pool pump switches off. System parameters: · Hoheyweíí AM101 Thernostatíc vaíves requíred for proper operation; · Renove check vaíves fron Thernostatíc vaíve 1 as ít ís used as a diverter valve; · Thernostatíc vaíve 2 ís a tenperíhg vaíve, · Reconnehded setpoíht 120°F for both vaíves, · Set tahkíess water heater tenperature to 140° F · Arístoh níhí tahk wííí províde íhcreased tenperature stability and quicker hot water delivery. (recommended but not required) · 3 port díverter vaíve wíth 120v actuator 7 Solar applications | 65 Design Guide - Bosch Solar Thermal Systems 7.6 Solar commercial hot water system with gas tankless tankloading The following provides a general overview of commercial hot water systems in conjunction with solar water heating. The tankless water heaters keep the comfort zone at top of tank at temperature. Use Ȼow·actívated Bosch GWH715ES or Bosch GWHC800ES wíth aquastat that actívates the círcuíator. Domestic Hot Water Solar Controller Symbols Service valve Pressure relief valve Honeywell Am-1 series thermostatic mixing valve Solar storage tank Flow direction Potable water expansion tank Well thermometer Circulator Thermostatic valve Setpoint 120°F Collector sensor Aquastat or tank sensor Drain valve Twin tube Expansion tank Cold Water Supply Aquastat or tank sensor DHW recirculation pump Hot water recirculation return line Solar Pump Station Flow check valve Hoheyweíí AM101 Thernostatíc vaíves requíred for proper operatíoh. For optínaí perfornahce, the Ȼow through the tankless water heaters should be between 3.5-5 gpm. 7 Solar applications 66 | Design Guide - Bosch Solar Thermal Systems 8 System design recommendations Listed below are important design recommendations to ensure proper operation of the entire solar thermal system. 1. Mouht coííectors oh a roof or waíí surface that has sufȺcíeht soíar exposure. Ensure at least 6 hours of direct unobstructed solar exposure per day. 2. Avoid mounting collectors where trees, adjacent buildings, or building features (chimneys, etc.) put a partial shade on the collectors. 3. lhsufȺcíeht íhsuíatíoh of soíar pípes íead to excessive losses. Use proper insulation on all pipes between the collectors and the tank. 4. On the roof ensure all insulation material is resistant to UV rays and weather related wear and tear, as well as does not attract birds or rodents. 5. Do not oversize the collector array in relation to the storage tank volume. 6. Check the systen at íeast ohce a year for Ȼuíd ahd pressure losses. Find and immediately mitigate any issues. 7. After commissioning, make sure the upper air vent is and remains closed. It only needs checking for accumulated air during the annual system inspection or if system performance indicates air may be in the system 8. Excessíve Ȼow rates doh't aííow the coííectors to reach síghíȺcaht tenperatures ahd the deíta T between supply and return are small. Refer to chapter 5.4.2 Fíow rate íh the coííector array for the correct Ȼow rate calculation. 9. DEV pressure setting: Refer to chapter 5.5.2 Diaphragm expansion vessel for details on how to determine the correct DEV pressure setting. 8 System design recommendations | 67 Design Guide - Bosch Solar Thermal Systems Notes Uhíted States ahd Cahada Bosch Thernotechhoíogy Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel: 603-552-1100 Fax: 603-584-1681 www.boschsolar.com Products manufactured by Bosch Thermotechnik GmbH D-35573 Wetzlar www.boschthermotechnik.de BTC 770001301 B [ 10.2009 2 | Design Guide - Bosch Solar Thermal Systems Contents Table of Contents 1 Principles 4 4 6.1 1.2 Free solar energy 4 6.2 6.3 1.3 Energy supplied by solar collector system in relation to energy demand 5 Pipework, thermal insulation & collector r temperature sensor extension cable 42 Air vent valve Roof mounting systems 43 45 58 6 Design/engineering information regarding the installation 42 1.1 Introduction 2 Description of the solar system 6 6.4 Lightning protection and grounding of solar systems 3 Technical description of system components 7 7 11 13 16 18 7 Solar applications 59 3.1 Solar collectors 3.2 Solar storage tank 3.3 Solar controller 3.4 Bosch KS pump stations 3.5 Other system components 7.1 Solar DHW system with electric backup element 60 7.2 Solar DHW system with gas tankless tankloading 7.3 Solar DHW system with gas tankless in line booster 7.4 Solar DHW system with gas tankless in line booster and recirc loop 61 62 63 4 Notes regarding solar systems 21 21 4.1 General information 7.5 Solar DHW system and swimming pool application with gas tankless in line booster 7.6 Solar commercial hot water system with gas tankless tankloading 64 65 4.2 Regulations and guidelines for designing engineering a solar collector system 22 5 Sizing 23 23 24 8 System design recommendations 66 5.1 Sizing principles 5.2 Sizing the collector array and solar storage tank 5.3 Space requirements for solar collectors 27 5.4 Hydraulic system engineering 5.5 5.6 Sizing of the diaphragm expansion vessel (DEV) 31 37 40 Sizing swimming pool water heating systems Design Guide - Bosch Solar Thermal Systems |3 This technical guide is designed to educate the homeowner. the installer. A solar thermal system uses the energy of the sun to heat domestic hot water (DHW).2 Free solar energy The energy that is provided by the sun can be used effectively in almost any part of North America. A considerable proportion of solar energy can be used for heat generation using solar collector systems. the average insolation that can be expected in your region (Figure 1). and fewer emissions reduce the burden on the environment and the earth’s climate. and the architect on solar product offered by Bosch. The installations in this manual have been tried and tested by Bosch and were selected for their simplicity. saving valuable fuel.1 Principles 1 Principles 1. Frequently people are unaware of the astounding proportion of heating that technically advanced solar systems can provide today. cost effectiveness. The systems for DHW heating are energy-saving and environmentally friendly. 1. It features descriptions of components. energy savings. Solar Figure 1 Average insolation in North America 4 | Design Guide . This protects the environment and lowers energy cost. and piping diagrams. and comfort.1 Introduction Solar thermal systems have become part of modern heating technology and reduce the consumption of fossil fuels.Bosch Solar Thermal Systems . the engineer. system sizing. Legend (Figure 2) a Energy demand b Energy provided by the solar system M Month Q Heating energy Solar energy surplus (available for a swimming pool.1 Principles 1. Q BTU (kWh) a b 1 2 3 4 5 6 M 7 8 9 10 11 12 Figure 2 Energy provided by a solar collector system in relation to the annual energy demand for DHW heating. a conventional backup system must still be able to cover the DHW demand independently of solar heating.3 Energy supplied by solar collector systems in relation to energy demand Solar collector systems for DHW heating Domestic hot water (DHW) heating is the most obvious application for solar collector systems. Nevertheless.Bosch Solar Thermal Systems |5 . A relatively constant demand for hot water all year round is a good match for solar energy. for example) Utilized solar energy (solar coverage) Energy demand that needs to be provided by the backup system (reheating) Design Guide . Long periods of bad weather may occur during which the convenience of hot water still has to be assured. Almost 100% of the energy demand for DHW heating during the summer can be covered by a solar system (Figure 2). Solar system components: Solar collectors contain an absorber that heats up when exposed to sunlight.2 Description of the solar system 2 Description of the solar system The solar system consists of several components that were designed and selected to work together. As the system heats up or cools down. because guests are staying at the house or during a series of cloudy days with limited sunshine. the system will stop and go into stagnation. the steam will liquefy and the system will be ready to collect more solar heat. that prevent unsafe operating conditions. The expansion tank takes in the added volume of the steam. a backup heater will provide added comfort. and the tank are connected with supply and return piping that is insulated to minimize losses. These safety devices are mechanical and work even during a power outage.Bosch Solar Thermal Systems . On days when more DHW is used than could be provided by the solar system. 6 | Design Guide . The absorber contains pipes that are the collectors is warmer than the bottom of the storage tank. The system is equipped with over temperature and over pressure devices. the pump station. The collector temperature will rise quickly causing the water in collectors. Once the tank can accept heat again and the collectors have cooled to a safe temperature.g. the controller will turn on the pump to transport hot The collectors. It is important that the backup heating system is capable of providing 100% of the demand to ensure comfort is never compromised. e. an expansion vessel heat. The solar and pressures of up to 87 psi (6 bar) in conjunction with the collector.3 Technical description of system components 3 Technical description of system components 3. The collector is covered with 1/8 inch (3.1 Solar collectors Selected features and characteristics Component design and functions highly selective black chromium coating mm) galvanized sheet metal.2 mm) thick single-pane tempered safety glass. The low-ferrous. rapid hydraulic connections. tools The 2-3/16 inch (55 mm) thick mineral wool provides extremely good thermal insulation and high (42 kg) The absorber consists of individual strips with a highly selective black chromium coating. M V V 1 2 3 4 R 6 5 R V M 1 2 3 4 5 6 7 8 Solar return Solar supply Sensor well Tempered glass Absorber plate Copper riser tubes Mineral wool insulation Galvanized steel back Fiber-glass frame Extruded plastic end cap Header pipe cover 8 7 R Design Guide . structured castglass is coated. highly good load-bearing capability. harp absorber with extremely good stagnation characteristics materials making simple.Bosch Solar Thermal Systems |7 . It is ultrasonically welded to the harp fan in order to provide an extremely good heat transfer. 26) 93 (42) 95% ± 2% 12% ± 2% 0. operating pressure (test pressure) Max.96 (2.26) 1/3 (1.½2" 3-½" R R 3-½" 81-½" 45.37) 24.½8" R R 45.22 (50) 370 (188) 87 (6) 248 (120) horizontal 8 | Design Guide .3 Technical description of system components Bosch FKC-1s Bosch FKC-1w M V V V V M 81.29 (2.½8" R Solar return V Solar supply M Measuring point (sensor well) in inches Bosch FKC-1 flat-plate collector Type of installation Gross absorber surface area Aperture area (light entry area) Absorber contents Weight Absorptivity Emissivity Nominal flow rate Stagnation temperature Max. operating temperature V gpm (l/h) °F(°C) psi (bar) °F(°C) ft (m ) ft2 (m2 ) gal (l) lbs (kg) 1/4 (0.Bosch Solar Thermal Systems .86) 90 (41) 2 2 Bosch FKC-1s vertical 25. It is ultrasonically welded to the harp fan in order to provide an extremely good heat transfer.3 Technical description of system components Selected features and characteristics Component design and functions The housing of the Bosch FKB-1 solar collector performance (0. The Bosch FKB-1 has four pipe connections for making simple. R V M 1 2 3 4 5 6 7 8 Solar return Solar supply Sensor well Tempered glass Absorber plate Copper riser tubes Mineral wool insulation Galvanized steel back Fiber-glass frame Extruded plastic end cap Header pipe cover Design Guide . The glass has a high light transmissivity (86%) and good load-bearing capability. rapid hydraulic connections.2 mm) thick single-pane tempered safety glass.Bosch Solar Thermal Systems |9 . The solar coating tools (42 kg) harp absorber with extremely good stagnation characteristics materials and pressures of up to 87 psi (6 bar) in conjunction with the collector. A 2-3/16 inch (55 mm) thick mineral wool provides extremely good thermal insulation and high The absorber consists of individual strips with a selective black lacquer coating.6 mm) galvanized sheet metal. The collector is covered with 1/8 inch (3. 29 (2. operating pressure (test pressure) Max.22 (50) 370 (188) 87 (6) 248 (120) 10 | Design Guide .½2" 3-½" R R 45.26) 1/4 (0.37) 24.86) 90 (41) 86% ± 2% 30% ± 2% 0.½8" R Solar return V Solar supply M Measuring point (sensor well) in inches Bosch FKB-1 flat-plate collector Type of installation Gross absorber surface area Aperture area (light entry area) Absorber contents Weight Absorptivity Emissivity Nominal flow rate Stagnation temperature Max. operating temperature V gpm (l/h) °F(°C) psi (bar) °F(°C) ft (m ) ft2 (m 2 ) gal (l) lbs (kg) 2 2 Bosch FKB-1s vertical 25.Bosch Solar Thermal Systems .96 (2.3 Technical description of system components Bosch FKB-1s M V V 81. economical installation Design Guide . leak detection bottom to prevent mixing with heated water for prolonged tank life Figure 9 Indirect double wall coil storage tank and anode rod at top of tank for easy access and fast.1 Indirect double wall coil storage tank Available in 80 and 120 Gallon Models front of tank for convenient installation retention prolongs tank life around and secured to the tank.Bosch Solar Thermal Systems | 11 .2 Solar storage tank 3.2.3 Technical description of system components 3. ship wt.3 R 17. Note: To prevent corrosion.8 10. Cap. single phase non-simultaneous wiring and 4500 watt heating element.3 Technical description of system components coil solar tank Description Roughing in dimenstions Energy information Approx. operate up to 150 PSI.6 Length of Tubing Around Tank (feet) 120 143 Approximate R-value of insulation R 17.3 4.2 2.7 12. proper pH levels in transfer Figure 11 Opening for probe type thermostat 1) probe type thermostat access cover Copper Coil Data (Type L Copper) SolaraideHE Tank Capacity 80 Gallons 120 Gallons Coil Capacity (gallons) 2.3 120 SOL -RET120 4500 W* 62 28-½ 380 R-17. (lbs) 222 80 SOL -RET80 58-¾ 24-½ R-17. Model number Element wattage upper 4500 W* Height (inches) Diameter (inches) Approx.3 Figure 12 Copper coil data Flow rate 80 Gallon 1 GPM 2 GPM 3 GPM 1.0 Figure 13 Pressure drop through coil 12 | Design Guide .6 5.Bosch Solar Thermal Systems .0 Head Loss (Feet) 120 Gallon 1. R-Factor Type Gal. Special features 1 solar storage tanks.3 * Heaters furnished with standard 240 volt AC. If there is adequate insolation. The maximum storage tank temperature can be set in the controller based on the individual requirements. the solar circuit pump starts and the storage tank is heated.with system running Limited Sunlight Design Guide . To do this. the controller compares the collector temperature using the collector sensor and the temperature in the lower area of the storage tank (tank sensor). the set temperature differential between the collector and the storage tank is exceeded. The solar circuit controller switches the solar circuit pump off when the maximum storage tank temperature has been reached.3 Solar controllers Temperature differential control insolation and low DHW consumption. After a long period of Solar Pump Station Solar Pump Station Full Sunlight (Left) .e. storage tank.3 Technical description of system components 3. i. The solar controller does not switch the pump off until the temperature differential has dropped below the minimum temperature. high temperatures occur in the storage tank.Bosch Solar Thermal Systems | 13 . the controller switches the pump on as soon as the collector system is prevented from freezing. Discharging the solar system over night prevents the solar system idling in stagnation for extended periods.3 Technical description of system components 3. 14 | Design Guide . There it is heated by the sun and transported back to the storage tank. vacation).g. the system will resume operation as soon as the temperature drops Anti-freeze Function If the anti-freeze function is activated. The tank to the collectors. the pump is switched on and the pump symbol shown rotating on the display. Automatic Pump Protection During periods of high insolation. If the temperature difference between collector and storage tank falls below no longer shown on the display. Once the sun heats the collector and there is a collector and the storage tank. If the collector reaches Vacation Function The vacation function is used to cool down a completely heated storage tank via the collector. The storage tank can heat up too much if no DHW is drawn over an extended period of time (e. the temperature In order to protect the pump from overheating.Bosch Solar Thermal Systems . where the heat is transferred to the domestic water.1 TR 0301 U Differential Temperature Controller The standard delivery of the controller includes: sensors with compression cable lug (Temperature An optional 3rd tank temperature sensor (top) Pt1000 sensors with compression cable lug (Temperature limit purposes.3. Figure 15 Solar Controller TR0301U Automatic Storage Tank Loading The TR0301 U controller constantly compares the temperatures between the collector (T1) and the lower area of the storage tank (T2) via temperature sensors. Automatic Stagnation If the lower area of the storage tank (T2) reaches the set maximum storage tank temperature (factory default 140 °F Figure 16 Display Legend 1 Temperature sensor symbols 2 Temperature and faults code display 3 Vacation function 4 Anti-freeze function 6 Evacuated tube collector function 7 Setting maximum storage tank temperature system in operation reached 10 Warning display if fault occurs 11 Indicates system stagnation be reached before charging can resume. The TR 0603mc U has 6 inputs for recording temperature measurement.3 Technical description of system components 3.17 HP (120 V~) 1 x (fault reporting output) 7‘. The TR 0603mc U stores the system‘s operational data on a SD memory card. Pumps and switching valves are controlled by 3 outputs. 1 x temperature recording or pulse calculation) Additional input rate) Outputs 3 1 x relay switched output.Bosch Solar Thermal Systems | 15 . which allows you to view the operating conditions of each system. The 40-programmed systems and numerous additional functions allow universal use of the controller.5 HP (120 V~) 2 x triac output for speed control. which can be used for data evaluation purposes. max. The large display panel shows the animated control circuits. 0. Figure 15 Solar Controller TR0301U Technical Data Product Features Operating voltage consumption Inputs 6 5 x temperature recording (Pt1000). 18 AWG rated at 221 °F 40 Additional output Line cord Number of preschemes according to the time of the year) Interfaces Data logging Permitted ambient temperature Display Protection class Dimensions lxwxh IP 20/DIN 40050 SD card Design Guide .3. 0. max.2 TR 0603mc U Differential Temperature Controller The TR 0603mc U is designed exclusively for the North America. 3 4 6 7 8 connections) Safety relief valve Pressure gauge Fill & drain valve Solar circuit pump Flow volume indicator not part of the standard delivery of the Bosch KS pump station. 10 9 2 6 2 8 V R Figure 17 Layout of the Bosch KS0105 pump station Legend V Supply from collector to storage tank R Return from storage tank to collector 1 Ball valve with thermometer and integrated gravity brake ball valve open The solar stations for collector arrays with up to 5 collectors are already equipped with an air separator. It must be sized for each individual case.4 Bosch KS pump stations Features and characteristics The Bosch pump station assembly consists of all required components such as the solar circulator. See chapter 5. For two tanks two solar stations can be combined in one system. the safety pressure relief valve.Bosch Solar Thermal Systems . Two safety assemblies (part of the standard delivery) and two diaphragm expansion vessels (DEV) are required for this arrangement. This enables the hydraulic balancing of two storage tanks with different pressure drop values. This arrangement provides two limiters. the pressure 1 V 2 R 3 protection. 2 1 4 5 6 7 The Bosch KS pump station is designed for one solar storage tank. hydraulic balancing of the two collector arrays with different pressure drop values is now feasible. Another application of two pump stations in one system is the implementation of a solar system with two collector arrays in different orientation (east/west control).3 Technical description of system components 3. the gravity brake.5 Sizing of the Diaphragm Expansion vessel for details 10 Regulating/shut-off valve 16 | Design Guide . Here too it is important to have two separate As previously described. Two collector arrays with different orientation are controlled using two independent solar controllers. Bosch Solar Thermal Systems | 17 .34 0 . current load Throughput limiter adjusting range Weight Flow range Head range Motors Maximum fluid temperature Minimum fluid temperature Maximum working pressure °F (°C) °F (°C) psi in (mm) V AC Hz W A gpm (l/min) lbs (kg) gpm feet psi (bar) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) KS0105 5 1 14" (355) 11-1/2" (290) 9-1/4" (235) 5-1/8" (130) 3-1/8" (80) 2" (50) 1/2" ID × 1 ¾" 87 (6) Grundfos Solar 15-58 5-⅛" (130) KS0110 10 1 14" (355) 11-1/2" (290) 9-1/4" (235) 5-1/8" (130) 3-1/8" (80) 2" (50) 22 × 1 ¾" 87 (6) Grundfos Solar 15-58 5-⅛" (130) KS0120 20 1 14" (355) 11-1/2" (290) 9-1/4" (235) 5-1/8" (130) 3-1/8" (80) 2" (50) 28 × 1 ¾" 87 (6) Grundfos UPS 25-99 5-⅛" (130) Supply/return 120 60 60 0. power consumption Max.4-¼ (2-16) 16 (7.3) 0 . recommended # of collectors Number of storage tanks Casing dimensions Height H Width W Depth D Detailed dimensions A C E Copper pipe connection size (clamping ring fitting) Expansion vessel connection Safety relief valve Circulation pump Type Finished length Electrical power supply Frequency Max. single phase 230 (110) 36 (2) 145 Design Guide .3 Technical description of system components station Bosch K S pump station Bosch K S pump station B A C E T Figure 18 Dimensions of the KS pump stations Pump station Max.54 ½ .1-½ (0.5–6) 120 60 125 0.5 0 .1) 0 .1) 0 . single phase 230 (110) 36 (2) 145 120 60 195 0.5 0 .25 ⅛ .85 2-7 (8-26) 16 (7.17.19 2 pole. single phase 230 (110) 36 (2) 145 21 (9.17.30 2 pole.19 2 pole. The junction box must be located within 10 ft. A Space for a bending radius of at least 5 inches (125 mm) for routing the Twin-Tube 1/2 inch must be available on site (Figure 20). It is designed for situations where lightning strikes in the vicinity of the solar collectors. The overvoltage protection is not a lightning rod.1 Twin-Tube piping system Twin-Tube is a thermally insulated double tube for solar supply and return piping with UV protective jacket and integrated sensor lead. UV-resistant AWG18 (2 × 0.3 Technical description of system components 3. (3.5. V FSK E FSK SP1 Collectors KS0105 SP1 Automatic all-metal air vent valve (accessory) Collector temperature sensor (standard delivery of the controller) pump station Lightning protection Twin-T ube Pump station R DEV V R Figure 22 Overvoltage protection for controller example 18 | Design Guide . inch (mm) inch (mm) 1/2 INCH 3" (73) 2" (45) 2 × 1/2" ID inch 50 EPDM rubber 2/3" (15) 374 (190) PE.5.2 Lightning protection for the controller The collector temperature sensor in the lead collector can be subject to overvoltage during a thunderstorm because of its exposed location on the roof.Bosch Solar Thermal Systems .5 m) of the FSK collector temperature sensor (Figure 22). Safety diodes limit this overvoltage to a level that will not damage the controller. This overvoltage can damage the sensor and the controls. B Figure 20 Bending radius for Twin-Tube 1/2 inch Twin-Tube Dimensions A B Pipe dimensions Diameter Length Insulating material Insulation thickness Temperature resistant up to Protection film Sensor lead inch (mm) ° F (°C) ft.75 mm 2 ) 3. -4°F (–20) A Solar fluid L / L "G" -58°F (–50) 0 10 20 30 40 50 60 PP: glycol/% by vol. Suitable pH indicator strips and a refractometer (frost protection) are included in the Bosch solar service kit. Ready-mixed heat transfer fluid Heat transfer fluid L 50/50 pH value in the delivered condition approx. Outside temperature min. value and the antifreeze value. Both mixtures are clear. Aging is also accelerated by oxygen (air-borne systems) and impurities such as copper or iron shavings introduced during installation. subject to the glycol-water mixture. are repeated overheating and over pressure. 8 Figure 24 pH limits for checking ready-mixed heat transfer Design Guide .3 Technical description of system components collectors to the tank. non-toxic. and protect the system from freezing and corrosion. bio-degradable.Bosch Solar Thermal Systems ∂ ∂ of 42% propylene glycol and 58% water. pH 7 | 19 . 32 (0) 14°F (–10) °F (˚C) -22°F (–30) -35°F (–37) Legend (Figure 23) A Heat transfer media based on mixtures of propylene glycol and water have a long service life if the system is sized well for the application and properly maintained. 7 EK Figure 25 DHW tempering valve installation diagram with optional DHW recirculation line Legend (Figure 25) AW EZ 2 3 4 5 6 8 DHW outlet DHW recirculation inlet (use is optional) DHW recirculation pump (optional) Thermostatic mixing valve / tempering valve Shut-off valve with check valve DHW recirculation line Faucet. Take suitable measures to provide protection against scalding. Anti-scald protection / tempering valve If the maximum storage tank temperature is set higher protection against scalding. The following options are available: EZ AW 5 4 3 8 MIX 1 8 6 2 Install a thermostatically controlled DHW mixing valve (tempering valve) downstream of the storage tank’s DHW connection.5. shower. EK 1 1 See Figure 25 for system integration of a thermostatically controlled DHW mixing valve (tempering) and a recirculation pump. etc. Solar systems can easily reach water temperatures that can scald.4 Thermostatically controlled domestic hot water mixer WARNING: Hot water can scald.Bosch Solar Thermal Systems .3 Technical description of system components 3. Shut-off valve 20 | Design Guide . g. Installation of an air vent is not needed if a high head and high speed filling station is used for filling and charging the system. (continued on the next page) Design Guide . For ease of installation. The choice of pump station is subject to the number of storage tanks. and the collector array pressure drop. position upright and at the highest point of the system. and insulate appropriately. AWG18 (2 × 0. or at a secondary peak of the piping where air is expected to collect.4 Notes regarding solar systems 4 Notes regarding solar systems 4. If Twin-Tube cannot be used install standard L-type copper piping and sensor cable on site (e. The Bosch KS0105 pump station contains all important hydraulic components for the solar circuit. complete with its heat and UV protection jacket and integrated FSK collector sensor cable.1 General information 2 1 Domestic Hot Water 7 Solar Controller 3 Solar Pump Station 4 6 5 Cold Water Supply Symbols Honeywell Am-1 series thermostatic mixing valve Well thermometer Service valves Pressure relief valve Solar storage tank Expansion tank Flow direction Circulator Figure 26 Sample diagram in connection with the general information regarding solar systems Item System components Collectors Pipework with incline to the air vent (Optional) Connection lines Twin-Tube General design The size of the collector arrays must be determined independently of the hydraulic system.Bosch Solar Thermal Systems | 21 .75 mm ). use of the double copper tube Twin-Tube 1/2" is recommended. the number/arrangement of collectors or connections. 1 2 3 4 Pump station Figure 27 General information regarding solar systems. If an air vent is installed. provide a heat insulating loop or a check valve. To prevent natural circulation.2 Regulations and guidelines for designing/engineering a solar system Installation and commissioning must be carried out by a licensed and experienced contractor. Run recirculation pump on a timer only a few times per hour during peak demand times. Determine the size of the storage tank independently of the hydraulic system. Observe all relevant accident prevention regulations! Apply all state-of-the-art technical standards to all work. If this is not possible. 5 6 7 Diaphragm expansion vessel DHW storage tank Hot water tempering valve 8 DHW water recirculation Figure 28 General information regarding solar systems 4. Using a poorly designed DHW recirculation system can reduce the net solar yield considerably. It is the installer’s responsibility to comply with the building and installation codes in effect and all regulations that apply to the operation of a solar hot water system. DHW recirculation (not shown above) causes significant standby losses.4 Notes regarding solar systems Item System components General design information Size the diaphragm expansion tank according to the system volume and the safety valve so that it can adequately compensate for the volume fluctuations in the system. install the thermostatically controlled DHW mixing valve below the storage tank's DHW outlet.Bosch Solar Thermal Systems . A pre-cooling vessel is required if the DHW heating coverage is above 60% or in central heating systems. Take appropriate personal safety measures when carrying out any installation work on the roof. 22 | Design Guide . Reliable protection from excessively hot water temperatures ( risk of scalding! ) is provided by a thermostatically controlled hot water tempering valve (WWM). With east/west systems an additional diaphragm expansion vessel is required for the 2nd collector array. Design the safety equipment in accordance with all applicable regulations. generally desirable for DHW heating systems for single family homes and two-family homes. A coverage of less than 50% is generally appropriate in multifamily buildings. The collector array and the solar storage tank must therefore be pre-sized for the computer simulation. The required output result is obtained in stages. Simulation programs require consumption values as well as the size of the collector should always be obtained.1 Sizing principles 5.2 Sizing with computer simulation For larger solar thermal systems and systems for process water heating Bosch recommends using computer simulation for proper sizing: With six collectors or more. A system putting too much emphasis on fuel savings may not meet the homeowner’s approval if it does not provide DHW comfort during periods of bad weather.1. fuel savings. Set DHW temperature Existing DHW heating equipment (if an existing system is being extended) Recirculation losses Location Orientation Slope Design Guide . The T-Sol program a database of climate data such as The following values are important: Daily DHW demand well as appliance data. and a long service life. Verify each case individually as to whether it is possible to upgrade an existing DHW system with a solar thermal system. The conventional heat source must be able to provide 100% of the hot water in a building independently of the solar system.1.Bosch Solar Thermal Systems | 23 . since values taken from literature are of little use. 5.1 Solar DHW heating Proper sizing of a solar thermal system for DHW heating is crucial for performance and comfort. or If the system differs greatly from the calculation conditions in the sizing diagrams T-Sol is an extremely practical simulation software for calculating solar systems. Sizing for less than 50% is also realistic if the consumption data is unknown or unreliable.4 Notes regarding solar systems 5 Sizing 5. information on the actual DHW demand. This information can be displayed on screen in many different ways and can be printed out for further analysis and to prepare a quotation. 1.5 Sizing 5. The typical number of occupants and the average consumption per person per day are essential for a reasonably accurate estimation.1 Systems for DHW heating in single family homes and two-family homes Number of collectors Empirical values from single family homes and two family homes can be used when a residential solar heating system for DHW heating is being sized. South-facing roof orientation Roof incline 45° Location Albany. For larger systems and non-standard hot water demand.2 Sizing with computer simulation) is advisable.2. a T-Sol simulation (5. the storage tank and the pumping station for solar collector systems for DHW heating: Location 3 8 a 7 6 5 nP 4 c b Roof slope (collector angle of inclination) Roof orientation (south-facing collector) 2 1 1 2 n 3 4 5 6 Take the draw-off temperature in accordance with the existing or intended sanitary equipment into consideration.Bosch Solar Thermal Systems .2 Sizing the collector array and solar heating storage tank 5. 4+ collectors: SOL -RET120 120 gal storage tank. NY Draw temperature 113 °F Determining the number of collectors in accordance with 60% Example Household with four occupants and a DHW demand of 50 gallons per day Solar system for DHW heating 24 | Design Guide . Figure 29 Diagram for an approximate determination of the number of Bosch FKC-1 collectors for DHW heating (observe calculation principles!) Legend n np Number of occupants Calculation principles the following system parameters: DHW demand curves: a Low (< 10 gallons per person per day) b Average (13 gallons per person per day) c High (20 gallons per person per day) 1-3 collectors: SOL -RET80 80 gal storage tank. Information about particular draw-off habits and comfort requirements are ideal. The collector array. According to Figure 31 there is a correction factor for every collector array deviation from due South.14 60° 1. and within 10° East or West of due South.05 45° 1.09 –60° 1.Bosch Solar Thermal Systems | 25 . For constant year-round use.25 Correction ranges: Figure 31 Correction factors with south deviation of Bosch solar collectors for different angles of inclination Example Parameters – Household with four occupants with DHW demand of 50 gallons per day – Location: Albany. For maximum solar yield align the collectors at an angle of inclination close to the latitude of the site.04 –30° 1.13 1. Angle of inclination 90° 25° 1.03 0° 1. 40° Latitude) – Angle of inclination 25° with rooftop installation of – Deviation to the west by 60° To achieve the same energy yield as with direct collectors. use angles greater than the latitude.19 Correction factors for Deviation to the west by 75° 1.21 –1.5 Sizing solar yield Collector orientation Orientation of the solar collectors with the points on the Use of solar heat for Optimum angle of inclination of collectors 30° – 45° 30° – 45° DHW Domestic hot water + swimming pool water Figure 30 Angle of inclination of collectors subject to the use of solar system The optimum angle of inclination depends on the use of the solar system. If the collector array orientation deviates to the east or west.04 1.10 1. energy that can be harvested by a collector array. This will reduce the performance of the collector array.07 30° 1. If the collector array is mounted on a steep roof or a wall. the orientation of the collector array is identical to that of the roof or wall.10 collector orientation deviation from south South 15° 1. NY (approx.03 1 . In snowy climates shallow collector angles may lead to snow accumulation and further reduce performance. the For better results during the winter months.22 > 1. the rays of the sun will no longer strike the absorber area in the most effective way.25 –75° 1. Design Guide .20 Deviation to the east by –45° 1.11 –1.17 –90° 1.00 –1. The collector area that was determined under ideal conditions must be multiplied by this factor to achieve the same energy yield as is achieved with direct southern orientation. Angles shallower than the latitude are typically not recommended as they reduce performance in the winter and offer little performance increase during the summer months.06 1.06 –1. and subject to the degree of its pitch.16 –1.15 –15° 1. 3 approx. no. 3-4 Capacity Rec.8 . DHW storage tank Recommended daily DHW demand in gallons with storage tank temperature of 140 °F (60 °C) and draw-off temperature of 113 °F (45 °C) up to 53/66 up to 66/80 Recommended number of occupants with a DHW demand per person per day of 10 gallons Low approx.Bosch Solar Thermal Systems . In a multi-storage tank system the stored volume of DHW should be able to cover twice the daily demand with a draw-off level of 85%. 167 °F ncollector nWE Number of residential units 26 | Design Guide . 6-8 13 gallons Average approx.7 · nWE Marginal conditions for formula Re-circulation cost: 340 BTU/hr per unit (100W/ unit) Old building: 480 BTU/hr per unit (140W/unit) Pre-heat storage tank temperature max.5 Sizing Storage tank selection A suitable ratio between collector output (size of collector array) and storage tank capacity (storage tank volume) is The size of the collector array is limited by the storage tank capacity (Figure 32). Rule of thumb A storage tank volume of twice the daily demand has proven to be adequate. 4-5 approx. 1. 1) Collectors FKC-1 or FKB-1 gallons 80 120 2–3 3–4 SOL-RET80 SOL-RET120 Figure 32 Standard values for selecting DHW storage tank 1) Determining the number of collectors Daily heating/disinfection control Follow local codes and regulation for disinfection and prevention of Legionnaires’ disease outbreak.0 gallons of the collector area in properties with a uniform Figure 33 Formula for the required number of Bosch FKC-1 solar collectors in relation to the number of residential units (observe marginal conditions!) consideration: Calculating sizes ncollector = 0. 5-6 20 gallons High approx.2. 5–6 approx. Collector area sizing Apply a daily consumption of approx. Figure 32 shows standard values for selecting the DHW storage tank subject to the DHW demand per day depending on the number of assumed. Allow 16 inches above the collector array (beneath automatic air vent (if installed).Bosch Solar Thermal Systems | 27 . Figure 34 Space requirements on the rooftop Design Guide .3. Dimension D represents the roof overhang.3 Space requirements for solar collectors 5. Allow 20 inches to the right and/or left of the collector array for the connection lines (underneath the roof!). Besides the area above the roof. Installation on corrugated sheet and standing seam metal roofs is only permissible on roof pitches between 5° and 65°. Allow 12 inches beneath the collector array (underneath the roof!) for routing the return connection line.5 Sizing 5. Dimensions A and B represent the area requirement for the selected number and layout of collectors. including the gable end thickness.1 Rooftop installation On pitched roofs Bosch solar collectors can be installed with a pitch of 25° to 65°. ≥ 20 in A ≥ 20 in C D D ≥ 16 in B ≥ 12 in ridge. the space required underneath the roof must also be taken into consideration. Route the return line with a rise to the automatic air vent valve (if installed). 5 Sizing Area required for solar collector rooftop installation X 1 2 3 4 5 6 7 8 9 10 A B C X Y Width of collector row Height of collector row Distance from roof ridge Distance between collectors rows side by side Distance between collectors rows above each other C B Y B 1 2 3 4 5 A 6 7 8 9 10 Figure 35 Area required for collector arrays for rooftop installation Dimensions Collector array dimensions for Bosch flat-plate collectors Bosch FKC-1 and FKB-1 at rooftop installation FKC-1 and FKB-1 vertical FKC-1 horizontal 81-1/2” 164-3/16” 246-1/2” 329-1/8” 411-3/8” A for 1 collector for 2 collectors for 3 collectors for 4 collectors for 5 collectors in in in in in 45-1/4” 91-3/8” 137-7/16” 183-1/2” 229-1/2” B C X Y in in in 81-1/2” 12" or 2 rows of tiles 8” subject to roof construction (batten spacing) 45-1/4” 12" or 2 rows of tiles 8” subject to roof construction (batten spacing) collectors for rooftop installation 28 | Design Guide .Bosch Solar Thermal Systems . consider that snow will slide off the collectors and may accumulate at their base. The area required for the collectors supports used plus a space for pipework routing.Figure 36 and dimension B .3. Angle of inclination Collector row dimensions FKC-1 and FKB-1 vertical B in 25° 30° 35° 40° 45° 50° 55° 60° 72-7/16” 68-7/8” 66-1/8” 62-3/16” 58-1/4” 58-1/4” 58-1/4” 58-1/4” FKC-1 horizontal B in 41-3/4” 40-3/16” 37-3/16 35-13/16” 33-7/16” 33-7/16” 33-7/16” 33-7/16” supports.Figure 37) Number of collectors Collector row dimensions FKC-1 and FKB-1 vertical A in FKC-1 horizontal A in 164-1/2” 247-1/4” 330” 412-5/8” 2 3 4 5 92-1/8” 138-3/16” 184-1/4” 230-5/16” roof supports Design Guide .2 Flat roof installation Flat roof installation is possible with vertical and horizontal collectors. In locations with snowfall. A B Figure 37 Flat roof stand installation dimensions on the collectors (dimension A . In areas with large amounts of snowfall consider measures for snow removal to minimize service interruptions. This space should be at least 20 inches (50 cm) to the left and inches (100 cm) from the roof edge.Bosch Solar Thermal Systems | 29 .5 Sizing 5. In addition to the width of the collector array.3. A 33 ½ Figure 40 Installation dimensions of wall mounting kits dimensions in inches (dimension A .Figure 42) Number of collectors Collector row dimensions for Bosch FKC-1 horizontal A in Figure 42 Shade-free spacing for several rows of wall installation kits for horizontal other.Bosch Solar Thermal Systems 145 .5 Sizing 5. allow at least 20 inches to the left and right (dimension A . In winter. when the sun’s path is lower. This allows taking advantage of the sun while creating an architectural feature. solar gain can provide an additional source of energy. The wall must have adequate loadbearing capacity! The space requirement on the wall for the collector rows depends on the number of collectors. Take provisions that the installation does not pose a risk to property and cause personal injury from falling snow and ice. Several rows of collectors arranged above of each other must be kept at least 145 inches apart to prevent the collectors from casting shadows on each other (Figure 41). or where shading of windows and doors is desired. windows and keep rooms nice and cool.0m). Figure 41 Collector row dimensions when using wall mounting supports 30 | Design Guide . and only for an installation height of up to 65 ft above ground. Dimensions in inches 2 3 4 5 164-1/8” 246-1/2” 329-1/8” 411-3/8” Snow and ice accumulating on the collectors may give way and slide off suddenly. The space between the collector row and the edge of the wall must be at least 3ft. (1. The wall mounting kit is particularly suitable for buildings with non-ideal roof orientation. Figure 40) for routing the pipework.3 Space requirements for wall mounting Minimum row spacing suitable for wall mounting. V R Figure 44 Hydraulic connection of collector arrays that are interrupted by a dormer Design Guide .5 Sizing 5. The hydraulic connection is shown in the following diagram in the example of a rooftop installation. 10 collectors per row Connection in parallel Max. number of collectors per row Figure 43 Collector array layout options Connection in series The hydraulic connection of collector rows in series is accomplished quickly because of the simple connection If there are several arrays (rows) in a system.1 Hydraulic circuit Collector array A collector array must consist of the same type of collectors and have the same orientation (all vertical or all would otherwise not be uniform.4. distribution of the entire array.e. the number of collectors per row may not differ by more than one. In small systems it is preferable to connect collectors in series. A maximum of ten Bosch row and hydraulically connected in parallel if the supply and return connections are on alternate sides. Connection in series Row(s) 1 2 3 Max. number of collectors per row 10 5 3 Never connect more than three rows in series! Row(s) 1 2 3 4 4 … … n With supply and return on opposite sides max.Bosch Solar Thermal Systems | 31 . Additional automatic air vent valves may be required if such valves cannot be installed at the highest point (i.4 Hydraulic system engineering 5. series is limited to 10 collectors and 3 rows (Figure 43). Bosch FKC-1 and FKB-1 E E FSK Dormer Collector array with dormer The following hydraulic scheme represents one option for solving the challenge posed by dormers. It is important that the maximum number of collectors in one row in series is not exceeded. can be found in Figure 46.3 Pressure drop calculation in collector array Collector row pressure drop The pressure drop of a collector row increases with the number of collectors.Bosch Solar Thermal Systems .2 Flow rate in the collector array sized systems is 0. V ` Vk. Pressure drop for a row consisting of n collectors Bosch FKC-1 and FKB-1 vertical Bosch FKC-1 horizontal at a flow rate per collector (nominal flow rate 0.22 gpm) Figure 46 Pressure drop values for collector rows with Bosch FKC-1 including AAV and connection at an average temperature of 122°F (50°C) 1) Flow rate per collector.4. The pressure drop for a row including accessories.22 gpm (50l/h) per collector.4. resulting VA = V nK nK Calculating sizes required by the solar circuit pump. Nom nk Nominal flow rate of collector in gpm Number of collectors 5. connected in two row 2) Flow rate per collector. subject to the number of collectors per row. connected in three rows Non-permitted 32 | Design Guide .5 Sizing 5. 5 Sizing Rows of collectors connected in series The pressure drop of the array results from the sum of all pipework plus each row of collectors. Nom V R Figure 49 Connection in series of two collector rows Design Guide . Nom n n – Read from Figure 50: 13.Bosch Solar Thermal Systems | 33 . H O The pressure drop of the collector array is 27.Nom ⋅ n Row 0.85 in. H2O per collector row rows of collectors connected in series – Pressure drop of array: Calculation parameters (Figure 47 and 48) Array Row Array = Row nRow = 13. The pressure drop of rows of collectors connected in series is cumulative.2 in. Number of collector rows Flow rate through the individual collectors in gpm Nominal flow rate of collector in gpm E FSK nRow Vk Vk. H2O. take into from the individual collectors connected in series.85 in.22 gpm ⋅ n Row k. the – Flow rate through one collector: gpm): Vk V VK V K. Example Δp Array Δp Row ⋅ n Row Parameters Figure 47 Formula for pressure drop of a collector array with rows of collectors in series Wanted – Pressure drop of collector system As far as Figure 48 is concerned. Bosch Solar Thermal Systems . the (50 l/h).5 Sizing Collector rows connected in parallel The pressure drop for the array results from the total of the pipework pressure drop values up to a collector row and the pressure drop of an individual collector row.Nom Calculation parameters (Figure 50 and 51) Array Row The pressure drop of the collector array is 4. H2O per collector row – Pressure drop of array: with rows of collectors connected in parrallel Array = Row 2O V K = V K. – Flow rate through one collector: Vk = Vk. Nom n – Read from Figure 50: 4. Nom Flow rate through the individual collectors in gpm Nominal flow rate of collector in gpm E FSK V R Figure 52 Two collector rows connected in parallel using reverse-return piping 34 | Design Guide . Example Δp Array Δp Row Parameters with 5 solar collectors Wanted – Pressure drop of overall collector array Figure 50 Formula for the pressure drop of a collector array with rows of collectors connected in parrallel Unlike the situation when connecting in series. H 2O E Vk Vk.45 in.45 in. 5 Pressure drop of the selected solar storage tank The pressure drop of the solar storage tank depends on coils of the solar storage tank have various pressure drop characteristics because of their differing dimensions.4.4' 1.3' SOL-RET120 in feet of head 0.70 Figure 53 Flow velocity and pressure drop per ft of straight copper pipe for a 50/50 glycol:water mix at 122°F (50°C) 5.1' 1.3 ft/sec to allow air remaining in the heat transfer medium to be transported to the next air separator.8' 1.Bosch Solar Thermal Systems | 35 .6' 0.5 Sizing 5. The pressure drop in the table applies to a 50/50 glycol:water mixture at Figure 54 Pressure drop values of solar storage tanks for a 50/50 glycol:water mixture at 122°F (50°C) Design Guide .88 1. Use Number of collectors Flow rate Pressure drop in solar indirect coils of the storage tank SOL-RET80 gpm 2 3 4 5 0.1 in feet of head 0.4.44 0.66 0.11 0.88 1.66 0.8' 1.38 1.2' 1.4 Pressure drop of pipework in the solar circuit Calculating the pipework 1.69 1.10 ft/s 0. Take individual resistance values (caused by bends.6' Figure 54 to estimate the pressure drop.61 gpm 2 3 4 5 0.42 0. for example) into consideration in the pressure drop calculation by adding 30% to 50% to the pressure drop of the straight pipework. Number of collectors Flow rate Flow velocity v and pressure dropR in copper pipes with pipe dimensions of 1/2 inch v R in H 2 O/ft 0. Flow noise can occur from velocities of 3 ft/sec and higher.17 0.44 0.00 1. 4.Bosch Solar Thermal Systems . K S0105 40 0 0 1 2 3 V/gp m 15 n FKC-1/FKB-1 6 nCPC12 8 10 4 5 6 7 0 0 2 5 4 10 20 12 25 14 30 16 35 36 | Design Guide .6 Bosch KS0105 pump station The pump station needs to overcome the following pressure drops: Pressure drop in the collector array Pipework pressure drop Pressure drop in the solar storage tank 200 160 120 80 in W.5 Sizing 5.C. 5.33 (1.0251 (0.86) Calculating sizes VA Vk System filling volume Volume of one collector Number of collectors Solar indirect coil volume Volume of a Bosch KS0105 pump station (approx. 1/4 gal (1 l)) Pipework volume Type Flat-plate collector Flat-plate collector FKC-1 FKB-1 Version vertical horizontal vertical nk VWT Vks VR Figure 58 Filling volume of Bosch solar collectors Design Guide .1 System volume calculation The volume of a solar system with the Bosch KS0105 pump Pipe dimension Ø × wall thickness in 1/2" 3/4" 1" Specific line volume gallons per foot (l/ft) 0.23 (0.5 Sizing of the diaphragm expansion vessel (DEV) 5.0450) 0.0429 (01624) the solar system with a Bosch KS0105 pump station: V A = V K n K + V WT + V KS + V R systems with Bosch KS0105 pump station Solar collectors Collector content gallons (liters) 0.23 (0.86) 0.0950) 0.Bosch Solar Thermal Systems | 37 .0121 (0.5 Sizing 5.25) 0. 5 Sizing 5.442 h stat + 5. Filling pressure The expansion vessel creates an equilibrium between (Vv Figure 64) is set with the system cold and monitored via the pressure gauge after bleeding the air from the system. This can cause system malfunctions. 38 | Design Guide . like early stagnation.2 bar). A controlled evaporation event of stagnation.Bosch Solar Thermal Systems . VV formula: p 0 = p V + 5psi p0 expansion vessel Calculation parameters (Figure 61) and picture legend (Figure 62) o V DEV filling pressure in psi DEV precharge pressure in psi Figure 62 Filling pressure of a diaphragm expansion vessel Vv pressure always leads to a reduction in available volume.8psi Figure 59 Formula for inlet pressure of a diaphragm expansion vessel Calculation parameters (Figure 59) and picture legend (Figure 60) V pV DEV inlet pressure in bar Static height in ft between center of DEV and highest point of system Figure 60 In a precharged diaphragm expansion vessel that is disconnected from the system the hstat The minimum precharge is 17.2 Diaphragm expansion vessel for solar systems Calculation principles Precharge Adjust the precharge of the diaphragm expansion The required system precharge is calculated using the following formula: p V = 0. The system pressure should be dialed in at 5 psi above the DEV preset pressure.5.4 psi (1. min = ( V A n + V D ) --------------------( pe − p0 ) Figure 65 Formula for minimum DEV volume VD = nK VK VV + Ve Figure 66 Formula for evaporation volume pe Figure 64 Final pressure of diaphragm expansion vessel Design Guide .min VA System filling volume in gallons Expansion coefficient Evaporation volume in gallons DEV outlet pressure in psi DEV filling pressure in psi Number of collectors Volume of collectors n VD e o expansion vessel subject to the safety valve response pressure Calculation parameters (Figure 63) and picture legend (Figure 64) e sV nk Vk DEV final pressure in psi Safety valve response pressure in psi Expansion volume Hydraulic seal Ve Vv ( p e + 14. (stagnation).9 pSV for for pSV ≤ 44psi pSV > 44psi Vn. A DEV is sized on the basis of the following assumptions and formula: Calculation parameters (Figure 65 and 66) pe ≤ pSV − 3psi pe ≤ 0. If a solar system is not intrinsically safe.7) V n..Bosch Solar Thermal Systems | 39 . the safety valve responds during stagnation resulting in loss of rating and the required size of the DEV are determined by determined using the following formula: re-started and must be properly balanced to avoid future service interruptions.5 Sizing Intrinsic safety of a solar system A solar system is considered to be intrinsically safe if the DEV can absorb the volume change as a result of solar additional expansion volume (Figure 64). sizing a solar heating system for heating swimming pool water can only ever be approximate. covered – Pool water temperature 76 °F Wanted swimming pool water heating Read above table 75 °F pool water temperature pool water heating.3 additional collectors for every +1 °F above pool water temp of 75 °F Example Parameters – Indoor swimming pool.Bosch Solar Thermal Systems . the sizing has to be oriented to the area of the pool. we recommend the use of a dual-mode solar heating storage tank with a large solar indirect coil and limited storage tank heating up to 140 °F.5 Sizing 5. If the solar swimming pool water heating system is combined with DHW heating. Standard values for indoor swimming pools with covers Pool basin covered when not in used (insulation) Set pool water temperature 75 °F If the required set water temperature is higher than 75 °F. Basically. 40 | Design Guide . the number of required collectors increases by the correction factor listed below Range Reference size Sizing with solar collectors FKC-1 Pool surface Correction factor for pool water temperature Pool surface in ft² Deviation above 75 °F pool water temperature 1 collector for every 50 ft² 1.6 Sizing swimming pool water heating systems The weather conditions and the swimming pool heat loss For that reason. The water cannot be guaranteed to be at a certain temperature over several months. Do not add the collector areas for central heating. add the required collector areas for the swimming pool water and DHW.Bosch Solar Thermal Systems | 41 . The solar heating system heats the outdoor swimming pool in summer and central Design Guide . In this case the standard value ratio is 1:1. DHW heating and/or central heating backup. This means collectors must be the same size as the pool surface. Covered outdoor swimming pool (or indoor swimming pool without insulation) A ratio of 1:2 applies as standard value. Then carry out a heat demand calculation. This means that the size of the pool surface area.5 Sizing Standard values for outdoor swimming pools The standard values only apply if the swimming pool is insulated and embedded in the ground in a dry condition. First insulate the pool if the swimming pool is at the level of groundwater without insulation. If the solar heating system is intended for an outdoor swimming pool. provided that they are suitable for use with a water:glycol mixture and respectively high temperatures of rise towards the collector array or the air vent valve. Provide a shield for the collector temperature sensor extension lead. diaphragms in expansion vessels etc.6 Design/engineering information regarding installation 6 Design/engineering information regarding installation 6. or galvanized components are not suitable for solar systems. Collector temperature sensor extension lead When routing the pipework. sliding clamps. Hemp seals must also be coated with temperature-resistant and glycol-resistant thread paste. Pipe diameter inches 1/2 5/8 3/4 1 1-1/4 1-1/2 Twin-Tube (double tube) insulation thickness inches 1/2" – 1/2" – – – Aeroflex SSH pipe diameter × insulation thickness inches – 5/8 x 1" 1 x 1" 1 x 1" 1-1/4 x 1-1/2" 1-1/2 x 1-1/2" Aeroflex HT pipe diameter × insulation thickness inches 1/2 x 1" 5/8 x 1" 1 x 1" 1 x 1" 1 x 1-1/2" 1-1/2 x 1-1/2" Mineral wool insulation thickness (indoor application only) inches 3/4" 3/4" 3/4" 3/4" 1-3/16" 1-3/16" Figure 67 Thickness of thermal insulation for solar system connection lines. The pipes must be routed with provisions for expansion (bends. The thermal insulation of the connection lines must be designed for the operating temperature of the solar system.Bosch Solar Thermal Systems . PEX.) must be made from glycol-resistant materials and carefully sealed. also route a two-core lead (up to 164 ft length 18 AWG) for the collector sensor alongside. since water:glycol mixtures have a greater proven to be effective. Open ducts must be properly sealed to prevent heat loss caused by rising air (convection). Thermal insulation ducts and wall cavities (in new buildings). Plastic pipework. Pipework routing All connections in the solar circuit that do not have Bosch- used. compensators) to prevent damage and leaks. Follow building codes when collectors provide an easy and reliable seal for collector available for providing a reliable connection to the TwinTube double tube. weather and temperature resistant. be used as thread paste (follow the manufacturer’s instructions).1 Pipework. if it is routed next to a 120 V cable. thermal insulation and collector temperature sensor extension cable Glycol and temperature-resistant sealing gaskets for valve seats. Heat expansion must be taken into consideration when routing the pipework. Graphited cord is suitable for sealing glands. if installed. Figure 67 shows standard values for the insulating not suitable for outdoor applications because it absorbs water and then fails to provide thermal insulation. An appropriate lead is provided in the insulation of the Bosch Twin-Tube. Therefore use appropriate high temperature-resistant insulating materials such as insulation exposed to the elements on the roof must be UV. Install the FSK collector temperature sensor in the sensor well of the top supply header of the Bosch 42 | Design Guide . E E R V Figure 69 Hydraulic diagram with air vent valve for each installation (connection in series) E R V Figure 70 Hydraulic diagram with air vent valve above the top row on the example of rooftop installation (connection in series) Design Guide . in dormers. Use only automatic allmetal air valves.g. Figure 68) and.2.2 Air vent valve 6.6 Design/engineering information regarding installation 6. with a new rise (e. install a manual air vent valve. E R V Figure 68 Hydraulic diagram with air vent valve at the highest point of system heating systems because of the high temperatures that metal air vent valve with an upstream ball valve. for every change of direction. provide an air vent valve for above the top row (Figure 70). this valve must be closed and remain closed to FSK system in the event of stagnation. Provide an air vent valve at the highest point of the system (detail E. If there are several rows of collectors.1 Automatic air vent valve plate collectors are vented via quick-acting air vent valves Bosch FKC-1 and FKB-1 E completed.Bosch Solar Thermal Systems | 43 . Figure 44). Low-maintenance operation If the collector array consists of several rows connected in parallel.2 Filling station and air separator resulting in most air being pushed out of the system during needed in this case. followed by pressurization.Bosch Solar Thermal Systems . Reduced installation effort because no air vent valves are needed on the roof deaeration in one step .6 Design/engineering information regarding installation 6.2. provide each individual row with a shut-off valve A 2 No air vent valve needed 1 1 Pressure hose 5 ft 2 Return hose 6 ft pump 44 | Design Guide . shingle.3. protection from sliding off or on-site attachment) Without accessories (observe securing flat roof supports!) With flat roof support kit (observe flat roof support fixing!) Without accessories Without flat roof support kit up to 43 lbs/ft² – Permissible building heights (wind loads) of up to 65 ft. sheet steel.6 Design/engineering information regarding installation 6. plain tiles.1 Permissible standard snow loads and building heights The following table contains the permissible standard snow loads and building heights for the different installation options. Rooftop installation Vertical/horizontal Tiles.3 Roof mounting systems 6.at wind speeds of up to 94 mph Standard snow loads 0–2 5 lbs/ft² Standard snow loads > 25 lbs/ft² Without accessories Only vertical collectors with rooftop installation kit Without accessories Only vertical collectors with rooftop installation kit up to 35 lbs/ft² Without accessories Not permissible Without accessories Not permissible Figure 73 Permissible standard snow loads and building heights Design Guide . bitumen 25°–65°.Bosch Solar Thermal Systems | 45 . sheet steel roof) Flat roof installation Vertical/horizontal Wall mounting 45–60 Horizontal Roof cover/wall – load-bearing Permissible roof pitch 0° (with slightly sloping roofs of up to 25°.at wind speeds of up to 80 mph Permissible building heights (wind loads) of up to 300 ft . 5°–65° (corrugated sheets. This information is most useful during the planning phase of a solar thermal project. slate. corrugated sheets. Bosch Solar Thermal Systems 1-1/4" (35 mm ) . Roof connections for different roof covers rooftop installation kits are identical for all roof connections. Figure 74 Roof connection versions for different roof covers (dimensions in inches (mm)) 46 | Design Guide . In place of the single-side collector clamps (item 1 Figure 75) the extension kit contains so-called double-sided collector clamps (item 5 Figure 75) and Roof connection for tile and plain tile covers 1/3" (9 mm) 1-1/2" (35 mm) 11-1/4" (285 mm) 16" (407 mm) 1/3" (9mm) 1-1/4" (33 mm) 2 . The various installation kits for tile and plain tile.1/2" (62 mm ) mm ) 12" (304 mm ) 2-3/4" (70 mm ) DIA 1/3" 1-1/2" (40 mm ) 4" (10 mm ) 11-3/4" (300 1/3" (8 mm ) mm ) (9mm) 1-1/2 .3-1/4" (50 – 80 mm) R oof h ook R a f t er a n ch o r Roof connection for slate and shingle covers 6-1/2" (165 2 .2 Rooftop installation The collectors are secured directly to the roof at the same pitch of the roof itself. additional collector in the same row (Figure 74).2-1/4" (38 – 59 mm) Roof hook 2-1/3" 201/2" (61 mm ) (65 mm ) 1/3" (8 mm ) 2-1/2" (65 mm ) Roof connection for corrugated sheet roof 7" (180 mm) 2-1/4" (55 mm) M12 3" (75 mm) For information on attachment systems for standing seam steel or alumimum roofs.6 Design/engineering information regarding installation 6. please contact Bosch. Use the rooftop installation extension kit only in conjunction with a standard kit. slate and shingle cover as well as for corrugated sheet and sheet steel roofs only differ with regard to the type of roof hook (Figure 74) or special attachment materials used (Figure 75).3. On roofs with simple battens. On roofs with counter battens. the roof jacks (Figure 74) are hooked over the existing roof battens (Figure 76) and fastened to the A 1-1/3" (35mm) (50-86 mm) 2 .Bosch Solar Thermal Systems | 47 .3-13" B 7 When considering installation on a tile roof. lower part Figure 76 Installed roof jack 5 1 2 Legend (Figure 77) 1 Hexagon nut 2 Serrated washer 3 Wood screws 4 Roof jack. lower part 5 Sheathing 3 4 Figure 77 Roof jack fastened to the sheeting Design Guide . check can be met. This is done by turning the lower part of the roof jack over. if they 3 1 2 The tile cover should not exceed 5 inches. the roof jacks are fastened to the sheathing (Figure 76). Where 6 5 mm Allen wrench 4 only mounted on parts of the roof that are capable of providing the necessary support under all foreseeable conditions.6 Design/engineering information regarding installation Roof connection for tiled roofs Figure 75 shows an example for a rooftop installation on a tile roof. Use the roof jacks supplied. the lower section of the roof jack can be shimmed up. Figure 75 Rooftop installation standard kit and extension kit (highlighted in blue) for one (detail A: dimensions in inches (mm)) Legend (Figure 75) 1 Single-sided collector tensioner (only in the standard kit) 2 Roof jack. adjustable 5 Double-sided collector clamp (only in the extension kit) 1 7 Sheathing 2 3 4 Legend (Figure 76) 1 Hex nut 2 Serrated washer 3 Roof batten 4 Roof jack. If additional height compensation is needed. 5 4 2 Legend (Figure 79) 1 Flashing top (on site) 2 Flashing bottom (on site) 3 Overlapping shingle or slate 4 Gasket or caulking (on site) 5 Roof jack 6 Screw (provided) 3 Figure 79 Special roof jack with waterproof cover (optional) for attaching a rooftop installation shingle roof 48 | Design Guide . 2 on plain tiles. Legend (Figure 78) 1 Plain tiles (cut along the dotted line) 2 Roof hook. Trim and attach the plain tiles on site.Bosch Solar Thermal Systems . lower part fastened to sheathing 1 Figure 78 Roof jack attached on a plain tile roof Roof connection with slate or shingle Roof jack installations on slate or shingle roofs 6 1 4 in the same way as on a tile roof (Figure 75). same way as with regular tiles (Figure 75). if needed.6 Design/engineering information regarding the installation Plain tile roof connection Figure 78 shows attaching the roof jack (item 2) to a plain tile roof. Use Design Guide . Use of a Attachment on corrugated sheet roofs Installation on a corrugated sheet roof is only possible if the headless screws can be fastened at least 1½ inches into a structural element with adequate loadbearing capacity (Figure 81). Legend (Figure 81) 3 4 5 Retaining bracket Hex nut Gasket installation on a corrugated sheet roof. Legend (Figure 80) 1 Roof tile 2 Roof jack 3 Insulation on rafters 4 Rafter 5 Adequate screw for load (provided on site) 6 Board (at least 1 x 8 inches) Fsx Load parallel to the roof surface Fsy Load perpendicular to the roof surface 4 Figure 80 Example of on-site attachment of additional boards on top of insulation on rafters. The force generated by the roof hook must be transferred by this board to the loadbearing 6 5 1 2 design must be able to safely bear the following loads: Force parallel to the roof surface: Fsx m m ) Fs Fs y x 3 Force perpendicular to the roof surface: Fsy 6 5 8" (2 00 1 >= 1" (2 8m = m ) 2 3 4 special roof jacks in the same way as they are with a tile roof (Figure 75). In order to establish an adequate secures wooden boards with a minimum cross-section of 1 x 8 inches to the rafters.6 Design/engineering information regarding the installation Roof connection in situations with added insulation on rafters Figure 80 shows a scenario with insulation on rafters using the roof hooks.Bosch Solar Thermal Systems > 1-1/2" (40 mm) The corrugated sheet roof connection kit contains headless screws including retaining brackets and gaskets that are used instead of the roof jacks in the rooftop installation kit. Design may vary based on conditions. 3 3 retaining brackets of the screws. 1 2 4" (105 mm) < 2-1/2" (60mm) 4 5 | 49 . Sleeves can also be soldered or brazed to the roof. > 1-1/2” Secure a sleeve similar to the one shown in Figure 82 to the roof on site and use appropriate measures to 1 Install a snow guard and an additional rail (accessories) on buildings between 65 ft and 300 ft in 2 3 4 loads on the roof. Figure 83 Rooftop installation kit with snow guard and additional rail Legend (Figure 83) 2 Additional rails (including collector tensioner) 3 Additional roof connection (snow guard standard delivery) 1 50 | Design Guide . Legend (Figure 82) 6 3 1-1/2” 4 5 7 3 Retaining bracket 5 Sleeve 6 Sheet metal roof 7 Load bearing sub-structure (minimum 2 x 2 inches) Figure 82 On-site attachment of sleeves for watertight mounting of screws for installation on sheet metal roofs (dimensions in inches) installation and avoid water damage to the building. at least 2 x 2 inches) through the sleeve. but at least four. Both other roof types. 2 6 4 5 7 1 per collector based on their load rating. http://www. It is recommended to consult a < 2-3/8” 3 4-1/8” penetrated.boschsolar. The or load-bearing beam. Figure 83 shows the installation of a snow guard and an additional rail on the example of tile cover.6 Design/engineering information regarding the installation Installation on standing seam steel or aluminum roofs attachment clamps for standing seam metal roofs.com/ Figure 88 shows a mounting option for metal roofs without standing seams.Bosch Solar Thermal Systems . and an air vent is needed (-> 6.6 Design/engineering information regarding the installation Hydraulic connections The rooftop connection kits are used to make the hydraulic collector connections (Figure 84). The roof and the substructure must have an adequate load-bearing capacity. Legend (Figure 84) 2 Dummy plug 3 Spring clips 4 Hose coupling with R 3/4 inch connection or 5/8 inch locking ring 2 3 Figure 85 Ventilation tile example Legend (Figure 85) 1 Supply line 2 Return line 3 Sensor lead 4 Ventilation tile 5 Air vent valve Static requirements The rooftop installation kit is exclusively designed for the secure mounting of solar collectors. in spite of the change of direction at the penetration. Ensure still that it marks the highest point of all piping. On tile roofs a for the supply and return lines. It is recommended to penetrate the roof close to the collector connection. A used for this if the return line runs in the attic (Figure 85). Route the return line to the pump station. since the collector connections are above roof level. A load of about 100 resulting from wind. Never attach other rooftop equipment such as antennae to the collectors or collector mounting kits. if required. and avoid long pipe runs above the roof. mount the air vent in the attic.2). An additional air vent valve is not usually required.Bosch Solar Thermal Systems | 51 . and is mounted perfectly vertical to ensure proper Figure 84 FKC-1 and FKB-1 rooftop connection kit 4 5 valve. For asphalt shingle roofs use standard plumber’s rubber 1 3 3 3 4 2 3 3 1 3 4 2 outlets are required for supply and return. Design Guide . The lead from the collector temperature sensor also runs through this tile. snow and other factors into account. 1 4 damage to the building. The values in Figure 86 are standard snow loads and building heights for rooftop installation. If the site allows. via the upper ventilation tile. Total number of collectors Number of rows Number of collectors per row Tiles Plain tiles Standard kit 1) Slate and asphalt shingle Corrugated sheet Sheet metal roof Tiles Plain tiles Extension kit 1) 2 1 2 2 1 1 3 3 2 2 1 3 1 1 4 4 2 2 1 5 5 2 3 2 1 2 1 2 3 1 2 1 2 Slate and asphalt shingle Corrugated sheet sheet metal roof Tiles Plain tiles 1 – 2 1 – 3 2 4 3 FKB-1 and FKC-1 portait Additional kit Standard kit 2) Slate and asphalt shingle Corrugated sheet Sheet metal roof Tiles Plain tiles 1 2 1 2 3 1 2 1 2 Additional kit Extension kit 2) Slate and asphalt shingle Corrugated sheet Sheet metal roof Tiles Plain tiles 1 – 2 1 – 3 2 4 3 Standard kit 1) FKC-1 landscape Slate and asphalt shingle Corrugated sheet Sheet metal roof Tiles Plain tiles 1 2 1 2 3 1 2 1 2 Extension kit 1) Slate and asphalt shingle Corrugated sheet Sheet metal roof 1 – 2 1 – 3 2 4 3 Figure 86 Installation materials for rooftop installation systems 52 | Design Guide .6 Design/engineering information regarding the installation Rooftop installation system component selection aid Include appropriate connection materials in the design based on the number of collectors and their hydraulic connections.Bosch Solar Thermal Systems . The support For buildings more than 65 ft in height or with snow (standard kit addition) and each extension kit must be installation kits with an additional rail (standard kit and extension kit addition). Figure 88 Flat roof support standard kit and extension collector substructures consisting of I-beams. 1 45˚ 45˚ 30˚ 15˚ 2 30˚ Accessories are required for buildings more than 65 ft 15˚ adjusted in steps of 5° as follows: inclination trimming the telescopic rail) by trimming the telescopic rail) means of weighting (ballast) or by attaching them to the roof substructure.Bosch Solar Thermal Systems | 53 . for example substructure must be designed such that the wind force acting upon the collectors can be absorbed.6 Design/engineering information regarding the installation 6.3 Flat roof installation Flat roof installation is intended for level roof surfaces. or where the collectors are to be positioned at an angle steeper than the pitch of the roof (Figure 87). 22-3 /16 22-3 /8) (13-7 /16 /8) (13-7 anchoring to a substructure consisting of center contact surface (blue) only required for buildings above 65ft in height.3. Design Guide . 6 Design/engineering information regarding the installation 38-1/2” 46” 38-1/2” Figure 90 Collector support spacing in standard version with FKC-1 and FKB-1 (dimensions in inches) 38-1/2” 7 -1 / 2 ” 38-1/2” 7 -1 / 2 ” 38-1/2” Figure 91 Collector support spacing in standard version supports for vertical collectors FKC-1 and FKB-1 (dimensions in inches) 71-5/8 ” 10-11/16” 71-5/8 ” supports for horizontal FKC-1 collectors (dimensions in inches) 54 | Design Guide - Bosch Solar Thermal Systems 6 Design/engineering information regarding the installation Securing by means of ballast trays when the collectors are weighed down (dimensions: subject to the height of the building. With a building up to 65 ft high and snow loads of up to 42 and 10th collector in a row when ballast trays are used in conjunction with vertical collectors. The installation kit includes one additional support when horizontal collectors are used. The additional supports are required for hooking in the trays. For buildings higher than 65 ft or with snow loads of 42 additional rail (standard kit addition) and each extension kit for vertical collectors must include an additional support and an additional rail (extension kit addition). With horizontal collectors, all installation kits must be equipped with an additional rail (standard kit and extension kit addition). Erect the entire structure on protective building mats to protect the roof membrane. Ensure that the roof and building can support the weight of the collectors and ballast. 4 5 3 2 1 Figure 93 Flat roof support with ballast trays and additional guy ropes 1 2 3 5 4 Hydraulic connections 87). Route the supply line parallel to the collector to prevent damage to the connection due to the movement of the collector in the wind. 4 1 Static requirements Follow Figure 73 snow loads and building heights. 3 2 Legend (Figure 94) 1 Bracket with R 3/4 inch connection on the system-side or 5/8 inch locking ring 2 Stop washer 3 Nut G1 4 Dummy plug 5 Spring clips Legend (Figure 95) 1 Pipe clamp (on site) alongside the collector 3 Bracket (connection kit standard delivery) 4 Supply line Figure 95 Collector supply line routing Design Guide - Bosch Solar Thermal Systems | 55 6 Design/engineering information regarding the installation Flat roof support weights Standard kit, vertical: 27 lbs Extension kit, vertical: 16 lbs Building height Wind velocity Base anchoring Ballast Protection against tilting Guy rope Protection against slippage Max. tensile strength per rope lbf 360 560 740 Number and type of screws 1) ft 0-25 25-65 65-300 mph 60 80 90 2x M8/8.8 2x M8/8.8 3x M8/8.8 Weight (e.g. concrete bricks) lbs 595 990 2) Weight (e.g. concrete bricks) lbs 400 700 990 1) Per collector support 2) Not permitted Flat roof installation; component selection aid connections. Total number of collectors Number of rows Number of collectors per row Installation kits with ballast tray 1) 2 1 2 2 1 1 3 3 2 2 1 3 1 1 4 4 2 2 1 5 5 2 3 2 Standard kit FKC-1 and FKB-1 vertical Extension kit Additional support 2) Standard kit addition 3) Addition to extension kit 3) Standard kit FKC-1 horizontal Extension kit Standard kit addition 3) Addition to extension kit 3) Installation kits for on-site attachment FKC-1 and FKB-1 vertical FKC-1 horizontal Standard kit Extension kit Standard kit addition 3) Addition to extension kit Standard kit Extension kit Standard kit addition 3) Addition to extension kit 3) 3) 1 1 – 1 1 1 1 1 1 2 – – 2 – 2 – 2 – 1 2 – 1 2 1 2 1 2 2 1 – 2 1 2 1 2 1 3 – – 3 – 3 – 3 – 1 3 1 1 3 1 3 1 3 2 2 – 2 2 2 2 2 2 1 4 1 1 4 1 4 1 4 2 3 – 2 3 2 3 2 3 1 1 1 1 1 1 1 1 2 – 2 – 2 – 2 – 1 2 1 2 1 2 1 2 2 1 2 1 2 1 2 1 3 – 3 – 3 – 3 – 1 3 1 3 1 3 1 3 2 2 2 2 2 2 2 2 1 4 1 4 1 4 1 4 2 3 2 3 2 3 2 3 1) The standard installation and extension kits contain one set of ballast troughs each 2) Not required if the additional extension kit is selected 3) Required in addition to the standard and extension kit with snow loads in excess of 42 lbs/ft² or building height exceeding 65ft 56 | Design Guide - Bosch Solar Thermal Systems 3.353 | 57 .4 Wall installation Static requirements height of 65 ft.6 Design/engineering information regarding the installation 6. permitted collector pitch on a wall 1: pitch (absolute angle relative to the horizontal) 2: collector angle of inclination 38-1/2" 38-1/2" 5-5/16" 38-1/2" 38-1/2" Figure 99 Wall mounting with wall support standard kit and inches Snow and ice accumulating on the collectors may give way and slide off suddenly. standard kit.Bosch Solar Thermal Systems 0. These kits collectors on the wall may only be set to between 45° and 45˚ 30˚ 2 1 60˚ 45˚ Secure the collector supports on site to structural elements of a wall capable of bearing the load of the collector array in addition to possible snow and wind loads Figure 98 Max. The values in Figure 73 are the permissible standard snow loads and building heights. Component selection aid for wall mounting system for Bosch FKC-1 horizontal Total number of collectors Number of rows Number of collectors per row Installation kits FKC-1-w Standard kit for wall mounting Extension kit for wall mounting 1 1 2 – 1 2 2 1 3 – 1 3 2 2 1 4 2 3 1 2 2 2 1 1 3 3 2 2 1 3 1 1 4 4 2 2 1 5 5 2 3 2 Figure 100 Fixing materials for wall mounting system for Bosch FKC-1 horizontal Design Guide . Take provisions that the installation does not pose a risk to property and cause personal injury from falling snow and ice.353 0. Every additional collector in the same row is installed using a wall support extension kit. In residential installations solar systems are typically not from the addition of a solar thermal system. government. Take into account that the collector array may be adding height to the building. should be discussed with an expert and/or the building operator.4 Lightning protection and grounding of solar systems Requirements for lighting protection Follow the national and local building codes on the installation on lightning arrestors. buildings or horizontal In buildings open to the public (schools. and that the metal rails may increase the likelihood of a lightning strike. determine whether the collector array and the piping are protected by this system. the supply and return of a solar system must always be grounded with a copper cable (minimum AWG If a lightning protection system is present. This discussion should take place in the planning phase of the solar system. In the absence of such regulations for the building in question. Lightning protection is typically required for buildings that measure more than 65 ft in height Grounding of the solar system Irrespectively of whether a lightning protection system is present.6 Design/engineering information regarding the installation 6. it is the building owner’s responsibility to decide after consulting with professionals if a lightning protection system should be installed. 58 | Design Guide . consult a specialist electrical contractor. If in question.Bosch Solar Thermal Systems . 61 7. procedures and applications. 64 7. 65 Design Guide .7 Solar applications 7 Solar applications The following drawings are conceptual in nature and may not necessarily display all design.2 Solar DHW system with gas tankless tankloading______________________________________pg. 60 7. The following drawings are not to scale. These designers. It is expected that installers and system designers have adequate knowledge of industry practice for the equipement.6 Solar commercial hot water system with gas tankless tankloading_____________________________pg.Bosch Solar Thermal Systems | 59 . 63 7.4 Solar DHW system with gas tankless in line booster and recirc loop__________________pg. installation. and licensed installers. Additional safety and/or auxillary equipment may be needed or required by code. and design considerations.3 Solar DHW system with gas tankless in line booster___________________________________pg. 7.5 Solar DHW system and swimming pool application with gas tankless in line booster__pg. 62 7.1 Solar DHW system with electric backup element__________________________________________pg. 1 Solar DHW system with electric backup element Electric element keeps comfort zone at top of the tank at System can be combined with third party solar PV system for generation of electricity used for electric element. Collector sensor Domestic Hot Water Thermostatic valve Setpoint 120°F Solar Controller Solar Pump Station Electric Element Cold Water Supply Tank sensor Symbols Honeywell Am-1 series thermostatic mixing valve Well thermometer Service valves Pressure relief valve Solar storage tank Expansion tank Flow direction Circulator 60 | Design Guide .Bosch Solar Thermal Systems . pumps. and other loads.7 Solar applications 7. contact Bosch Thermotechnology.Bosch Solar Thermal Systems | 61 .2 Solar DHW system with gas tankless tankloading Tankless water heater keeps comfort zone at top of tank at temperature. Use of a timer is recommended to interrupt reheating during night time. Aquastat / Water Heater setpoints Aquastat setpoint Water heater setpoint 14°F above Aquastat setpoint 140°F GWH 715 ES 140°F 140°F * If local codes require higher setpoint or to increase the recovery capacity of the water heater. See appliance manual for details and wiring diagram. 715ES or C800ES gas tankless water heater Thermostatic valve Setpoint 120°F Solar Controller Solar Pump Station Aquastat or tank sensor Cold Water Supply Tank sensor Symbols Honeywell Am-1 series thermostatic mixing valve Well thermometer Service valves Pressure relief valve Solar storage tank Expansion tank Flow direction Circulator Design Guide . Collector sensor Domestic Hot Water 345/450 ESR. Bosch GWH345ESR or GWH450ESR requires optional 12kOhm tank sensor.7 Solar applications 7. and the circulator wires directly to the water heater. stability and quicker hot water delivery. Thermostatic valve 2 acts as a tempering valve that brings potentially hot water temperatures down to a level that is safe for the inhabitants. (recommended but not required) Collector sensor Solar Controller Solar Pump Station Hot Cold Tank sensor Thermostatic valve 1 Domestic hot water Thermostatic valve 2 Ariston GL6+ or GL8ti mini tank Water supply Symbols Honeywell Am-1 series thermostatic mixing valve Well thermometer Service valves Pressure relief valve Solar storage tank Expansion tank Flow direction Circulator 62 | Design Guide .3 Solar DHW system with gas tankless in line booster System parameters: The tankless water heater only runs when solar water needs a boost.Bosch Solar Thermal Systems .7 Solar applications 7. Thermostatic valve 1 ensures that warm solar water bypasses the water heater and directs cooler water through the appliance when reheating is needed. used as a diverter valve. Recommended appliances: proper operation. Buffer tank provides small amounts of DHW instantly and increases comfort by smoothing out DHW temperature. (recommended but not required) of the recirculation loop Collector sensor Solar Controller Solar Pump Station Hot Cold Tank sensor Thermostatic valve 1 Domestic hot water Thermostatic valve 2 Ariston GL6+ or GL8ti mini tank Water supply Symbols Honeywell Am-1 series thermostatic mixing valve Well thermometer Service valves Pressure relief valve Solar storage tank Expansion tank Flow direction Circulator Flow check valve Design Guide . Recommended appliances: System parameters: proper operation. Instead it is recommended to use a timer for the recirculation pump at 3 to 6 runs per hour. The tankless water heater only runs when solar water needs a boost. The timer should also limit recirculation pump operation to the time of day when occupants are home and likely to use hot water.4 Solar DHW system with gas tankless in line booster and recirc loop Identical to system 7. used as a diverter valve.7 Solar applications 7. Thermostatic valve 2 acts as a tempering valve that brings potentially hot water temperatures down to a level that is safe for the inhabitants. Thermostatic valve 1 ensures that warm solar water bypasses the water heater and directs cooler water through the appliance when reheating is needed. Do not run the recirculation pump continuously.Bosch Solar Thermal Systems | 63 . stability and quicker hot water delivery.4. Buffer tank provides small amounts of DHW instantly and increases comfort by smoothing out DHW temperature. but with domestic recirculation added. as it would drain the solar tank. Each run must be long enough for hot water to reach the farthest tap. (recommended but not required) Collector sensor Solar Controller Solar Pump Station Hot Cold Tank sensor Domestic hot water Thermostatic valve 1 Thermostatic valve 2 Ariston GL6+ or GL8ti mini tank Water supply POOL Symbols Temperature sensor Expansion tank Service valves Drain valve Flow direction Honeywell Am-1 series thermostatic mixing valve Well thermometer Heat exchanger Pressure relief valve Solar storage tank Circulator 64 | Design Guide . the swimming pool pump switches off.Bosch Solar Thermal Systems .7 Solar applications 7. Thermostatic valve 1 ensures that warm solar water bypasses the water heater and directs cooler water through the appliance when reheating is needed. Once the DHW target temperature is met. System parameters: proper operation.5 Solar DHW system and swimming pool application with gas tankless in line booster The tankless water heater only runs when solar water needs a boost. used as a diverter valve. the diverter valve is activated opening the port to the pool heating exchanger. Thermostatic valve 2 acts as a tempering valve that brings potentially hot water temperatures down to a level that is safe for the inhabitants. Recommended appliances: The swimming pool pump is switched on as soon as the switch-on temperature difference between the external heat exchanger and the swimming pool is reached. Buffer tank provides small amounts of DHW instantly and increases comfort by smoothing out DHW temperature. stability and quicker hot water delivery. When the switch-off temperature difference between the external heat exchanger and the swimming pool is reached. Bosch Solar Thermal Systems | 65 .5-5 gpm. Collector sensor Domestic Hot Water Solar Controller Twin tube Thermostatic valve Setpoint 120°F Aquastat or tank sensor Solar Pump Station Aquastat or tank sensor Hot water recirculation return line Cold Water Supply DHW recirculation pump Symbols Honeywell Am-1 series thermostatic mixing valve Well thermometer Pressure relief valve Solar storage tank Potable water expansion tank Flow direction Circulator Service valve Drain valve Expansion tank Flow check valve Design Guide .7 Solar applications 7. tankless water heaters should be between 3. The tankless water heaters keep the comfort zone at top of tank at temperature.6 Solar commercial hot water system with gas tankless tankloading The following provides a general overview of commercial hot water systems in conjunction with solar water heating. adjacent buildings. It only needs checking for accumulated air during the annual system inspection or if system performance indicates air may be in the system 8. Do not oversize the collector array in relation to the storage tank volume. 4. 5. between supply and return are small. as well as does not attract birds or rodents. make sure the upper air vent is and remains closed. 66 | Design Guide . or building features (chimneys.8 System design recommendations 8 System design recommendations Listed below are important design recommendations to ensure proper operation of the entire solar thermal system. 7. Refer to chapter rate calculation. On the roof ensure all insulation material is resistant to UV rays and weather related wear and tear. 6. Ensure at least 6 hours of direct unobstructed solar exposure per day.) put a partial shade on the collectors. pressure losses.2 Diaphragm expansion vessel for details on how to determine the correct DEV pressure setting. After commissioning. 2.5. Avoid mounting collectors where trees.Bosch Solar Thermal Systems . Use proper insulation on all pipes between the collectors and the tank. Find and immediately mitigate any issues. DEV pressure setting: Refer to chapter 5. 9. 3. etc. excessive losses. 1. Bosch Solar Thermal Systems | 67 .Notes Design Guide . de . NH 03053 Tel: 603-552-1100 Fax: 603-584-1681 www.boschthermotechnik.com Products manufactured by Bosch Thermotechnik GmbH D-35573 Wetzlar www.boschsolar.50 Wentworth Avenue Londonderry.